Automatic Torque Gun Shifting for Safe High-Speed Bolting
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Solution Overview
Problem
High-speed and high-torque bolting operations using torque power tools pose safety risks due to abrupt mode changes, which can cause operator injury from pinch points and dangerous reaction arm movements, as the reaction torque varies significantly between modes.
Innovation Solution
The development of automatic torque gun shifting assemblies, including rotation speed-sensing and torque-sensing centrifugal multi-speed automatic shifting assemblies, which automatically switch between high-speed/low-torque and low-speed/high-torque modes, utilizing clutch plate packs, spring mechanisms, and gear shifting to manage speed and torque transitions safely and efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automatic clutch mechanism is used for high speed and high torque bolting applications, then productivity is improved through automatic mode shifting, but operator safety deteriorates due to pinch points and dangerous reaction arm movements during mode transitions
Solution Approach 1:
The reaction arm is designed to dynamically adjust its state between locked and unlocked positions based on operating mode. During high-speed mode transitions, the reaction arm automatically unlocks to prevent dangerous pinching, while during low-speed high-torque operations, it locks to provide necessary reaction force. This dynamic adaptation resolves the contradiction by making the reaction arm's behavior conditional rather than fixed.
Solution Approach 2:
The system incorporates a reaction arm position sensor that continuously monitors the reaction arm's position and provides feedback to the control system. This feedback enables the controller to detect when the reaction arm is in an unsafe position during mode transitions and automatically adjust the clutch engagement or reaction arm positioning to prevent operator injury, thereby maintaining both productivity and safety.
2Object-affected harmful factors
If reaction arm is locked during high-speed mode, then operator safety is improved, but device complexity increases due to additional control mechanisms
Solution Approach 1:
The reaction arm locking and unlocking functions are merged with the existing clutch control system. The same controller that manages clutch engagement for mode shifting also controls the reaction arm positioning, eliminating the need for a separate control system. This integration maintains safety while avoiding additional complexity from redundant control mechanisms.
Solution Approach 2:
The reaction arm system is designed to automatically lock and unlock based on pre-programmed sequences tied to mode transitions. The control system automatically adjusts reaction arm positioning in response to detected mode changes without requiring manual intervention or complex external control, making the system self-regulating and reducing overall control complexity.
3Productivity
If multi-speed automatic shifting assembly is used, then productivity is improved through faster fastener run-down, but device complexity increases due to additional clutch plate packs and gear stages
Solution Approach 1:
The reaction arm serves multiple functions: it provides reaction force during high-torque operations, acts as a safety barrier during mode transitions, and its position is used as a feedback signal for control decisions. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity while maintaining productivity benefits.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
These assemblies effectively manage speed and torque transitions, reducing the risk of operator injury by ensuring safe and controlled mode shifts, enabling operation between 4,000 rpms and 4 rpms with reduced reaction arm hazards, thus enhancing safety standards in industrial bolting applications.
Implementation Method 1
Rotation speed-sensing centrifugal multi-speed automatic shifting assemblies
Implementation Method 2
clutch plate packs
Implementation Method 3
spring mechanisms
Data Source
Figure 1A
Figure 1B~1C
Figure 1D~1E
AI summary
Disclosed inventions include: • integrated pneumatic flow pressure regulator assemblies with and/or without filters and/or swivels, per FIGS. 1A, 1B, 1C, 1D, 1E, 1F, 1G, 1H, 1I, 1J, 1K, 1L, 1M and 1N for use with all of Applicant's pneumatic torque gun models; • activation, or trigger, lock safety assemblies, per FIGS. 2A1, 2A2, 2B1 and 2B2, for use with all of Applicant's electric and pneumatic torque gun models; • automatic torque gun shifting assemblies including: - rotation speed-sensing centrifugal multi-speed automatic shifting assemblies, per FIGS. 3A, 3B and 3C, for use with all of Applicant's electric and pneumatic torque gun models; - torque-sensing centrifugal multi-speed automatic shifting assemblies, per FIGS. 4A, 4B, 4C, 4D, 4E, 4F, 4G, 4H, and 4I, for use with all of Applicant's electric and pneumatic torque gun models; • helical cam, or wobbling, turning force multiplication assemblies, per FIGS. 5A, 5B, 5C, 5D, 5E, 5F and 5G, for use with all of Applicant's electric and pneumatic torque gun models; • pneumatic pressure release, or burst, valve assemblies, per FIGS. 6A, 6B, 6C, 6D, 6E, 6F, 6G, 6H, 6I and 6J, that allow bleeding of pressure to unstick a locked up tool for use with all of Applicant's pneumatic torque gun models; • pneumatic fluid directional valve assemblies, per FIGS. 7A, 7B and 7C, for use with all of Applicant's pneumatic torque gun models; • pneumatic fluid directional and activation, or trigger, lock safety valve assemblies, per FIGS. 8A and 8B, for use with all of Applicant's pneumatic torque gun models; and • pneumatic tool cycle counter, or odometer, assemblies, per FIGS. 9A and 9B, that recognize tool actuations as drops in pneumatic pressure for use with all of Applicant's pneumatic torque gun models.