Torque-Off Weld Stud Socket Assembly for Bending Moment Reduction
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Solution Overview
Problem
Current methods for torque-off weld testing are prone to excessive variation due to unintentional bending moments and potential pre-test damage, leading to unreliable data and increased time and cost for evaluation.
Innovation Solution
A testing apparatus that positions a torque wrench at a consistent distance from the sheet metal, reduces bending moment introduction, and allows remote lock nut tightening to prevent pre-test damage, ensuring repeatable and accurate torque measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a nut and lock nut combination is used for torque-off testing, then the weld can be loaded during testing, but unintentional bending moments are introduced and pre-test damage may occur
Solution Approach 1:
The patent introduces a specialized socket assembly as an intermediary device between the torque wrench and the weld stud. This socket with flange and stopper mechanism mediates the torque application process, ensuring that pure torsional load is applied without introducing bending moments that would compromise test reliability.
Solution Approach 2:
The patent replaces the traditional nut and lock nut mechanical system with a socket-based system that has a polygonal exterior surface mating with the torque wrench. This substitution eliminates the need for pre-test torquing operations that could damage the weld while maintaining the ability to apply controlled torque loads.
2Object-affected harmful factors
If the torque wrench is positioned close to the sheet metal, then the bending moment is reduced, but the setup complexity increases
Solution Approach 1:
The socket assembly is pre-configured with a flange that has a predetermined distance from the sheet metal surface. This preliminary positioning action ensures that when the socket is installed on the weld stud, the torque wrench application point is automatically at the correct distance to minimize bending moments, eliminating the need for complex real-time adjustments.
Solution Approach 2:
The flange on the socket assembly serves itself by providing the correct positioning geometry. The flange's distance from the sheet metal is built into the tool design, so the tool automatically positions itself correctly without requiring external positioning mechanisms or complex setup procedures.
3Strength
If pre-test torquing of the nut/lock nut combination is performed, then the weld can be secured, but the weld may be unintentionally damaged
Solution Approach 1:
The patent extracts the securing function from the traditional nut and lock nut combination. The socket assembly with its stopper mechanism provides the securing function without requiring pre-test torquing operations that could damage the weld. The lock nut is only used to secure the stopper to the socket, not to secure the weld itself.
Solution Approach 2:
The patent inverts the traditional approach by using the stopper and lock nut to secure the socket to the stud rather than using a nut and lock nut on the stud itself. This inversion allows the weld to remain undisturbed during setup while still achieving secure attachment for torque application.
4Reliability
If multiple test samples are generated to account for data variation, then confidence in results improves, but time and material requirements increase
Solution Approach 1:
The standardized socket assembly provides consistent and repeatable torque application geometry across all test samples. This consistency reduces data variation and improves confidence in results, meaning fewer replicate tests are needed to achieve statistical confidence, thereby improving testing efficiency.
Data Source
AI summary
A testing apparatus for torque off weld stud testing has a socket to receive a weld stud welded to a metal sheet for testing strength of the weld. A stopper is received in the socket indexing the weld stud. A nut locks the stopper in position to enable repeated socket indexing to like weld studs.