Torque Socket Assembly with Strain Transducer for Fastener Measurement
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Solution Overview
Problem
Existing methods for measuring torque and angular displacement in threaded fasteners are either inaccurate, complex, costly, or impractical, often requiring secondary devices and incorporating unnecessary mechanical features that reduce precision and increase weight.
Innovation Solution
A compact assembly intercalated between a torque tool and a fastening element, featuring a socket subassembly with a strain transducer and electronic components for precise measurement of torsional strain, conversion to standard torque values, and remote monitoring, allowing for automatic tool shut-off when pre-established parameters are met.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasonic transducer socket assembly is used to directly measure bolt tension, then measurement accuracy is improved, but device complexity and weight increase significantly
Solution Approach 1:
The patent replaces complex mechanical ultrasonic transducer systems with a strain gauge-based electrical measurement system. Instead of using mechanical cylinders, rotatable transducers, and couplant layers, the invention uses strain gauges bonded to the socket to directly measure torque through electrical resistance changes, eliminating the need for complex mechanical measurement components.
Solution Approach 2:
The invention extracts only the essential measurement function from the ultrasonic transducer system. Rather than incorporating a complete ultrasonic measurement apparatus with all its mechanical components, the patent uses a simplified strain gauge sensor that directly measures the torque applied to the fastener through elastic deformation of the socket material.
2Measurement precision
If ultrasonic transducer socket assembly is used to measure bolt tension, then direct measurement capability is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive ultrasonic transducer manufacturing with cost-effective strain gauge technology. Strain gauges are inexpensive electrical sensors that can be bonded to the socket using standard manufacturing processes, eliminating the need for precision-machined mechanical transducer assemblies and reducing manufacturing complexity.
Solution Approach 2:
The invention uses inexpensive strain gauge sensors that can be easily replaced or repositioned compared to costly ultrasonic transducer assemblies. The strain gauges are simple electrical components with minimal manufacturing requirements, making them economically advantageous for production.
3Measurement precision
If ultrasonic transducer socket assembly is used to measure bolt tension, then measurement capability is improved, but socket length and weight increase making it impractical
Solution Approach 1:
The patent replaces heavy mechanical ultrasonic transducer components with lightweight electrical strain gauges. The strain gauges are thin foil or wire sensors that add minimal weight to the socket, whereas ultrasonic transducers require heavy mechanical cylinders, motors, and coupling mechanisms that significantly increase socket mass.
4Device complexity
If strain gauge is used to measure torque, then measurement simplicity is improved, but angular displacement measurement capability is lost
Solution Approach 1:
The patent makes the measurement system capable of performing multiple functions. In addition to torque measurement via strain gauges, the socket incorporates angular position sensors (such as optical encoders or magnetic sensors) that measure the rotation angle of the fastener. This multi-functional approach allows the same device to provide both torque and angular displacement data, enabling comprehensive fastener tightening monitoring.
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
Provides reliable, precise, and compact measurements of torque and angular displacement in standard engineering units, enabling remote monitoring and automatic tool control within defined limits, enhancing measurement accuracy and operational efficiency.
Implementation Method 1
a strain transducer subassembly, for measuring torsional strains on the socket subassembly
Implementation Method 2
measuring torques by means of a strain transducer
Data Source
Figure 1
Figure 1A~1C
Figure 2
AI summary
The assembly comprises: 1 ) a socket subassembly having an unitary elongated body, including at one extremity a first engaging cavity, at an opposite extremity, a second engaging cavity: and incorporating an externally open, annular channel provided between the extremities of the socket subassembly: 2) a strain transducer subassembly, for measuring torsional strains on the socket subassembly, mounted in the externally open annular channel: 3) a circular cover attached to the socket subassembly for enclosing the externally open, annular channel: and 4) an electronic subassembly for converting the torsional strains on the socket subassembly to standard torque values and for determining tightening angular displacements by means of a sensor: the electronic subassembly being interconnected to the strain transducer subassembly and mounted on the circular cover to face the strain transducer subassembly.