Networked Torque Tool Control for Consistent Fastener Tightening
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Solution Overview
Problem
Existing industrial bolting systems face errors due to incorrect tool selection, calculation mistakes, and improper setting of parameters, leading to defective screw connections, which can result in operator injury, property damage, and production losses.
Innovation Solution
An operation parameter regulation unit for networked electrically powered torque tools that automatically captures and regulates parameters such as torque, pretensioning force, and rotation speed, ensuring accurate setting parameters are applied without human error, using a processing unit, data capturing unit, and control unit to maintain predetermined values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual setting of parameters is used, then operator flexibility is maintained, but human error increases leading to defective screw connections
Solution Approach 1:
The system automatically determines setting parameters by capturing data from the fastener connection equipment and bolting application, eliminating the need for manual parameter entry by operators. The processing unit autonomously calculates optimal parameters based on captured data, thereby reducing human error while maintaining operational simplicity.
Solution Approach 2:
The patent replaces manual mechanical parameter setting with an automated electronic system. Data capturing units collect information, which is then processed electronically to determine setting parameters automatically, substituting the manual mechanical adjustment process with an automated computational system that reduces errors.
2Reliability
If automated parameter determination is implemented, then human error is reduced, but system complexity increases
Solution Approach 1:
The operation parameter regulation unit serves multiple functions: it captures data from multiple sources, processes information to determine setting parameters, regulates operation parameters of torque tools, and monitors fastener connection processes. By consolidating these diverse functions into a single multi-functional unit, the system achieves automated parameter determination without proportionally increasing overall system complexity.
Solution Approach 2:
The processing unit acts as an intermediary between data capturing units and torque tools. It receives raw data from various sensors and equipment, processes this information to determine appropriate setting parameters, and then transmits regulated parameters to the torque tools. This intermediary layer simplifies the overall system architecture by centralizing the complex processing logic in one component.
3Productivity
If multiple networked torque tools are used for simultaneous tightening, then productivity increases, but maintaining consistent operation parameters becomes more difficult
Solution Approach 1:
The operation parameter regulation unit continuously monitors the actual operation parameters of each torque tool during the tightening process and compares them against target values. When deviations are detected, the system automatically adjusts parameters in real-time to maintain consistency across all networked tools, enabling simultaneous tightening while preserving parameter uniformity.
Solution Approach 2:
The system dynamically adjusts operation parameters for each torque tool based on real-time conditions and feedback. Rather than using static pre-set parameters, the regulation unit continuously optimizes parameters during operation to account for variations in the bolting process, tool performance, and fastener characteristics, thereby maintaining precision across multiple simultaneous operations.
Data Source
AI summary
The present invention relates to an operation parameter regulation unit (50) for use with a bolting system having a plurality of networked electrically powered torque tools (10, 11) and/or drive portions of torque tools (10, 11) for simultaneous tightening of industrial threaded fasteners (40), the operation parameter regulation unit (50) including: a processing unit (53); an output unit (51) an input unit (52) an activation unit (55) for activating operation units and/or drive portions of torque tools (10, 11); and a control unit (54) for controlling operation parameters (41) of each of the plurality of networked electrically powered torque tools (10, 11) and/or drive portions of torque tools (10, 11) to maintain a difference between the operation parameters (41) within a predetermined value.