Torque Tool Dual-Sensor Verification for Over-Tightening Detection
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Solution Overview
Problem
Current torque tools lack the ability to track if adjustments are erroneously made, fail to verify the achievement of desired torque, and cannot integrate with remote monitoring systems for quality assurance.
Innovation Solution
An intelligent torque application tool equipped with load cell and strain gauge sensors provides real-time data to a microprocessor, allowing it to monitor torque application, detect over-rotation, and communicate with remote systems for data analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional click wrenches are used, then the tool structure remains simple, but the ability to track adjustments and verify torque achievement is lost
Solution Approach 1:
The patent replaces the purely mechanical click mechanism with an electronic sensor system that uses load cells and strain gauges to detect torque. This substitution enables digital tracking and verification of torque application while maintaining the fundamental mechanical torque delivery function, thus improving reliability without excessive complexity increase.
Solution Approach 2:
The patent implements feedback mechanisms through sensors that continuously monitor torque application and provide real-time data to a control system. This feedback enables verification of torque achievement and detection of over-tightening, significantly improving reliability by ensuring torque specifications are met.
2Reliability
If basic mechanical switches are added for signal feedback, then torque delivery can be signaled, but the ability to detect erroneous adjustments and over-rotation is lost
Solution Approach 1:
The patent divides the torque detection function into multiple specialized sensors: load cells for primary torque measurement and strain gauges for deformation detection. This segmentation allows each sensor to optimize its function while collectively providing comprehensive torque verification and error detection capabilities.
Solution Approach 2:
The patent adds a new dimension of measurement by incorporating strain gauges that detect tool body deformation, complementing the load cell measurements. This multi-dimensional approach enables detection of over-rotation and erroneous adjustments that single-sensor systems would miss.
3Loss of information
If remote monitoring capability is added, then torque data can be transmitted to PLC or PC systems, but the integration complexity with external systems increases
Solution Approach 1:
The patent implements a universal communication interface that can transmit torque data to multiple external systems (PLC, PC, remote monitors) through a single integrated communication module. This multi-functionality reduces integration complexity by providing a single point of data export rather than requiring separate interfaces for each external system.
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
Ensures accurate torque delivery, detects over-tightening, and enables remote monitoring and data integration with PLC or PC-based systems, enhancing operational reliability and quality assurance.
Implementation Method 1
a first sensor assembly (load cell sensor assembly) configured to receive force exerted by the torque selection mechanism and output one or more values corresponding to the amount of force received
Implementation Method 2
a second sensor assembly (strain gauge sensor assembly) configured to measure a deformation of the tool body
Data Source
AI summary
By way of non-limiting example, the present approaches use a combination of at least a load cell sensor and a strain gauge sensor to provide near real time and real time data to a microprocessor for evaluation of the torque applied to a work piece. The microprocessor is further configured to communicate data obtained from the at least two sensors to a remote data monitoring, storage or analysis platform. In one or more implementations, the data obtained by the microprocessor from the at least two sensors include the ability to track if any adjustments are erroneously made to the torque application tool itself or if the torque application tool is configured to send an incorrect signal that corresponds to the amount of torque applied to a workpiece.