Torque Tool Control via Gear Torsion Measurement
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Solution Overview
Problem
Existing electric torque tools face inaccuracies in measuring and controlling torque during tightening and unscrewing of screw connections due to mechanical element phenomena, leading to errors and inconsistencies in torque application.
Innovation Solution
A control system for electric torque tools that includes a torque sensor measuring torsional deformations of the reduction gear, coupled with a controller to correct motor output signals, utilizing a single control loop and cascade regulation system to maintain desired torque levels, with wireless communication via radio waves and a strain gauge for precise measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If current measurements are used to determine torque, then the torque can be controlled, but measurement accuracy deteriorates due to mechanical errors and difficult to overcome phenomena in mechanical elements
Solution Approach 1:
The patent replaces current measurement methods with a torque sensor that directly measures torsional deformations of the reduction gear element. This substitution of the measurement principle eliminates the influence of mechanical errors and phenomena affecting current-based measurements, achieving accurate and reliable torque determination.
Solution Approach 2:
The torque sensor acts as an intermediary element that directly measures the torsional deformation of the reduction gear element. By positioning the sensor within the torque path and using it as a mediator between the mechanical system and the control system, the patent achieves direct and accurate torque measurement without being affected by mechanical errors in other components.
2Measurement precision
If a torque sensor is added to measure actual torque, then measurement accuracy improves, but device complexity increases
Solution Approach 1:
The patent merges the torque sensor with the reduction gear by integrating it into the existing mechanical structure. The sensor is positioned to measure torsional deformations of the reduction gear element, combining the measurement function with the existing torque transmission path and eliminating the need for separate complex measurement systems.
Solution Approach 2:
The reduction gear element itself serves as the measurement object, and its torsional deformation directly provides the torque information needed. The existing mechanical components serve dual purposes: torque transmission and torque measurement, eliminating the need for additional complex measurement infrastructure.
3Manufacturing precision
If direct torque measurement is implemented, then torque control accuracy improves, but the system requires more complex control regulation
Solution Approach 1:
The patent implements a feedback control system where the torque sensor continuously measures the actual torque and feeds this information back to the controller. The controller compares the measured torque with the target torque and adjusts the motor output accordingly, achieving precise torque control through continuous monitoring and adjustment.
Solution Approach 2:
The control system dynamically adjusts the motor output based on real-time torque measurements. The controller modifies the control signal to the motor according to the difference between target and actual torque, enabling adaptive and precise torque control throughout the tightening process.
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
This solution enables direct and accurate measurement and control of torque, improving the recurrence and accuracy of tightening and unscrewing processes, reducing instances of excessive torque application compared to conventional methods.
Implementation Method 1
the measuring component of the sensor is in form of a strain gauge
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a control system of a torque tool (1) provided for tightening and unscrewing of screw connections with adjustable torque. The system has a controller (3) of an electric motor (2) of the torque tool (1), and comprises a sensor (6) measuring the torque. The sensor (6) is configured to measure torsional deformations of a reduction gear (5) component of the torque tool (1) transferring the torque. Moreover, the sensor (6) is coupled with the controller (3), and the controller is configured to correct the output control signal to the electric motor (2) on the basis of the signal from the sensor (6) of the measured actual torque. The application also refers to a method of controlling the torque tool (1).