Torque Tool Sensor Fusion for Real-Time Torque Verification
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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
A torque application tool equipped with a load cell sensor and strain gauge sensor to provide real-time data to a microprocessor, which communicates with remote systems, monitors torque application, and alerts users to over-rotation or incorrect signaling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a simple mechanical switch is added to the internal click mechanism to verify tool operation, then the ability to confirm torque check process is improved, but the device complexity increases
Solution Approach 1:
The patent replaces the simple mechanical switch with a comprehensive sensor system including load cell sensors and strain gauge sensors that provide electronic measurement and verification of torque application, eliminating reliance on basic mechanical indicators while reducing overall system complexity through integrated electronic monitoring
Solution Approach 2:
The patent implements feedback mechanisms where sensors continuously monitor torque application and provide real-time data to verify proper torque achievement, enabling automated confirmation of torque checks without requiring complex mechanical verification systems
2Loss of information
If current tool solutions are used without additional sensors, then the device complexity is reduced, but the ability to track adjustments and verify torque achievement is lost
Solution Approach 1:
The patent replaces traditional mechanical torque indication systems with electronic sensor systems including load cell sensors and strain gauge sensors that provide precise digital measurement of torque application, enabling complete tracking and verification of torque data
Solution Approach 2:
The patent implements self-monitoring capabilities where the sensor system automatically tracks and records torque application data without requiring external verification equipment, enabling the tool to independently verify proper torque achievement and provide complete operational data
3Object-affected harmful factors
If existing tools are configured without over-rotation detection, then the ease of operation is improved, but the ability to detect excessive torque application is lost
Solution Approach 1:
The patent implements feedback mechanisms where strain gauge sensors continuously monitor torque application and provide real-time data to detect when excessive torque is applied, enabling automated warning or shutdown to prevent over-tightening damage to workpieces
Solution Approach 2:
The patent replaces passive mechanical torque application with an active electronic monitoring system using strain gauge sensors that detect and report excessive torque conditions, preventing damage through electronic control rather than mechanical limitation
4Reliability
If tools are equipped with remote monitoring capability, then the quality assurance is improved, but the loss of time for data integration is increased
Solution Approach 1:
The patent implements continuous real-time data transmission from sensors to remote monitoring systems, eliminating the need for batch data collection or manual data transfer, thereby maintaining continuous quality assurance monitoring without time loss for data integration
Solution Approach 2:
The patent implements real-time feedback loops where sensor data is continuously transmitted and analyzed by remote systems, enabling immediate detection and correction of torque application issues without delaying quality assurance processes
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 application, 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) 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) 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.