Portable Torque Tool Shifting for Fast and Accurate Bolt Tightening
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Solution Overview
Problem
Existing torque power tools face challenges with slow driving speed, large size, and complexity in shifting between high and low torque modes, leading to inefficiencies and increased operator reliance on manual settings, which can result in inaccurate and time-consuming fastener tightening.
Innovation Solution
A portable torque power tool with a motor, drive, turning force multiplication mechanism, shifter assembly, and wireless torque transducer for accurate torque measurement, along with an operation parameter regulation unit for networked tools, enabling simultaneous tightening of industrial fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If high torque values are generated from small portable tools with large gear reduction ratios, then torque output is improved, but driving speed becomes quite slow
Solution Approach 1:
The patent applies dynamics by implementing a shifter assembly that enables the tool to switch between different operating modes (high torque/low speed and low torque/high speed). This allows the tool to adapt its characteristics dynamically based on the operational requirements, resolving the contradiction between torque output and driving speed.
Solution Approach 2:
The patent changes operational parameters by providing multiple gear reduction ratios through the shifter assembly. The tool can switch between a first operating mode with a first gear reduction ratio (for high torque) and a second operating mode with a second gear reduction ratio (for higher speed), thereby adjusting parameters to suit different tasks.
2Device complexity
If manual settings are used for torque control, then device complexity is reduced, but accuracy and time efficiency deteriorate
Solution Approach 1:
The patent incorporates a torque transducer that provides feedback on the actual torque being applied. This feedback mechanism allows the control system to monitor and adjust the torque output, ensuring accuracy without requiring complex manual settings or procedures from the operator.
Solution Approach 2:
The tool performs self-adjustment of torque parameters through its control system, which automatically manages the torque application based on pre-programmed sequences. This eliminates the need for manual torque settings by the operator while maintaining high accuracy through automated control and torque transducer feedback.
3Force
If multiple planetary gear stages are used to multiply output torque, then torque output is improved, but device complexity and size increase
Solution Approach 1:
The patent uses a shifter assembly that can selectively engage or disengage planetary gear stages, allowing the tool to switch between different torque multiplication ratios. This dynamic configuration reduces the need for permanently complex multi-stage gearboxes, as only the necessary gear stages are engaged for each specific task.
Solution Approach 2:
The gearbox is segmented into multiple independent planetary gear stages that can be selectively engaged through the shifter assembly. This allows the tool to use only the required number of gear stages for a given task, reducing overall complexity while maintaining the capability for high torque multiplication when needed.
4Speed
If impact wrenches are used for high run down and run off speed, then speed is improved, but accuracy and rotation control deteriorate
Solution Approach 1:
The patent incorporates a torque transducer and control system that provide feedback on rotation and torque parameters. This feedback mechanism allows the tool to maintain high speed during run-down and run-off operations while simultaneously ensuring rotational accuracy and proper nut seating, eliminating the trade-off present in impact wrenches.
Solution Approach 2:
The patent replaces the purely mechanical impact mechanism with a controlled system that uses torque transducers and electronic control to manage the fastening process. This substitution allows for both high speed operation and precise control of rotation and torque, achieving what traditional impact wrenches cannot accomplish.
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
The tool achieves simplified design, reduced size, enhanced portability, and improved usability with accurate torque control, ensuring efficient and repeatable fastener tightening while minimizing operator error.
Implementation Method 1
a motor to generate a turning force
Implementation Method 2
a turning force multiplication mechanism assembly to multiply the turning force
Data Source
AI summary
A portable torque power tool is disclosed herein and includes: a motor to generate a turning force; a drive to transfer the turning force; a turning force multiplication mechanism assembly to multiply the turning force; a shifter assembly to shift the tool between a lower speed/higher torque (LSHT) mode and a higher speed/lower torque (HSLT) mode; a torque transducer to measure torque output; wherein torque output is controlled by the torque transducer in LSHT mode; and wherein torque output is controlled by motor current in HSLT mode. In one embodiment of the present application, the torque transducer is a wireless torque transducer assembly formed at or near an output of a housing of the turning force multiplication assembly to improve measurement accuracy of torque output. Advantageously, simplified tool and system design and operation; reduced tool and system size; expanded functionality, greater durability and intuitive usability; and increased tool and system portability, efficiency, reliability and repeatability, all at low cost, are achieved. Further disclosed herein is an operation parameter regulation unit for use with a bolting system having a plurality of networked electrically powered torque tools and/or drive portions of torque tools described above for simultaneous tightening of industrial threaded fasteners. The operation parameter regulation unit includes: a processing unit; an output unit connected and/or integrated with the processing unit; an input unit connected and/or integrated with the processing unit; an activation unit connected and/or integrated with the processing unit for activating operation units of the plurality of networked electrically powered torque tools and/or drive portions of torque tools; and a control unit for controlling operation parameters of each of the plurality of networked electrically powered torque tools and/or drive portions of torque tools to maintain a difference between the operation parameters within a predetermined value. Advantageously, innovations disclosed in this application include operation parameter regulation units for bolting systems having a plurality of networked electrically powered torque tools and/or drive portions of torque tools for simultaneous tightening of industrial threaded fasteners. Indeed SIMULTORC® is achievable with a plurality of networked electrically powered torque tools and/or drive portions of torque tools, particularly those of the handheld and/or mobile variety.