Electronic Torque Tool Unlocking via On-Site Calibration Verification
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Solution Overview
Problem
Calibratable electronic torque tools, such as torque wrenches and screwdrivers, can become improperly calibrated due to shocks, excessive strain, or overuse, leading to potential damage or loosening of workpieces if used without recalibration, which is a time-intensive process.
Innovation Solution
A method and system that utilize a direct data link between the torque tool and a testing device to compare tool-side and testing device-side torque values within a specified tolerance range, generating an unlocking signal to override the tool's lock if the values are within tolerance, ensuring proper calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the torque tool is locked after a calibration-impairing event to prevent improper use, then the reliability of torque application is improved, but the productivity is worsened due to time-intensive recalibration requirements
Solution Approach 1:
The calibration verification process is segmented into two distinct levels: a comprehensive calibration performed at a calibration laboratory and a quicker verification process performed on-site using a testing device. This segmentation allows the tool to be locked after potential calibration impairment events, maintaining reliability, while enabling rapid verification and unlocking on-site, improving productivity by avoiding complete recalibration cycles.
Solution Approach 2:
The testing device performs preliminary verification of calibration status before the tool is put back into service after a locking event. By conducting this preliminary check on-site using torque test values and comparison against tolerance ranges, the system determines whether full recalibration is actually necessary, thus improving productivity while maintaining reliability standards.
2Measurement precision
If complete recalibration in a calibration laboratory is performed after every lock event, then the measurement precision is ensured, but the loss of time increases significantly
Solution Approach 1:
Instead of performing complete recalibration every time the tool is locked, the system applies partial action through on-site verification using a testing device. This partial verification process checks whether the calibration deviation is within acceptable tolerance ranges, allowing the tool to be quickly unlocked if verification passes, thus reducing time loss while maintaining measurement precision through periodic full calibration.
Solution Approach 2:
The testing device enables the torque tool to essentially self-verify its calibration status on-site. The tool's own torque sensor measurements are compared against reference values from the testing device, allowing the system to determine whether recalibration is needed without requiring immediate intervention from calibration laboratory personnel, significantly reducing time loss.
3Object-affected harmful factors
If a lock mechanism is implemented to prevent use of potentially improperly calibrated tools, then the harmful factors affecting workpieces are reduced, but the ease of operation is worsened due to additional verification steps
Solution Approach 1:
The testing device acts as an intermediary between the locked torque tool and the user. It provides an automated verification process that objectively determines whether the tool should remain locked or be unlocked, removing the need for subjective judgment and simplifying the operator's task to merely connecting the testing device and interpreting the automated result, thus maintaining safety while improving ease of operation.
4Manufacturing precision
If frequent calibration checks are performed to ensure accuracy, then the manufacturing precision is maintained, but the device complexity increases due to additional testing equipment and data links
Solution Approach 1:
The testing device is designed with multi-functionality to justify its complexity: it can verify calibration accuracy, establish data links with the torque tool, compare measurement values against tolerance ranges, and control the locking/unlocking state. By consolidating these functions into a single device, the system maintains manufacturing precision through frequent verification while minimizing the overall complexity that would result from separate systems for each function.
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
Facilitates faster and simpler recalibration verification, preventing the use of improperly calibrated tools by electronically overriding the lock only when calibration is confirmed, thus ensuring accurate torque application.
Implementation Method 1
determining a testing device-side torque test value of the torque tool by a torque sensor of the torque testing device
Data Source
AI summary
A method and system for unlocking a calibratable electronic torque tool and a torque testing device and the calibratable electronic torque tool. To unlock the calibratable electronic torque tool, a tool head of the calibratable electronic torque tool is coupled to the torque testing device and a direct data link is established. The calibratable electronic torque tool and the torque testing device separately determine torque test values, which are transferred to a data processing device of the torque testing device and compared with each. If the difference between the torque test values is within a specified or specifiable tolerance range, an unlocking signal is transferred to the calibratable electronic torque tool via the data link and the calibratable electronic torque tool is unlocked by overriding a lock via the transferred unlocking signal.