Torque Wrench Adapter System with Digital Calibration
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Solution Overview
Problem
Existing torque wrench systems with adapters face inaccuracies in torque value application due to the use of constant torque multipliers, leading to parts being torqued out of specification.
Innovation Solution
A system comprising torque wrench adaptors and accompanying software that allows users to select the correct torque settings for their specific setup, using calibration methods and collected information to ensure accurate torque values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If constant torque multipliers are used to accommodate adapters, then the torque wrench can operate with various adapters, but the torque value accuracy deteriorates because the multiplier only approximates the actual torque value
Solution Approach 1:
The system transitions from static constant torque multipliers to dynamic torque calculations. The torque wrench computer receives real-time inputs about the adapter and fastener characteristics, then dynamically calculates the correct torque value using the formula: Torque = Force x Distance, where the distance is specifically calculated based on the adapter's geometric characteristics and its attachment points to both the wrench and fastener.
Solution Approach 2:
The patent replaces manual mechanical torque multiplication methods with a digital computation system. Instead of relying on fixed mechanical multiplier ratios that approximate torque values, the system uses a computer to calculate the precise torque based on the specific geometric configuration of the adapter and fastener assembly, substituting mechanical approximation with digital precision.
2Measurement precision
If individual torque calculations are performed for each setup, then torque value accuracy improves, but the complexity of the system increases due to the need for software and calibration procedures
Solution Approach 1:
The torque wrench system performs self-calibration and self-calculation. The computer automatically receives geometric data about the adapter and fastener, computes the correct torque values without external intervention, and displays the results to the user. This eliminates the need for manual calibration procedures or external reference standards, allowing the system to serve itself in determining accurate torque values.
Solution Approach 2:
The system incorporates feedback loops where the computer continuously monitors and processes inputs about the adapter and fastener configuration, adjusts torque calculations based on this information, and provides real-time feedback to the user. This feedback mechanism ensures that the torque values displayed are always accurate for the current setup, reducing system complexity by automating the calculation process.
3Measurement precision
If calibration methods with torque meters are implemented, then torque value accuracy is verified, but the time required for setup and calibration increases
Solution Approach 1:
The system performs preliminary calculations and verifications before actual torque application. The computer pre-calculates the correct torque values based on the geometric characteristics of the adapter and fastener, and can pre-verify these calculations against established tolerances. This preliminary action eliminates the need for time-consuming post-application calibration, as the accurate torque values are determined in advance.
Solution Approach 2:
The patent uses digital models and virtual representations of the adapter and fastener geometries to perform calculations and verifications. Instead of physically measuring and calibrating with torque meters, the system creates digital copies of the physical components and performs computations on these models, significantly reducing the time required for calibration while maintaining verification accuracy.
Data Source
AI summary
Many fasteners need to be tightened or “torqued” to precise values, and adjustable torque wrenches are used for this purpose. Unfortunately, many fasteners don't have torque wrench-compatible sockets and thus require torque wrench adapters. These adapters introduce torque offsets, leading to inaccurate torque settings. Here, an improved adapter system is taught, which can be used with ER collet nuts and other popular nuts. In addition to mechanical improvements, the adapters may be marked with computer-readable markings. A smartphone system reads these markings and can either directly or using an internet server, recommend optimal torque conversion settings for a given fastener, adapter, and torque wrench combination.