Torque Wrench Tilt Compensation via Gravity Sensor Correction
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Solution Overview
Problem
Conventional torque wrenches suffer from inaccuracy errors due to tilt angles during operation, which affect the accuracy of rotational angle measurements, and existing angle sensors are prone to damage and have design limitations.
Innovation Solution
A torque wrench equipped with a torque sensor, an angle sensor, a gravity sensor, and a processor that corrects the rotational angle value based on the tilt angle sensed by the gravity sensor, using components like gyroscope chips and microprocessors to improve measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional angle sensors are used to measure rotational angle, then rotational angle can be obtained, but measurement precision deteriorates due to tilt angles during operation
Solution Approach 1:
The patent introduces gravity sensors as intermediary devices that detect tilt angles and serve as mediators between the actual wrench orientation and the angle sensor measurements. The gravity sensors provide tilt angle data that is used to correct the rotational angle measurements, thereby compensating for the inaccuracy caused by tilt without requiring the angle sensor itself to be tilt-resistant.
Solution Approach 2:
The system implements feedback by continuously monitoring tilt angles through gravity sensors and using this information to correct the rotational angle measurements in real-time. The processor receives both the angle sensor data and gravity sensor data, calculates the tilt correction, and adjusts the final rotational angle measurement accordingly, creating a closed-loop feedback system that improves measurement accuracy.
2Productivity
If angle sensors are installed in the torque wrench to measure rotational angle, then rotational angle data can be obtained, but the angle sensors are prone to damage and have design limitations
Solution Approach 1:
The gravity sensors act as intermediary devices that indirectly provide the necessary tilt information without requiring the angle sensor to operate in harsh conditions. By measuring tilt angles separately and using this data to correct angle sensor readings, the system protects the angle sensor from direct exposure to the damaging operational environment while still achieving accurate measurements.
Solution Approach 2:
The patent replaces part of the mechanical angle sensing function with a combination of gravity sensing and computational correction. Instead of relying solely on a mechanical angle sensor to accurately measure rotational angle under tilt, the system substitutes some of this function with gravity sensors that detect tilt and a processor that calculates corrections, thereby reducing the burden and stress on the angle sensor.
3Measurement precision
If tilt angle compensation is implemented using gravity sensors, then measurement accuracy is improved, but device complexity increases
Solution Approach 1:
The gravity sensor serves multiple functions: it detects the tilt angle of the wrench, provides data for correcting rotational angle measurements, and can potentially be used for other orientation-related measurements. By making the gravity sensor a multi-functional component, the patent reduces the need for additional dedicated tilt sensors, thereby limiting the increase in device complexity while still achieving improved measurement precision.
Solution Approach 2:
The patent merges the tilt detection function with the existing angle measurement system by integrating gravity sensors into the same measurement pipeline. The processor combines data from both the angle sensor and gravity sensor to produce a corrected rotational angle measurement, merging multiple sensing functions into a unified system that achieves high precision without requiring completely separate subsystems.
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 solution effectively reduces inaccuracy errors by accounting for tilt angles, enhancing the precision of rotational angle measurements and extending the lifespan of angle sensors through improved design and functionality.
Implementation Method 1
The gravity sensor senses the tilt angle of the wrench body
Implementation Method 2
The angle sensor obtains a rotational angle value by measuring the rotation of the wrench body
Implementation Method 3
The torque sensor senses whether the torque is greater than a predetermined torque value
Data Source
AI summary
A torque wrench includes a wrench body, a torque sensor, an angle sensor, a gravity sensor and a processor. The wrench body can provide a torque to a workpiece. The torque sensor can sense whether the torque is greater than a predetermined torque value. The angle sensor can obtain a rotational angle value by measuring the rotation of the wrench body after the torque is greater than the predetermined torque value. The gravity sensor can sense the tilt angle of the wrench body. The processor is programmed to correct the rotational angle value according to the tilt angle of the wrench body.