Electronic Torque Wrench Obstacle Detection via Dual Flex Sensors
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Solution Overview
Problem
Existing electronic torque wrenches fail to automatically detect and signal incorrect operating conditions, such as encountering obstacles during torque measurement, which can lead to inaccurate readings, especially in confined spaces where visual detection is difficult.
Innovation Solution
The electronic torque wrench employs two flex sensor elements spaced along its axis to detect changes in bending moments, calculating if the flexing value at the sensor closest to the front end is less than that at the farthest end, and emits an error signal if this condition is met, using an electronic control circuit and acoustic signaling to alert the user.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single flex sensor element is used to detect torque, then the device complexity is reduced, but the ability to detect obstacles and incorrect operating conditions deteriorates
Solution Approach 1:
The single flex sensor element is divided into two separate sensor elements (first and second) positioned at different locations along the wrench body. This segmentation allows independent detection of bending moments at different points, enabling obstacle detection while maintaining reasonable device complexity through modular sensor placement
2Device complexity
If visual inspection by user is relied upon to detect obstacles, then the device complexity remains low, but the measurement precision deteriorates due to undetected obstacles in confined spaces
Solution Approach 1:
The wrench performs self-detection of obstacles through the dual flex sensor system that automatically monitors bending moment distribution during operation. The electronic control circuit continuously compares sensor readings to identify abnormal patterns indicating obstacle contact, eliminating the need for user visual inspection and ensuring continuous accurate measurement
3Reliability
If two flex sensor elements are used to detect bending moments at different positions, then the obstacle detection capability is improved, but the device complexity increases
Solution Approach 1:
The two flex sensor elements serve multiple functions: they detect torque magnitude, detect obstacle contact through bending moment pattern analysis, and provide data for electronic control calculations. This multi-functionality justifies the increased sensor quantity by eliminating the need for separate detection systems
4Ease of operation
If the wrench is used in confined spaces with projecting parts, then the ease of operation is improved for accessing tight areas, but the risk of undetected obstacle contact increases
Solution Approach 1:
The electronic control circuit continuously monitors the relative bending moment values from both sensor elements and provides real-time feedback about obstacle contact conditions. When abnormal bending patterns indicate obstacle contact, the system generates alerts to warn the user, ensuring that information about obstacles in confined spaces is not lost
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
This solution enables the automatic detection and signaling of obstacles during torque measurement, ensuring accurate torque calculation and user awareness of incorrect operating conditions, thereby preventing measurement alteration.
Implementation Method 1
a sensor for detecting a torque applied with the wrench to the coupling and comprising two flex sensor elements which are arranged spaced apart along the longitudinal axis
Data Source
AI summary
An electronic torque wrench (10) comprises a body with an axial extension along a longitudinal axis; a front end provided with a coupling (14) intended to engage the wrench on a joint to be tightened by manual rotation around a rotation axis (15) which is transverse to the longitudinal axis (11); a handle (13) along the body for operating the wrench; and a sensor (16) for detecting a torque applied with the wrench to the coupling (14) and comprising two flex sensor elements (16a and 16b) which are arranged spaced apart along the longitudinal axis (11). An electronic control circuit (17) is connected to the sensor (16) for receiving signals from it and applying a method which comprises the steps of calculating, depending on the flexing values detected by the two sensor elements (16a and 16b), whether the flexing value detected by the sensor element closest to the front end is less than the flexing value detected by the sensor element farthest from the end front; and, if so, emitting an error signal.