Torque Wrench Optical Motion Analysis for Overtorque Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing torque wrench technologies cannot analyze the load condition of tightened members during tightening operations, specifically failing to detect excessive torque values beyond the preset torque value.
Innovation Solution
A tightening operation analysis apparatus and system that includes a motion information acquisition unit and an analysis unit within a torque wrench, utilizing a light emitting and receiving element to detect the turning motion of the wrench's main body, allowing for the analysis of load conditions based on the acquired motion information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical torque wrench is used to detect tightening torque, then the worker can know when the preset torque value is reached through clicking noise and vibration, but the load condition of the tightened member cannot be analyzed and excessive torque cannot be detected
Solution Approach 1:
The patent replaces the purely mechanical detection system (clicking noise and vibration) with an optical detection system. A light emitting element and light receiving element are used to detect the turning motion of the main body, converting mechanical motion into optical signals for analysis. This substitution enables detailed measurement of motion characteristics to determine load conditions and detect excessive torque.
Solution Approach 2:
The patent introduces an intermediary analysis apparatus that bridges the torque wrench and the analysis system. The motion information acquisition unit captures turning motion data, which is then processed by the analysis unit to determine load conditions. This intermediary system enables indirect measurement of torque conditions through motion characteristics.
2Ease of operation
If the main body is made to turn when preset torque value is reached, then the worker is notified of the tightening completion, but the turning motion cannot provide information about excessive torque
Solution Approach 1:
The patent applies dynamics by analyzing the motion characteristics of the turning main body. Instead of simply detecting whether the main body turns (which only indicates preset torque is reached), the system measures the angular velocity, acceleration, and duration of the turning motion. These dynamic parameters provide information about the magnitude of applied torque and whether it exceeds the preset value.
Solution Approach 2:
The patent implements feedback by using the motion information to determine load conditions and provide analysis results back to the operator. The analysis unit processes the turning motion data and provides feedback about whether the applied torque is within the preset value or excessive, enabling real-time monitoring and control of the tightening operation.
3Loss of information
If a light emitting and receiving element is added to detect turning motion, then load condition analysis becomes possible, but the device complexity increases
Solution Approach 1:
The patent applies multi-functionality by integrating the light emitting element and light receiving element into the existing torque wrench structure. These elements serve dual purposes: they detect the turning motion of the main body (providing motion information) and can also be used to determine the preset torque value. This multi-functional approach reduces the need for separate dedicated components.
Solution Approach 2:
The patent merges the detection function with the existing torque wrench structure. The light emitting and receiving elements are integrated into the main body and head assembly, combining the torque application function with the motion detection function in a unified device. This integration minimizes additional complexity by utilizing the existing mechanical structure for both purposes.
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
Enables the analysis of load conditions during tightening operations, specifically identifying whether the applied torque exceeds the preset value, thereby preventing overtorque and improving the accuracy of tightening processes.
Implementation Method 1
utilizing a light emitting and receiving element to detect the turning motion of the wrench's main body
Data Source
AI summary
There is provided a tightening operation analysis apparatus configured to analyze a tightening operation performed by a worker using a tightening tool. The tightening tool includes a head configured to be able to engage with a tightened member, and a main body configured to pivotally engage with the head and turn when a tightening torque for tightening the tightened member reaches a preset torque value. The tightening operation analysis apparatus includes a motion information acquisition unit configured to acquire motion information indicating a turning motion of the main body, from the tightening tool, and an analysis unit configured to output a result of analysis of a load condition of the tightened member during the tightening operation, based on the motion information acquired by the motion information acquisition unit.