Hydraulic Torque Wrench Orientation Sensing for Flange Bolt Sequence
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Solution Overview
Problem
Hydraulic torque wrenches face challenges in ensuring proper orientation and sequence when tightening multiple fasteners, particularly around flange joints, which can lead to uneven load distribution and potential damage or leaks.
Innovation Solution
A hydraulic torque wrench system equipped with an orientation sensor and controller that determines the correct sequence and orientation for tightening fasteners by comparing measured orientation values to target values, inhibiting operation if not within tolerance, and alerting the operator, ensuring proper alignment and sequence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation of hydraulic torque wrench is used, then operator flexibility is maintained, but orientation control and sequence accuracy deteriorate
Solution Approach 1:
The system continuously monitors the wrench orientation using sensors (accelerometers, gyroscopes, magnetometers) and provides real-time feedback to the operator through visual or audible signals. The controller compares actual orientation with target orientation and alerts the operator when proper alignment is achieved, enabling precise orientation control while maintaining manual operation flexibility.
Solution Approach 2:
The patent replaces manual orientation judgment with electronic sensing systems. Instead of relying on operator skill to visually align the wrench, the system uses accelerometers, gyroscopes, and magnetometers to electronically detect and measure orientation, substituting mechanical/sensory operations with electronic measurement and control.
2Manufacturing precision
If orientation sensor and controller are added to ensure proper alignment, then tightening precision is improved, but device complexity increases
Solution Approach 1:
The controller serves multiple functions: it processes sensor data from accelerometers, gyroscopes, and magnetometers; calculates orientation angles; compares with target values; controls the hydraulic actuator; and provides user feedback. This multi-functionality reduces the need for separate dedicated components for each task, thereby managing system complexity while achieving precise tightening control.
Solution Approach 2:
The patent combines multiple sensing functions (acceleration measurement, rotation rate measurement, magnetic field detection) into a single integrated sensor package mounted on the wrench. This merging of multiple sensing elements into one compact unit reduces overall system complexity compared to using separate sensors for each measurement type.
3Stability of the object's composition
If sequence control is enforced through orientation monitoring, then load distribution uniformity is improved, but operation time increases
Solution Approach 1:
The system pre-stores the correct tightening sequence and target orientation values for all fasteners in the controller's memory before operation begins. This preliminary preparation allows the controller to immediately compare real-time sensor readings against predetermined targets, enabling rapid sequence verification without requiring manual planning or calculation during the actual tightening process.
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 system ensures safe and effective tightening of fasteners by maintaining proper orientation and sequence, preventing damage and leaks, and ensuring even load distribution around flange joints.
Implementation Method 1
the orientation sensor may measure the orientation of the wrench with respect to gravity
Implementation Method 2
the orientation sensor may measure the orientation of the wrench with respect to Earth's magnetic field
Implementation Method 3
the orientation sensor may measure rotational acceleration of the wrench with respect to three mutually orthogonal axes that are fixed in relation to the wrench
Data Source
AI summary
A hydraulic torque wrench system includes an object including a plurality of fasteners and a hydraulic torque wrench. A wrench includes an orientation sensor and a controller having an electronic processor and a memory. The controller is configured to determine a desired sequence in which the wrench should tighten a plurality of fasteners on an object, receive a first measurement signal from the orientation sensor, and determine a first orientation value of the wrench based on the first measurement signal. The controller is further configured to compare the first orientation value to a first target orientation value associated with a first target orientation of the wrench for tightening a first fastener in the desired sequence, inhibit operation of the wrench if the first orientation value is not within a tolerance of the first target orientation value