Hydraulic Torque Wrench with Piston Proximity Sensor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydraulic torque wrenches require operators to manually monitor both the wrench and a pressure gauge, making it difficult to achieve the exact desired torque, leading to potential over- or under-tightening of fasteners.
Innovation Solution
A hydraulic torque wrench equipped with a proximity sensor connected to a controller, which detects the maximum extension of the piston and automatically reverses the hydraulic fluid flow, allowing for precise torque application without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual monitoring of both the wrench and pressure gauge is required, then the operator can observe the tightening process, but the precision of torque application deteriorates due to the difficulty of ceasing tightening at the exact desired pressure
Solution Approach 1:
The system performs self-monitoring and self-control through the proximity sensor detecting piston position and the controller automatically reversing hydraulic fluid flow. The operator only needs to initiate the process, after which the system autonomously monitors torque application and executes the reversal action, eliminating manual intervention requirements.
Solution Approach 2:
The proximity sensor provides real-time feedback on piston extension status to the controller. When maximum extension is detected, the controller receives this feedback signal and automatically reverses the hydraulic fluid flow direction, creating a closed-loop control system that ensures precise torque application without operator intervention.
2Reliability
If the operator cycles the hydraulic torque wrench until the hydraulic fluid pressure reaches an indicated threshold, then torque can be applied, but the reliability of achieving exact desired torque deteriorates due to the difficulty of stopping at the precise moment
Solution Approach 1:
The system pre-configures the reversal mechanism and proximity sensor detection threshold before torque application begins. The controller is programmed with the exact piston position corresponding to desired torque, so when the sensor detects this pre-determined position, the automatic reversal occurs immediately, eliminating the time loss associated with operator reaction and decision-making.
Solution Approach 2:
The manual mechanical operation of monitoring pressure gauges and timing the reversal is replaced by an automated electromechanical system. The proximity sensor and controller substitute for the operator's visual monitoring and manual timing, achieving more consistent and reliable torque application with reduced variability.
3Measurement precision
If a torque indicator (hydraulic pressure gauge) is provided, then the operator can monitor torque, but the device complexity increases due to requiring multiple monitoring components
Solution Approach 1:
The proximity sensor is integrated into the existing hydraulic torque wrench structure, combining the measurement function with the mechanical components already present. The sensor utilizes the existing piston and cylinder assembly, merging the measurement capability into the core mechanism rather than adding a separate external monitoring system.
Solution Approach 2:
The proximity sensor acts as an intermediary between the mechanical piston movement and the electronic control system. It converts the mechanical position information into an electrical signal that the controller can process, serving as a bridge that adds measurement capability without requiring direct integration of complex electronic components into the hydraulic system.
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 enables automatic and precise control of torque application, reducing the risk of over- or under-tightening and improving efficiency by eliminating the need for manual monitoring of both the wrench and pressure gauge.
Implementation Method 1
the torque wrench mounts a proximity sensor connected to the signal carrying connector and configured to detect maximum extension of the piston
Implementation Method 2
When the valve is configured to allow pressurised hydraulic fluid to move through the hydraulic torque wrench, a piston is caused to move by the pressurised hydraulic fluid
Data Source
AI summary
A hydraulic torque wrench comprises a ratchet link, a power head, and a signal carrying connector for connection to a controller. The ratchet link includes a housing and a drive plate mounted for rotation about an axis within the housing, the drive plate mounting one part of a first part of a ratchet drive. A socket is mounted for rotation within the housing, the socket providing a second part of the ratchet drive. During rotation of the drive plate in one direction the first and second part of the ratchet drive engage each other to cause rotation of the socket with the drive plate and during rotation of the drive plate in a second direction one of the first and second parts of the ratchet drive rides over the other such that the socket remains stationary while the drive plate rotates. The power head includes a piston and cylinder and hydraulic connections adapted for connection to a source of pressurised hydraulic fluid. The torque wrench mounts a proximity sensor connected to the signal carrying connector and configured to detect maximum extension of the piston. When maximum extension of the piston is detected the proximity sensor emits an electrical signal.