Torque Wrench Strain Gauge Sensor Wireless Monitoring
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Solution Overview
Problem
In aircraft assembly, monitoring and verifying the torque of nuts in complex hydraulic systems is challenging due to human error and limited access, especially in tightly clustered or obstructed areas, leading to potential hydraulic leaks and assembly inaccuracies.
Innovation Solution
A system that uses a torque wrench with a strain gauge sensor and UWB pulse signal transmitter to remotely monitor and display the completion of manufacturing operations in a 3D environment, allowing for accurate torque measurement and verification even in harsh RF environments with obstructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional torque-reading wrenches are used to tighten nuts, then torque verification is possible, but assembly workers cannot access nuts in tightly clustered or obstructed areas
Solution Approach 1:
A wireless transmitter is introduced as an intermediary device attached to the torque wrench. This transmitter wirelessly transmits torque data and location information to remote monitoring systems, allowing torque verification without requiring direct line-of-sight access to the nut, thus solving the contradiction between accessibility and measurement precision
Solution Approach 2:
The patent replaces the mechanical reading system (where an worker must physically read the torque wrench dial) with an electronic sensing and wireless transmission system. Strain gauge sensors electronically measure torque and transmit data remotely, eliminating the need for physical access to verify torque values on obstructed nuts
2Reliability
If assembly workers visually monitor torque operations, then local monitoring is possible, but human error prevents reliable verification
Solution Approach 1:
The system implements automatic feedback by capturing torque data from strain gauge sensors and wirelessly transmitting it to monitoring systems. This automated feedback loop eliminates human error in verification while maintaining simple operation for the assembly worker, who simply performs the torquing action without needing to interpret or record data
Solution Approach 2:
The torque wrench performs self-verification through integrated strain gauge sensors that automatically measure and record torque values. The wireless transmitter then self-transmits this data to monitoring systems, eliminating the need for human intervention in the verification process while maintaining system simplicity
3Loss of information
If marks are painted on nuts to indicate completion, then visual tracking is possible, but human error and lack of torque verification occur
Solution Approach 1:
The patent replaces the manual marking system with electronic sensing and wireless data transmission. Strain gauge sensors electronically capture torque values and wireless transmitters automatically send this data to monitoring systems, providing both completion tracking and precise torque verification without human error
Solution Approach 2:
Instead of physically marking the nut, the system creates a digital copy of the torque data and location information, transmitting it wirelessly to monitoring systems. This digital record provides accurate tracking and verification without the limitations of physical marking methods
4Productivity
If remote monitoring of torque operations is implemented, then completion tracking is improved, but system complexity increases
Solution Approach 1:
The wireless transmitter serves multiple functions: it captures torque data from strain gauges, determines location using GPS or other positioning systems, transmits data remotely, and enables completion tracking. This multi-functionality achieves comprehensive remote monitoring through a single integrated device, minimizing the increase in system complexity
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 precise monitoring and verification of nut torque, reducing human error and ensuring correct assembly, thereby preventing hydraulic leaks and improving manufacturing efficiency in complex aircraft assembly environments.
Implementation Method 1
The tool may comprise a torque wrench including a strain gauge sensor for sensing the applied torque
Implementation Method 2
a wireless transmitter on the tool for wirelessly transmitting a signal indicating the tool has completed an operation
Data Source
AI summary
An electronic torque wrench having a flexible head provides accurate torque measurements irrespective of the angular position of the head relative to a handle on which the force is applied. The head includes first and second portions connected by at least three pivotal links. One of the links is used to react against the entire torque applied to the handle, regardless of the pivotal position of the handle. An electronic strain gauge on the torque-reacting link provides a measurement of the torque applied to the fastener.