Wireless Clamp Tool Strain Gauge Power Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wireless clamp tools face challenges in power consumption and battery life due to the need for low power states when not in use, and the complexity of integrating radio transceivers in production environments, which hinders their widespread adoption in assembly processes.
Innovation Solution
A battery-operated wireless clamp tool with a strain gauge sensor and microprocessor that normalizes force data, transmits signals wirelessly to an interface box for error proofing, and operates effectively across various clamp types and orientations using 900 MHz or 2.4 GHz radio transmission, ensuring accurate data recording and analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a wireless clamp tool with radio transceiver and microprocessor is used, then cable usage is eliminated and operational flexibility is improved, but power consumption increases and battery life decreases
Solution Approach 1:
The system employs periodic transmission where the radio transceiver and microprocessor remain in low-power states between operations, activating only when needed for data transmission and reception. This allows wireless functionality while minimizing energy consumption during idle periods.
Solution Approach 2:
The qualifier technology provides feedback mechanisms that allow the system to monitor its own operational state and power consumption, enabling intelligent power management that activates components only when necessary for maintaining wireless communication and tool monitoring functions.
2Ease of operation
If radio transceivers are used to replace signal cables, then wireless operation is achieved, but device complexity increases
Solution Approach 1:
The radio transceiver and microprocessor are integrated into existing tool monitor and controller designs, allowing these components to serve dual purposes: maintaining their original tool monitoring functions while also enabling wireless communication capabilities. This reduces overall system complexity by reusing existing infrastructure.
3Duration of action of moving object
If low power states are employed to extend battery life, then energy efficiency is improved, but operational responsiveness may be reduced
Solution Approach 1:
The system prepares for rapid activation by maintaining standby modes where critical components remain in low-power states but can quickly transition to full operational mode when triggered, ensuring both extended battery life and maintained operational responsiveness.
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 tool provides reliable accountability and control, extending battery life and eliminating the need for signal cables, allowing for efficient operation and error-proofing in assembly processes, regardless of clamp orientation or obstructions.
Implementation Method 1
A flexure with applied electronic strain gauges to sense the forces being applied to and received from the release action of the clamp
Implementation Method 2
a radio transceiver to transmit an indication that a clamp has been released to the assembly control box. Transmission of the signals operates in the 900 MHZ or the 2.4 GHZ ranges
Data Source
AI summary
This system is a tool and monitor assembly that verifies clamps have been activated properly with the tool. The radio controlled clamp tool provides accountability and control with a strain gauge operation. The radio tool is designed to perform the operation of clamp tool, retain the signature and transmit the signal with data to an interface box for error proofing or tool analysis.