Wireless Torque Sensor for Fastener Locking Force Control
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Solution Overview
Problem
Conventional methods for measuring tightening torque and locking force in fasteners are inaccurate, costly, and inconvenient, often leading to damage or failure of fasteners and associated components due to excessive force application, and require complex and costly built-in sensors or load cells that slow down measurement operations.
Innovation Solution
An apparatus comprising a sensing device with a connector, sensor, and identifier, a transducing device for data transmission, and a control device with amplification, signal conversion, and power management, which continuously monitors and controls the torque and force applied to fasteners, providing real-time feedback and warnings to prevent excessive force and ensuring accurate measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional tightening tools are used to measure tightening torque, then the magnitude of tightening torque can be measured, but the user tends to excessively exert force on the fastener causing damage or breakage
Solution Approach 1:
The patent implements real-time feedback by continuously monitoring tightening torque through sensors integrated into the fastener and transmitting data to a control device. The control device compares measured torque against predetermined thresholds and provides immediate feedback to stop the tightening process when the threshold is reached, preventing excessive force application while ensuring accurate measurement.
Solution Approach 2:
The patent introduces an intermediary control device that acts as a mediator between the tightening tool and the fastener. This control device receives torque data from sensors, processes the information, and controls the tightening tool's operation to prevent direct excessive force application to the fastener, thereby protecting it from damage.
2Measurement precision
If built-in sensors, data transmitters and microprocessors are integrated into the fastener to achieve precise measurement, then measurement precision improves, but the manufacturing cost of the fastener significantly increases
Solution Approach 1:
The patent segments the measurement system into two parts: a simple, low-cost sensing device integrated into the fastener that only contains sensors and identifiers, and a separate, sophisticated control device that contains the microprocessor, data transmitter, and processing capabilities. This segmentation allows the fastener to remain inexpensive while still achieving precise measurement through the combined system.
Solution Approach 2:
The control device serves as an intermediary that handles the complex processing and communication functions externally, allowing the fastener itself to remain simple and cost-effective while still enabling precise measurement through the coordinated system.
3Measurement precision
If the load cell is electrically connected to the measurement device by wire to display locking force, then measurement precision improves, but the measurement operation is retarded
Solution Approach 1:
The patent replaces the traditional mechanical wire connection system with a wireless communication system. Sensors in the fastener transmit torque and force data wirelessly to the control device using electromagnetic signals, eliminating the need for physical wire connections and thereby reducing measurement operation time while maintaining measurement precision.
Solution Approach 2:
The wireless communication system acts as an intermediary that transfers measurement data without requiring direct physical contact or wire connections, thereby speeding up the measurement process while maintaining accuracy.
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 apparatus enhances measurement precision, prevents fastener damage by providing real-time feedback and warnings, and allows for continuous tracking of torque and force, reducing the risk of accidents and extending the range of applications through adaptable device sizes and shapes.
Implementation Method 1
The sensor is electrically connected to the first connector and senses the locking force or the tightening torque applied to the sensing device
Data Source
AI summary
This invention discloses an apparatus capable of controlling, tracking and measuring the tightening torque and the locking force and a method thereof. The device comprises a control device, a transducing device, and a sensing device. The transducing device comprises a second connector and a first signal transmitter. The control device communicates with the transducing device through a second signal transmitter and the first signal transmitter wiredly or wirelessly. The sensing device comprises a first connector and a sensor, and electrically connects to the transducing device through the second connector and the first connector. The sensing device senses the torque applied to a fastener to transmit real-time sensing data to the control device. The control device compares the real-time sensing data with a setting value so as to measure, control or track the locking force or tightening torque applied to the fastener in real time.