Wireless Torque Sensor for Rotating Shaft
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Solution Overview
Problem
Existing tightening machines face challenges in accurately measuring and controlling torque and rotation angle due to variations in voltage, deceleration mechanism efficiency, and the need for additional measurements, leading to inaccuracies and increased complexity with wired connections and visual check limitations.
Innovation Solution
A wireless data transmitting and receiving system is implemented, where a data transmitting unit on the rotary shaft detects torque and/or rotation angle using sensors and wirelessly transmits signals to a separate data receiving unit for display and control, eliminating the need for wired connections and enabling accurate torque and angle measurement without visual obstruction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the tightening-torque measuring unit is attached to the outer shaft side of the rotary shaft, then the tightening torque can be detected, but the display means cannot be visually checked during rotation or at some rotation stop positions
Solution Approach 1:
The patent replaces the mechanical connection (signal line) with a wireless communication system. The tightening-torque measuring unit attached to the rotating outer shaft transmits torque data wirelessly to a receiver on the stationary machine body, eliminating the need for physical wire connections that would wind or jam during rotation. This allows the display means to remain stationary and visually accessible while the sensor rotates with the shaft.
2Measurement precision
If the tightening-torque measuring unit is attached to the outer shaft side, then the torque can be measured, but a difference between torque acting on the outer shaft and torque acting on the inner shaft actually performing tightening may be caused
Solution Approach 1:
The patent introduces a reaction force receiver as an intermediary element that transfers the reaction force from the outer shaft to the inner shaft. This ensures that the tightening-torque measuring unit attached to the outer shaft accurately measures the torque being applied to the workpiece by the inner shaft, eliminating measurement discrepancies between the two shafts.
3Loss of information
If a signal line is used to connect the tightening-torque measuring unit and the display, then the torque value can be transmitted, but the signal line may wind around the tightening-torque measuring unit or jam during working
Solution Approach 1:
The patent replaces the mechanical signal line connection with a wireless communication system. The tightening-torque measuring unit transmits torque data wirelessly to a receiver on the stationary machine body, eliminating the physical wire that would wind or jam during rotation. This maintains reliable data transmission while removing the mechanical complexity of signal line management.
4Measurement precision
If the tightening-torque measuring unit rotates together with the rotary shaft, then the torque can be detected in real-time, but the tightening machine itself is increased in size
Solution Approach 1:
The patent divides the tightening machine into two functional segments: a rotating part (the outer shaft with the tightening-torque measuring unit) and a stationary part (the machine body with the receiver and display). This segmentation allows the sensor to rotate with the shaft for real-time detection while the receiver and display remain stationary, minimizing the overall size increase of the machine.
5Productivity
If the tightening-torque measuring unit is in the recessed portion during tightening, then the tightening can be performed, but the tightening torque cannot be visually checked
Solution Approach 1:
The patent uses wireless communication to transmit torque data from the rotating measuring unit in the recessed portion to a stationary receiver on the machine body. This allows the tightening operation to proceed with the sensor in the recessed portion while the torque values are displayed on the stationary display means, enabling visual checking without obstructing the tightening operation.
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
This solution provides accurate and reliable torque and rotation angle control, reduces the need for additional measurements, improves workability by minimizing electrical noise, and allows for remote management of tightening processes, enhancing the precision and efficiency of tightening operations.
Implementation Method 1
a torque sensor such as a strain gauge
Implementation Method 2
transmitting means that is electrically connected to the torque sensor and wirelessly transmits a signal regarding the torque detected in the torque sensor
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A wireless data transmitting and receiving system including: a data transmitting unit (20) provided on the rotary shaft (52) of a tightening machine (50) to detect the torque and the rotation angle, the data transmitting unit (20) including a torque sensor (21) disposed so as to be capable of sensing a toque acting on the rotary shaft (52), a rotation angle sensor (29) disposed so as to be capable of a rotation angle of the rotary shaft (52), and transmitting means (22) that is electrically connected to the foregoing sensors (21,29), and wirelessly transmits signals regarding the torque detected in the torque sensor (21) and the rotation angle detected in the rotation angle sensor (29); and a data receiving unit (30) including receiving means (32) that receives the transmitted signals regarding the torque and the rotation angle, and display means (40) that displays the signals regarding the torque and the rotation angle received by the receiving means (32).