Wireless Torque Sensor Tool for Aircraft Assembly Verification
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Solution Overview
Problem
In aircraft assembly, monitoring and verifying the torque of nuts in tight spaces is challenging due to human error and limited access, leading to potential hydraulic leaks and assembly inaccuracies.
Innovation Solution
A system comprising a tool with a sensor and wireless transmitter that transmits signals upon operation completion, allowing for remote monitoring and location measurement in a 3D coordinate system, enabling accurate verification of torque values even in harsh RF environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional torque-reading wrenches are used to tighten nuts in tight spaces, then torque verification is possible, but access is limited and measurement accuracy deteriorates
Solution Approach 1:
The patent replaces conventional mechanical torque-reading wrenches with a wireless sensor system. Sensors are integrated into the torque tool, automatically measuring torque values and wirelessly transmitting data to a monitoring system, eliminating the need for manual reading and verification while maintaining measurement accuracy in difficult-to-access locations
Solution Approach 2:
The patent introduces wireless communication as an intermediary between the torque tool and the monitoring system. The sensor data is transmitted via wireless signals, allowing remote monitoring of torque operations without requiring direct physical access to the tool or manual intervention, thus solving the access limitation problem
2Reliability
If assembly workers manually monitor and verify nut torquing, then completion tracking is possible, but human error increases and verification reliability decreases
Solution Approach 1:
The patent implements an automated feedback system where sensors continuously monitor torque values and immediately transmit data to a central monitoring system. This real-time feedback eliminates manual monitoring, prevents human error, and provides automatic verification that torque specifications are met, significantly improving reliability
Solution Approach 2:
The torque tool with integrated sensors performs self-monitoring and self-verification of torque operations. The system automatically records, transmits, and verifies torque data without requiring human intervention, eliminating human error while maintaining complete tracking of all torque operations
3Ease of manufacture
If painting marks are used to indicate torqued nuts, then visual indication is provided, but verification of correct torque values is not possible and human error persists
Solution Approach 1:
The patent replaces the simple painting mark method with electronic sensor-based measurement and wireless data transmission. This substitution maintains the simplicity of application (sensors are easily integrated into tools) while enabling precise verification of actual torque values, transforming a qualitative visual indicator into a quantitative verified measurement
Data Source
AI summary
A method and system comprise a tool, a number of radios, and a processor. The tool has a sensor and a wireless transmitter, and is configured to perform an operation on an area. The wireless transmitter is configured to transmit a signal comprising sensor data upon completion of the operation. The number of radios is configured to generate location measurements using the signal. The processor is configured to identify a location of the area using the location measurements and generate an indication of completion of the operation.