Wireless Torque Wrench with Visual Designator for Fastener Sequencing
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Solution Overview
Problem
The process of tightening nuts and bolts in large mechanical assemblies, such as aircraft engines, is prone to human error due to the need for precise sequencing and retorquing, which can lead to mistakes in the assembly process.
Innovation Solution
A wireless-enabled tightening system that includes a visual designator for guiding the operator, a torque wrench with a wireless transmitter to ensure correct torque application, and a camera with a microprocessor to track and sequence fastener tightening, minimizing errors by projecting indicators and capturing images to determine the correct sequence and torque application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual tracking and sequencing of fastener tightening is used, then the assembly process can be completed, but human error increases due to the complexity of tracking multiple fasteners and retorquing operations
Solution Approach 1:
The system enables self-service by allowing the workpiece itself to provide identification information through embedded RFID tags or data matrices. Each fastener contains its own identifier that the reader automatically detects, eliminating the need for external tracking systems or manual record-keeping. The fastener essentially serves its own identification and tracking function.
Solution Approach 2:
The patent replaces manual mechanical tracking methods with an automated electronic identification system. Instead of technicians manually tracking fastener positions and sequences, the system uses readers, RFID tags, and data matrices to automatically identify and track each fastener, substituting human cognitive effort with electronic detection and processing.
2Reliability
If automated identification and tracking systems are implemented, then human error is reduced, but the system complexity and cost increase
Solution Approach 1:
The system uses data matrices and RFID tags as information copies embedded in or associated with each fastener. These copies contain identification data that can be read electronically, replacing the need for physical inspection or manual tracking of each fastener's identity and status in the tightening sequence.
Solution Approach 2:
The reader device serves multiple functions: it identifies fasteners, tracks their positions, monitors tightening sequences, and interfaces with the control system. This multi-functionality reduces the need for separate dedicated systems for each task, thereby managing overall system complexity while maintaining high reliability.
3Productivity
If technicians manually track fastener sequences, then flexibility in assembly processes is maintained, but productivity decreases due to the time-consuming nature of manual tracking
Solution Approach 1:
The automated identification and tracking system operates continuously throughout the assembly process without interruption. As each fastener is positioned and tightened, the reader continuously detects its identifier and updates the sequence tracking, eliminating the intermittent nature of manual checking and maintaining continuous productive action.
Solution Approach 2:
The system provides real-time feedback to the control system as each fastener is identified and tightened. This immediate feedback allows the system to automatically advance to the next fastener in the sequence without waiting for manual verification, thereby maintaining continuous workflow and maximizing productivity.
Data Source
AI summary
A wireless-enabled tightening system for fasteners is disclosed. The system includes a visual designator configured to project an indicator onto a workpiece. The system also includes a torque wrench comprising a wireless transmitter and a means for identifying whether the correct torque has been applied to a fastener on the workpiece and configured to provide a feedback for a user. The system also includes a camera configured to capture an image of the workpiece when an appropriate amount of torque has been applied to the fastener. The system further includes a microprocessor for determining sequence of the fastener and identifying the tightened fastener.