Monitoring system and method for a bolting operation

Provided herein is a monitoring system and method for a bolting operation, during which a torque tool is coupled to a torque sensing and transmitting adapter disposed of with an RFID reader or a middle device to read the information in the RFID tag attached to each bolt following the preset bolting sequence. After receiving the information, a torque control device evaluates whether the bolts are valid and memorizes the bolting sequence, edits and stores in the memory. The torque control device continuously monitors whether the operator does follow the programmed bolting sequence and the bolting mode to fasten the bolt with target torque value and issues a warning if otherwise. Meanwhile, the torque control device writes the bolting information in the tag or stores the information in a peripheral server or in a cloud server via the Internet for later inquiry.

This application claims priority from Taiwan Patent Application No. 105121151, filed on Jul. 5, 2016 at the Taiwan Intellectual Property Office, the content of which is hereby incorporated by reference in its entirety for all purposes.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a bolting operation monitoring system and method. More particularly, the present invention relates to a system and method of monitoring a bolting operation by a torque sensing and transmitting adapter including an RFID reader or a middle device such as a transducing device together with a torque control device and a bolt with an RFID tag.

2. Description of the Related Art

The conventional technique of Taiwan Patent no. I342821 (U.S. Pat. No. 7,779,704B1) mainly focuses on using shock absorbable materials and structures for the torque sensing and transmitting adapter to steadily measure torque, as shown inFIG. 3andFIG. 4. When the target value is reached, the control device may promptly send a warning signal and switch off the power. In Taiwan Patent no. I454346 (U.S. Pat. No. 9,026,379), a transducing device coupled with a connector is used to connect and drive a bolt disposed of a strain sensing element (sensing bolt) for real-time clamping force inspection, as shown inFIG. 6andFIG. 7. In US2015/0041162A1, a torque control device and a program within are used to monitor tightening torque or clamping force, but the RFID in claim4of the document does not participate in bolting sequence monitoring and neither are the characteristics of the RFID tag used to store information about the production traceability, sales history and bolting information of the bolt to be able to verify that a correct bolt is used or to track responsibility. However, the bolting quality and safety are especially essential for public safety-related equipment. Therefore, the accuracy of the tightening torque control, the compliance with the bolting sequence, the follow-up tracking and auditing are increasingly necessary. For the purposes of following tracking and determining the liability of bolting operations, it is required to continuously monitor the key bolting operations and to transmit, store, and save all related data.

Current advanced techniques are able to remotely monitor the fastening status of a bolt, however when bolting and if following a is prescribed bolting sequence, the order is manually marked with a color pen. The procedure is not only cumbersome, but also not trackable.

Furthermore, the widely used RFID technique has transmission power, sensing distance, and transmitting interference problems. The transmitting capability and interference problems for an RFID reader to read a nearby tagged bolt are still big challenges.

The inventor of the present invention has devised a novel monitoring system and method for bolting operations on the basis of several patents. The design overcomes the aforementioned transmitting capability and interference problems. The increased usefulness of this technique should boost its usage.

SUMMARY OF THE INVENTION

To solve the mentioned problems, the purpose of the present invention is to provide a monitoring system and method to assure the quality of bolting operations. In the system and method, the monitoring program can automatically set up bolting sequences and bolting modes for operators to perform a bolting operation. The system and the method can monitor that bolting sequences are followed by operators and can well control the torque or clamping force being applied to the target value. The system and the method can also access the production and sales history on a bolt's tag to evaluate the specification of the bolt and can also transmit the operation related information to the RFID tag of the bolt or to store the information in a peripheral sever or to a cloud server via the Internet.

The purpose of the present invention is to provide a monitoring system and the method thereof for a bolting operation. The system includes a torque tool, a torque sensing and transmitting adapter with a built-in RFID, at least one bolt attached with an RFID tag, a middle device, and a torque control device. The torque tool may be manual, pneumatic, electrical, or hydraulic driven. The torque sensing and transmitting adapter may be coupled to the torque tool or included in the torque tool. The torque sensing and transmitting adapter include an output shaft (or a socket) and an axial connection recess, which are disposed at either edge of a sense axle. The output shaft includes a through hole, the opening of which is disposed on an edge surface of the output shaft. The axial connection recess is configured to accept an output end of a torque tool. The torque sensing and transmitting adapter includes an RFID reader, a circuit board module, and a power supply module, which are electrically coupled. The RFID reader is coupled to or included in the circuit board module. The RFID reader includes a transmitting antenna, which is configured to extend through the through hole and attached to a place on the edge surface of the output shaft closest to the tag of the bolt. The built-in data in the RFID tag of the bolt can be accessed by the antenna or the bolting information sensed by the torque sensing module can be stored in the RFID tag. The middle device is a conventional socket with a hollow structure. One edge of the middle device is detachably coupled to the output end of the torque sensing and transmitting adapter, and the other edge of the middle device is detachably coupled to the driving head of the bolt. The RFID tag is attached to the driving head of the bolt to receive and store the bolt related production traceability such as manufacturer code, batch production record, the material of the bolt, grade of the bolt, and allowable maximum tightening torque and sales history data. After finishing a bolting operation, the generated bolting information including bolting time, operator ID, applied torque value, or a combination thereof is stored in the RFID tag. The data in the RFID tag may also be accessed by the RFID reader through the transmitting antenna. The production traceability information accessed by the RFID reader in the torque sensing and transmitting adapter is provided to the torque control device to evaluate whether a bolt is valid or correct and to evaluate whether the target torque is within a tolerable range. The torque control device will issue a warning if otherwise. After finishing a bolting operation, the bolting information is stored in the RFID tag through the RFID reader of the torque sensing and transmitting adapter or is stored in a peripheral server and stored in a cloud server via the Internet.

Another purpose of the present invention is to provide a monitoring method for a bolting operation. The method includes the steps of: coupling a torque sensing and transmitting adapter to or including a torque sensing and transmitting adapter in a torque tool, wherein an edge surface of an output shaft of the torque sensing and transmitting adapter is disposed with a transmitting antenna of an RFID reader; coupling an end of a middle device having a hollow structure to the output shaft; performing a bolting operation on a bolt, wherein a driving head of the bolt is connected to the other end of the middle device, and the driving head of the bolt is attached with an RFID tag; sequentially bolt by bolt accessing data of the RFID tags by the RFID reader of the torque sensing and transmitting adapter during pre-bolting to evaluate whether a specification of each bolt is valid, wherein each data set includes production traceability and sales history data of the corresponding bolt, and transmitting tag identification codes to a torque control device to generate a bolting sequence and a bolting mode and to edit and store them; during the bolting operation, continuously monitoring to see whether the bolting operation performed by an operator is according to the programmed bolting sequence or the bolting mode, and issuing a warning or stopping the torque tool if otherwise, wherein, during the bolting operation, the bolting information generated by a torque sensing module of the torque sensing and transmitting adapter is transmitted to and stored on the RFID tag of the bolt through the microprocessor and the transmitting antenna of the RFID reader.

Another purpose of the present invention is also to provide a monitoring method for a bolting operation. The method includes the steps of: coupling a middle device (transducing device), which includes a built-in RFID reader, an antenna, and a wireless communication module, to a bolt attached with an RFID tag, and driving the middle device by a torque tool to perform a bolting operation; during pre-bolting, accessing the production information, including production traceability data such as manufacturer ID, production date, batch production record, the material of bolt, grade of the bolt, and allowable maximum torque of the bolt, and sales history data such as seller and selling date of the bolt by the RFID reader and antenna of the middle device for verifying whether the bolt is valid, and transmitting tag identification codes to a torque control device to generate a bolting sequence with bolting mode and to edit and store them; during the bolting operation, continuously monitoring to see whether the bolting operation performed by an operator is according to the bolting sequence or the bolting mode, and issuing a warning or stopping the torque tool if otherwise, wherein, during the bolting operation, wirelessly or manually inputting a bolting information generated by the torque tool to the torque control device and transmitting the bolting information to the communication unit of the transducing device through the communication module, and then transmitting the bolting information through the microprocessor and the transmitting antenna of the RFID reader to the RFID tag of the bolt.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1showsFIGS. 3 and 4of U.S. Pat. No. 7,779,704 granted to the inventor of the present invention. The patent serves as a basis technique for the torque sensing and transmitting adapter of the present invention. This basis technique mainly focuses on the shock absorbable materials and structures for the torque sensing and transmitting adapter to steadily measure the torque, such that when reaching the target value, the control device may promptly send a warning signal and switch off the power. In order to incorporate an RFID reader for the present invention, the technique has to be improved.

FIG. 2showsFIGS. 6 and 7of U.S. Pat. No. 9,026,379 granted to the inventor of the present invention. Based on the structure of this patent, the connector is, however, prone to be damaged, and the design does not take full advantage of the writing and reading properties of the RFID device.

FIG. 3showsFIG. 2of US2015/0041162A1 applied by the inventor of the present invention. This document discloses a method to monitor the tightening torque and the clamping force of a bolt by using a torque control device and programs. However, the RFID mentioned in claim4is not used to monitor bolting sequences and the properties of the RFID tag are not used to write and read the production traceability, the sale history, and the bolting related information about the bolt to ensure that the bolt is valid and to clarify bolting responsibility.

The following refers toFIG. 4, which is a structure of a torque sensing and transmitting adapter of the present invention. The torque sensing and transmitting adapter1includes an output shaft112and an axial connection recess1111, which are disposed at either edge of a sense axle11. The output shaft112includes a through hole113, the opening of which is disposed on an edge surface of the output shaft112. The axial connection recess1111is configured to accept an output end of a torque tool5. The torque sensing and transmitting adapter1includes a power supply module13and a circuit board module12, which includes a third microprocessor121, a torque sensing module122, an angle sensing module125, a communication module123, and a first RFID reader124. The power supply module13and the circuit board module12are electrically coupled to one another. The RFID reader124may be connected to or built in within the circuit board module12. An antenna1241of the RFID reader124is configured to extend through the through hole113to the edge surface of the output shaft112. The antenna is glued to the edge surface. In this manner, the RFID reader may read the build-in data in an RFID tag22′ on a sensing bolt2′ or on a tagged bolt2″. In another aspect, the RFID reader may send bolting data generated by the torque sensing module122to store the data on the RFID tag22′ or22″. An output shaft112(square head) may also be a hex socket head output shaft112′ or a hex key output shaft112″ to be suitable for various shapes of bolts' heads.

Referring toFIG. 5, which shows a structure of a transducing device of the present invention. The transducing device has several built-in components including a third microprocessor32′, a third RFID reader33′, a third communication unit34′, and a third power unit35′. The third microprocessor32′ includes an amplifier circuit321′ (not shown). The third communication unit34′ includes a communication antenna341′ and a communication antenna protector342′. The third RFID reader33′ includes a third RFID antenna331′. The transducing device3′ provides the functions of sensing and transmitting or the transducing device3″ includes a transmitting driving head. One end311′ or311″ of either of each is detachably connected to the output end of the torque tool5, and the other end312′ or312″ is detachably connected to the driving head21′,21″,21′″, or21″″ of a bolt attached with an RFID tag, e.g. a sensing bolt2′, a tagged bolt2″, a sensing hexagon socket head bolt2′″, or a tag hexagon socket head bolt2″″. Depending on the type of the output end of the torque tool5and the type of the driving head21′,21″,21′″, or21″″, the input end311′ or311″ and the output end312′ or312″ of the transducing device3′ or3″ may have their corresponding variants. Therefore, the transducing device can have broader applicability.

Particularly, when using the transducing device3′ on the sensing bolt2′, the data reading, writing, and storing can be done through wireless communication unit34′ and24′ without having the third RFID reader33′ on the transducing device3′ and the third RFID antenna331′ on the sensing bolt2′.

The following refers toFIG. 6, which shows structures of a sensing bolt and a tagged bolt of the present invention. The sensing bolt2′ or2′″ includes a second microprocessor22′, a second radio frequency identification device (RFID tag)23′, a second wireless communication unit24′, a second power unit25′, and strain sensing element26′. The RFID reader124may read and save the data in the RFID tag through the RFID antenna1241. The sensing bolt may receive and save the production traceability and the sales history data, including manufacturer code of the bolt, the batch production record, bolt materials, the grade of the bolt, maximum allowable tightening torque. The sensing bolt may also save the data generated during the bolting operation, including bolting time/date, operator ID, the applied torque value or any combination thereof. The tagged bolt2″ or2″″ includes a first radio frequency identification device (RFID tag)23″. Data can be read from or written to the tagged bolt2″ or2″″ through the RFID antenna1241, but clamping force can not be measured directly. The information about torque or clamping force from the circuit board module12of the torque sensing and transmitting adapter can be saved to the memory of the tag through the RFID reader123and the RFID antenna1241. Alternatively, the torque control device may handle the data read from the digital torque wrench and write to the memory of the tag through the microprocessor, the RFID reader124, and the RFID antenna1241of the transducing device.

Referring toFIG. 7, which shows a schematic diagram of a monitoring system for a bolting operation of the present invention. Square shaped axial connection recess111at the edge of the torque sensing and transmitting adapter is detachably connected to the output end of the torque tool5. The output shaft112is detachably connected to the input end of the middle device3(conventional transducing device). The other end of the middle device3is detachably connected to the driving head21′,21″,21′″, or21″″ of the sensing bolt3′ or the tagged bolt2″. The torque control device4decides if the specification of the bolt is correct based on the production traceability data in the RFID tag23′ or23″ read by the RFID reader124and the RFID antenna1241. The torque control device4also judges and issues a warning if the setting of the target torque is not within the tolerable range. After finishing the bolting operation, the torque control device4sends and writes bolting operation related information to the RFID tag23′ or23″ of the bolt through the RFID reader124and the RFID antenna1241or saves the bolting information in a peripheral or cloud server. As for the torque sensing and transmitting adapter1′ with hex socket head or the torque sensing and transmitting adapter2″ with hex key head, it can be directly and detachably connected to the driving head21′,21″,21′″, or21″″ of the sensing bolt2′ or the tagged bolt2″ with corresponding size. As for the transducing device3′ with hex socket head or3″ with hex key head, the axial connection recess311′ and311″ of it can be directly and detachably connected to the output end of the torque tool5. The output end312′ of the transducing device3′ can be detachably connected to the driving head21′ or21″ of the sensing bolt2′ or the tagged bolt2″. The312″ of the transducing device3″ can be detachably connected to the driving head21″ or21″″ of the sensing bolt2′″ or tagged bolt2′. The torque control device4verifies whether the specification of the bolt is correct according to the production traceability data in the RFID tag (23′ or23″) read by the RFID reader33′ and the RFID antenna331′ in the transducing device. The torque control device3also verifies the setting of the target torque sends out a warning if it is not within the tolerable range. After finishing the bolting operation, the torque control device4sends and writes the bolting information to the RFID tag (23′ or23″) of the bolt through the RFID reader33′ of the transducing device or saves the bolting information in a peripheral or cloud server. The aforementioned connection fashions or their functions are not limited to their sizes or types.

Following refers toFIG. 8, which shows a monitoring method and an operational flow chart of usage of a transducing device and a sensing bolt (or a tagged bolt) of the present invention. Also seeFIG. 7for reference. The torque tool5is coupled to the torque sensing and transmitting adapter1. The conventional hollow transducing device3is coupled to the torque sensing and transmitting adapter1to drive a sensing bolt2′ or a tagged bolt2″. Alternatively, the torque tool5drives a torque sensing and transmitting adapter1′, which is directly coupled to a sensing bolt2′ or a tagged bolt2″.

Alternatively, the torque tool5drives a torque sensing and transmitting adapter1″, which is directly coupled to a hexagon socket head bolt2′ or a tagged hexagon socket head bolt2′. When pre-bolting, the operator's ID is scanned by the RFID reader124built-in in the torque sensing and transmitting adapter1through the RFID antenna1241. Following the preset bolting procedure, the tag identification code on the bolt is read. According to the production traceability information of the bolt stored in the tag, the specification of the bolt is evaluated. If the bolt specification is not valid, the torque control device4issues a warning and disables the torque tool5. If the specification is valid, the tag identification code is sent to the communication module43and the control module41of the torque control device4through the communication module123in the circuit board module12of the torque sensing and transmitting adapter. Meanwhile, the torque control device4sets up the number of steps required for bolting and the value of the torque required for each step or modes for fastening each bolt. The torque control device4also selects the coaxial bolt sequence programming direction for bolting, e.g. clockwise or counterclockwise for the bolt sequence programming operation. The bolting is then performed. The torque control device4continuously monitors the bolting sequence, the bolting mode for each step, and the torque applied in each step. A warning will be issued if there is any problem and the power torque tool can only be activated if the problem is resolved, and the torque control device4issues a warning if the torque tool is operated manually. After finishing the bolting operation, the torque control device4sends bolting operation related information to the communication module123of the torque sensing and transmitting adapter through the communication module43, and the microprocessor121sends the information through the RFID antenna1241of the RFID reader124to write the information in the sensing bolt2′ or the tagged bolt2″. Alternatively, the information is sent to a peripheral or cloud server through the input-output module44of the torque control device4for later inquiry.

Following refers toFIG. 9, which shows a monitoring method and an operational flow chart of applying a torque sensing and transmitting adapter and sensing bolt (or a tagged bolt) of the present invention. Also seeFIG. 7for reference. A transducing device3′ is coupled to the torque tool5to drive a sensing bolt2′ or a tagged bolt2″. Alternatively, a transducing device3″ including a transmitting driving head is used to drive a sensing hexagon socket head bolt2′″ or tag hexagon socket head bolt2″″. While pre-bolting, the RFID reader33′ of the transducing device3′ or the transducing device3″ scans the operator's ID through the RFID antenna331′. According to the preset bolting sequence, the tag identification code on the bolt is read. According to the production traceability information of the bolt stored in the tag, the specification of the bolt is evaluated. If the specification is not valid, the torque control device4issues a warning signal and disables the torque tool5. If the specification is valid, the tag identification code is sent to the control module41through the communication unit34′ of the transducing device3′ or3″ and through the communication module43of the torque control device4. Meanwhile, the torque control device4sets up the number of steps required for bolting and the value of the torque required for each step or modes for fastening each bolt. The torque control device4also selects the coaxial bolt sequence programming direction for bolting, e.g. clockwise or counterclockwise for the bolt sequence programming operation. The torque control device4continuously monitors the bolting sequence, the bolting mode for each step, and the torque applied in each step. A warning will be issued if there is any problem. The power torque tool5can only be activated if the problem is resolved, and the torque control device4issues a warning if the torque tool is operated manually. After finishing the bolting operation, torque control device4sends the related information to the communication unit34′ of the transducing device3′ or3″ through the communication module43. The microprocessor32′ then sends the information through the RFID antenna331′ of the RFID reader33′ to write the information in the tag of the bolt. Alternatively, the information is sent to a peripheral or cloud server through the input-output module44of the torque control device4for later inquiry.

The following refers toFIG. 10, which shows a bolting sequence monitoring method of the present invention. The method is mainly based on the structure of the present invention and the RFID reader124is disposed in the torque sensing and transmitting adapter or the transducing device. The RFID antenna1241of the RFID reader124is led to the closest driving head (21′,21″,21′″, or21″″) attached with the RFID tag23′ of the bolt, or the RFID antenna331″ of the transducing device3′ or3″ with built-in microprocessor32′, RFID reader33′, communication unit34′, and power unit35′ is moved to the closest driving head (21′,21″,21′″, or21″″) attached with the RFID tag23′ of the bolt. Thereby the information can be read and written without interfering. (The RFID tag may include surface acoustic wave RFID device, such that the power supply unit can be omitted). When pre-bolting:

1. The tag information is read through the RFID antenna of the RFID reader to determine whether the bolt is correct.

2. During learning mode, the ID serial numbers of the bolt tags are read following the preset bolting sequence. The bolt sequence is transmitted, memorized, and saved in the control module41of the torque control device4. During scanning, the bolting modes (time, torque, angle, or a combination thereof) for specific bolts can be setup, and the control module41can simultaneously finish the editing of the bolting sequence. The editing of the sequence can be further defined as

3. During bolting mode, the operator may take any one of the bolts to start with. The following is the demonstration.

As shown inFIG. 10(A), if the coaxial clockwise direction is chosen and the pre-bolting sequence is3→4→1→2, the operator may choose any bolt to start with. For example, the bolting sequence may be2→1→3→4,4→3→2→1,3→4→1→2, or1→2→4→3.

As shown inFIG. 10(B), if the coaxial counterclockwise direction is chosen and the pre-bolting sequence is2→1→4→3, the operator may choose any bolt to start with. For example, the bolting sequence may be3→1→2,3→4→2→1,2→1→4→3, or1→2→3→4.

In addition to the device having RFID element and the sensing bolt for the sensing element in claim4of US2015/0041162 A1, under the structure designed in the present invention, which has ID code on the bolt for the RFID device and the torque sensing and transmitting adapter or transducing device built-in with RFID reader and RFID antenna, the production traceability and the sales history data of the bolt stored in the RFID tag can be retrieved without being interfered in the conditions of limited space and transmission power. The specification of the bolt is also confirmed before bolting. When the bolting is complete, the related bolting information such as operator ID, working time/date, the applied torque, and/or the magnitude of the clamping force are stored in the tag memory through RFID reader and RFID antenna. The information may also alternatively be stored in a peripheral through wireless communication module or stored in cloud server via the Internet. With the information, the quality of the bolt, the bolting sequence, the applied torque, and the clamping force can be fully monitored for later tracking. This can help to clarify the bolting responsibility.

Aside from monitoring the bolting sequence, the monitoring system and the method of the present invention can provide setup for each bolt such as the number of bolting steps and the percentage of the target torque or torque required for each step. For example, a bolting procedure requires 3 steps to reach the target torque 100 NM. In step 1, 50% of the target torque or 50 NM is applied. In step 2, 75% of the target torque or 75 NM is applied. In step3, the target torque or 100 NM is achieved. The torque control device4monitors the bolting procedure all the time. Only when the target value in the step for each bolt is achieved, the following step can be executed. The torque control device will send warning signal and put it on record if an operator does not follow the bolting procedure. The number of valid or invalid bolts can also be calculated.

The description above is only for the purpose of illustration but not a restriction. Without departing from the spirit of the present application, any equivalent modification or alteration should be considered as falling within the protection scope of the appended claims.