Intelligent power tool

• US 20030037423A1
• Filed: 08/24/2001
• Published: 02/27/2003
• Est. Priority Date: 08/24/2001
• Status: Active Grant

• Current Assignee: Intelligent Assembly LLC (Endpoint IP LLC)
• Original Assignee: Xerox Corporation (Xerox Holdings Corp.)
• Inventors: Siegel, Robert P.
• Granted Patent: US 6,571,179 B2
• Time in Patent Office: Days
• US Class Current: 29/407.01
• CPC Class Codes: B23P 19/066 by electrical means
• CPC Class Codes: B25B 21/00 Portable power-driven screw or nut setting or loosening tools; details or components, e.g. casings, bodies, of portable power-driven tools not particularly related to the operation performed B25F5/00; for mounting or dismounting wheels B60B29/006; Attachments for drilling apparatus serving the same purpose machines B23P19/06
• CPC Class Codes: B25B 23/14 Arrangement of torque limiters or torque indicators in wrenches or screwdrivers couplings for transmitting rotation or clutches F16D; devices for measuring torque per se G01L
• CPC Class Codes: Y10T 29/497 Pre-usage process, e.g., preloading, aligning
• CPC Class Codes: Y10T 29/49764 with testing or indicating
• CPC Class Codes: Y10T 29/53061 Responsive to work or work-related machine element

Abstract

An intelligent power tool system for a manufacturing process using one or more sensors that provide information for controlling, monitoring and/or evaluating the process. The one or more sensors may sense a vibratory signature and/or electrical current during the process and supply information, such as a data signal, to a software program or other processor for processing. For example, using a database of stored data regarding vibratory signatures and/or electrical currents for one or more power tool devices used in the manufacturing process, the information may be compared and analyzed to determine if it is within a specified range. Results of such analysis may be transmitted to an operator and/or graphically displayed. The results and/or display may instruct the operator to continue with the manufacturing process or inspect the process step just completed for possible error.

Claims

1. A method for assembly using an intelligent power tool device, the method comprising the steps of:

inserting a fastener into an assembly using a power tool device;

sensing a signature characteristic of the insertion of the fastener; and

evaluating the insertion of the fastener using the sensed signature characteristic.

2. The method of claim 1, further comprising transmitting a result based on the evaluation of the insertion of the fastener.

3. The method of claim 2, further comprising displaying the transmitted result.

4. The method of claim 1, wherein the signature characteristic is a vibratory signature.

5. The method of claim 1, wherein the signature characteristic is an electrical signature.

6. The method of claim 1, wherein the evaluating step comprises determining whether the insertion of the fastener is a complete insertion.

7. The method of claim 1, wherein the evaluating step comprises determining at least one of whether a desired length fastener is used, whether a desired number of washers is used and whether a desired thickness of washers is used.

8. The method of claim 1, wherein the evaluating step comprises:

counting a number of insertions for at least one of an assembly process step and an entire assembly process; and

determining whether a desired number of insertions is made.

9. The method of claim 1, wherein the evaluating step comprises comparing the signature characteristic to a predetermined signature characteristic.

10. The method of claim 9, wherein the comparing step comprises:

accessing a database of predetermined signature characteristics; and

determining whether the signature characteristic of the insertion of the fastener is a sufficient match to one of the predetermined signature characteristics of the database.

11. The method of claim 10, further comprising creating the database of predetermined signature characteristics based on the assembly process.

12. The method of claim 1, further comprising:

sensing at least one characteristic of the power tool device; and

evaluating the insertion of the fastener using the sensed characteristic of the power tool device.

13. The method of claim 12, wherein the characteristic of the power tool device is an electrical draw of the power tool device.

14. The method of claim 12, wherein the characteristic of the power tool device is a mechanical vibration characteristic of the power tool device.

15. The method of claim 12, wherein the characteristic of the power tool device is a force applied to the fastener by the power tool device.

16. The method of claim 12, wherein the evaluating step comprises comparing the characteristic of the power tool device to a predetermined characteristic.

17. The method of claim 16, wherein the comparing step comprises:

accessing a database of predetermined characteristics; and

determining whether the characteristic of the power tool device is a sufficient match to one of the predetermined characteristics of the database.

18. The method of claim 17, further comprising creating the database of predetermined characteristics based on the power tool device assembly.

19. An intelligent power tool system, comprising:

a power tool device for inserting a fastener into an assembly;

at least one sensor associated with the power tool device and arranged to sense a signature characteristic of the insertion of the fastener; and

a processor for evaluating the insertion of the fastener using the sensed signature characteristic.

20. The system of claim 19, wherein the at least one sensor is mounted on the power tool device.

21. The system of claim 19, further comprising a shop floor control in communication with the processor.