Tension control of fasteners

Abstract

There is disclosed a technique for tightening threaded fasteners in which values of offset torque, initial tension rate relative to angle, final tension rate relative to angle and other joint related factors are empirically determined by instrumenting a plurality of fasteners of the type ultimately to be tightened. In one embodiment, torque and angle are monitored during tightening. Calculations are conducted, while tightening, to determine the tension prevailing in the bolt at a particular angle of advance. By using the calculated tension value and the particular angle of advance, an instantaneous position of threading advance on the tension-angle curve of the fastener is established. From this instantaneous position, it is determined how much greater angle of advance or how much torque is required to tighten the fasteners to a final desired tension value. The same technique may also be used merely to monitor tightening which is terminated by a different tightening strategy. A number of quality control procedures are conducted to determine if the fastener and the tightening tool are performing normally. In another embodiment, analog devices are utilized to convert sensed values of torque and the rate of threading advance into parameters which control tool shut off.

I claim: 
     
       1. Apparatus for tightening seriatim a multiplicity of substantially identical joints having components including at least one threaded fastener to substantially the same final desired stress value, below the yield point of .[.any component.]. .Iadd.all joint components .Iaddend.that can be correlated with stress, appearing in the fastener, comprising a powered instructable tool, capable of terminating tightening in response to an instruction which varies from one fastener to the next, for applying torque to the fastener and tightening the same;   means for sensing the torque applied to the fastener at various angles of advance;   means responsive to the torque and angle sensings for determining, while tightening below the yield point of .[.any.]. .Iadd.all .Iaddend.joint .[.component.]. .Iadd.components .Iaddend.that can be correlated with stress, a tightening parameter value, variable from one fastener to the next, sufficient to tighten each fastener to the final desired stress value; and   means for instructing the tool to terminate tightening of each fastener in response to the determined tightening parameter value.   
     
     
       2. The apparatus of claim 1 wherein the determining means comprises means for determining the torque values sufficient to tighten each fastener to the final desired stress value. 
     
     
       3. The apparatus of claim 2 wherein the determining means comprises means for calculating the sufficient torque value from the ultimate equation ##EQU34## where F D  is the final desired stress value, dF/dα is the derivative of stress with respect to angle, T D  is the sufficient torque value, dT/dα is the derivative of torque with respect to angle, T os  is offset torque, and T pv  is prevailing torque. 
     
     
       4. The apparatus of claim 1 wherein the determining means comprises means for determining the angle of threading advance sufficient to tighten each fastener to the final desired stress value. 
     
     
       5. The apparatus of claim 4 wherein the determining means comprises means for calculating the angle of advance from the ultimate equation F D  =αFR where F D  is the final desired stress value, FR is the stress rate and α is the angular distance from the angle origin of stress to F D .  .[.6. A method of tightening a multiplicity of substantially identical joints having components including at least one threaded fastener to a final desired stress value below the yield point of any joint component that can be correlated with stress, including tightening the fastener with an instructable tool;   sensing torque at various angles of advance during tightening below the yield point of any joint component that can be correlated with stress;   calculating, while tightening below the yield point of any joint component that can be correlated with stress, the stress appearing in the fastener at least at one instant of tightening below the yield point of any joint component that can be correlated with stress from the sensed values of torque and angle;   determining the value of a tightening parameter sufficient to tighten the fastener to the final desired stress value below the yield point of any joint component that can be correlated with stress from the calculated stress;   instructing the tool to tighten the fastener to the determined parameter; and   terminating tightening in response to the attainment of the determined   
     
     
        parameter..]. 7. The method of claim .[.6.]. .Iadd.51 .Iaddend.wherein the 
     
     
        tightening parameter is angle of advance. 8. The method of claim .[.6.]. 
     
     
        .Iadd.51 .Iaddend.wherein the tightening parameter is torque. 9. The method of claim .[.6.]. .Iadd.51 .Iaddend.wherein the tightening parameter 
     
     
        is a linear combination of torque and angle. 10. The method of claim .[.6.]. .Iadd.51 .Iaddend.wherein fastener is a bolt and the final desired 
     
     
        stress value is final desired tension value in the bolt. 11. The method of claim .[.6.]. .Iadd.51 .Iaddend.wherein the tightening parameter includes a measure of tool overrun.  .[.12. Apparatus for tightening seriatim a multiplicity of substantially identical joints having components including at least one threaded fastener to substantially the same final desired stress value below the yield point, comprising a powered instructable tool for tightening the fastener;   means for sensing torque at various angles of advance during tightening below the yield point of any joint component that can be correlated with stress;   means for calculating the stress appearing in the fastener at least at one instant of tightening below the yield point of any joint component that can be correlated with stress from the sensed values of torque and angle;   means for determining a tightening parameter value sufficient to tighten the fastener to the final desired stress value below the yield point of any joint component that can be correlated with stress from the calculated stress; and   means for instructing the tool to tighten the fastener to the determined   
     
     
        parameter value..]. 13. The apparatus of claim .[.12.]. .Iadd.52 .Iaddend.wherein the calculating means and the determining means respectively comprises means for calculating the stress and means for determining the tightening parameter value in a time period commencing with the onset of threading and stopping with the termination of 
     
     
        tightening. 14. The apparatus of claim 13 wherein the time period is less than two minutes.  .[.15. A method of tightening a multiplicity of substantially identical joints having components including at least one threaded fastener to a final desired stress value below the yield point of any joint component that can be correlated with stress, comprising tightening the fastener with an instructable powered tool;   sensing torque at various angles of advance during tightening;   determining the torque rate of the fastener from the sensed values of torque and angle;   calculating the stress appearing in the fastener at least at least at one instant of tightening below the yield point of any joint component that can be correlated with stress from the determined torque rate and from sensed torque;   determining the value of a tightening parameter sufficient to tighten the fastener to the final desired stress value below the yield point of any joint component that can be correlated with stress from the calculated stress;   instructing the tool to tighten the fastener in response to the determined parameter; and   
     
     
       terminating tightening in response to the determined parameter..]. 16. The method of claim .[.15.]. .Iadd.53 .Iaddend.further comprising predicting the amount of tool overrun and wherein the instructing step comprises instructing the tool to tighten each fastener in response to the determined parameter and the amount of tool overrun, and the terminating step comprises terminating tightening in response to the determined 
     
     
        parameter and the amount of tool overrun. 17. The method of claim .[.15.]. .Iadd.53 .Iaddend.comprising the step of empirically determining the value of FR 1 , FR 2  and T os  where FR 1  is stress rate in a low stress range, FR 2  is stress rate in a higher stress range and T os  is offset torque, and the calculating step comprises calculating the stress from the empirically determined values of FR 1 , FR 2  and T os  as well as from the sensed values of torque and angle. .[.18. Apparatus for tightening a multiplicity of substantially identical joints having components including at least one threaded fastener to a final desired stress value below the yield point of any joint component that can be correlated with stress, comprising a powered instructable tool for tightening the fastener;   means for sensing torque at various angles of advance during tightening;   means for determining the torque rate of the fastener from the sensed values of torque and angle;   means for calculating the stress appearing in the fastener at least at one instant of tightening below the yield point of any joint component that can be correlated with stress from the determined torque rate and the sensed torque;   means for determining the value of a tightening parameter sufficient to tighten the fastener to the final desired stress value below the yield point of any joint component that can be correlated with stress; and   means for instructing the tool to tighten the fastener in response to the   
     
     
        determined parameter..]. 19. The apparatus of claim .[.18.]. .Iadd.54 .Iaddend.further comprising means for predicting the amount of tool overrun, and wherein the instructing means comprises means for instructing the tool to tighten the fastener in response to the determined parameter 
     
     
        and the amount of tool overrun. 20. The apparatus of claim .[.18.]. .Iadd.54 .Iaddend.wherein the determining means comprises means for determining the torque value sufficient to tighten the fastener to the 
     
     
        final desired stress value. 21. The apparatus of claim .[.18.]. .Iadd.54 .Iaddend.wherein the determining means comprises means for determining the angle of threading advance sufficient to tighten the fastener to the final 
     
     
        desired stress value. 22. The apparatus of claim .[.18.]. .Iadd.54 .Iaddend.wherein the fastener is a bolt and the calculating means 
     
     
        comprises means for calculating the tension in the bolt. 23. Apparatus for tightening a joint having components including at least one threaded fastener, comprising a powered tool for tightening the fastener;   means for monitoring stress in the fastener including means for sensing torque and angle while tightening; and   data processor means for calculating stress in the fastener below the yield point of .[.any.]. .Iadd.all .Iaddend.joint .[.component.]. .Iadd.components .Iaddend.that can be correlated with stress from sensed values of torque and angle; and     means for terminating tightening in response to a tightening parameter   
     
     
        related to monitored stress. 24. The apparatus of claim 23 wherein the 
     
     
        tightening parameter is torque. 25. The apparatus of claim 23 wherein the 
     
     
        tightening parameter is angle. 26. The apparatus of claim 23 wherein the 
     
     
        tightening parameter is a linear combination of torque and angle. 27. Apparatus for tightening substantially identical threaded fasteners in production lots to the same final desired stress value ±15%, comprising a powered instructable tightening tool having a source of energy, means for connecting and disconnecting the tool to the energy source, a torque sensor and an angle sensor;   a data processor connected to the torque and angle sensors including   means for determining a mid-point stop of the fasteners at least about 0.4 elastic limit of the weakest joint component from a sensed value of torque and angle and means for instructing the tool to halt tightening at the mid-point stop;   means for calculating a torque rate in a region adjacent the mid-point stop from sensed values of torque and angle;   means for calculating the stress appearing in the fastener at a location between the onset of tightening and the mid-point stop from a sensed value of torque at the location, the calculated torque rate and an empirically determined stress rate for the region including 0.1-0.5 elastic limit;   means for calculating a value of a tightening parameter sufficient to tighten the fastener to a final desired stress value from an empirically determined stress rate above the region 0.1-0.5 elastic limit;   means controlled by the data processor for resuming tightening; and   means responsive to the value of the tightening parameter for terminating   
     
     
        tightening adjacent the final desired value. 28. The apparatus of claim 27 further comprising means for calculating the amount of tool overrun adjacent the final desired stress value and wherein the tightening terminating means comprises means responsive to the value of the tightening parameter and the amount of tool overrun for terminating 
     
     
        tightening adjacent the final desired stress value. 29. The apparatus of claim 27 wherein the means for calculating the tightening parameter value comprises means for dividing the difference between the final desired stress value and the stress calculated at the location by the empirically 
     
     
        determined stress rate above the region 0.1-0.5 elastic limit. 30. The apparatus of claim 27 wherein the means for calculating the tightening parameter value comprises means for dividing the difference between the final desired stress value and the stress at an angular position adjacent the location by the empirically determined stress rate above the region 
     
     
        0.1-0.5 elastic limit. 31. The apparatus of claim 27 wherein the 
     
     
        tightening parameter is in units of angle. 32. The apparatus of claim 27 
     
     
        wherein the tightening parameter is in units of torque. 33. The apparatus of claim 27 wherein the torque rate calculating means includes means for storing and recalling the sensed values of torque and angle and means for 
     
     
        determining an average torque rate from the sensings. 34. A method of tightening a joint including a threaded fastener, comprising tightening the fastener;   sensing torque applied to the fastener and the angle of threading advance;   determining, during tightening, the origin of stress in the fastener from the sensed values of torque and angle;   determining a shut off parameter based on the origin of stress; and   
     
     
       terminating tightening in response to the shut off parameter. 35. Apparatus for tightening a joint including a threaded fastener, comprising a powered tool for tightening the fastener;   means for sensing the torque applied to the fastener and the angle of threading advance;   means for determining, during tightening, the origin of stress in the fastener pair from sensed values of torque and angle;   means for determining, during tightening, a shut off parameter based on the origin of stress; and   means for terminating operation of the powered tool in response to the shut   
     
     
        off parameter. 36. A method of tightening seriatim a multiplicity of substantially identical production joints including at least one threaded fastener, comprising empirically determining, prior to tightening the production joints, at least one joint characteristic;   applying torque to the fastener for tightening the production joint;   determining, while tightening below the yield point of .[.any.]. .Iadd.all .Iaddend.joint .[.component.]. .Iadd.components .Iaddend.that can be correlated with stress, a tightening parameter based on the empirically determined joint characteristic, which tightening parameter varies from one joint to the next; and   
     
     
       terminating tightening in response to the tightening parameter. 37. The method of claim 36 wherein the empirically determined joint characteristic 
     
     
        is the fastener tension rate. 38. The method of claim 36 wherein the 
     
     
        empirically determined joint characteristic is the offset torque. 39. Apparatus for tightening seriatim a multiplicity of substantially identical production joints including at least one threaded fastener and having at least one empirically determinable joint characteristic, comprising means for applying torque to the fastener;   means for determining, while tightening below the yield point of .[.any.]. .Iadd.all .Iaddend.joint .[.component.]. .Iadd.components .Iaddend.that can be correlated with stress, a tightening parameter based on the empirically determined joint characteristic, which tightening parameter varies from one joint to the next, including   means for delivering a signal to the determining means representative of the empirically determinable joint characteristic; and   means for terminating tightening in response to the tightening parameter.   
     
     
          . A method of tightening seriatim a multiplicity of substantially identical production joints including at least one threaded fastener, comprising determining, prior to tightening the production joints, at least one tightening tool characteristic;   applying torque to the fastener with the tightening tool for tightening the production joint;   determining, while tightening, a tightening parameter based on the determined tool characteristic, which tightening parameter varies from one joint to the next; and   
     
     
       terminating tightening in response to the tightening parameter. 41. The method of claim 40 wherein the determined tool characteristic is a 
     
     
        function of tool overrun. 42. The method of claim 41 wherein the 
     
     
        tightening tool characteristic is the stall torque of the tool. 43. The method of claim 41 wherein the tightening tool characteristic is the angle 
     
     
        overrun of the tightening tool under no torque conditions. 44. Apparatus for tightening seriatim a multiplicity of substantially identical production joints including at least one threaded fastener, comprising a tightening tool for applying torque to the fastener;   means for determining, while tightening, a tightening parameter based on a tool characteristic, which tightening parameter varies from one joint to the next, including   means for delivering a signal to the determining means representative of the determined tool characteristic; and   means for terminating tightening in response to the tightening parameter.   
     
     
        .Iadd.45.  The method of claim 57 wherein said joint characteristic is determined from one or more actual, representative joints. .Iaddend. .Iadd.46. The method of claim 57 wherein the joint characteristic is 
     
     
        proportional to the joint tension rate. .Iaddend. .Iadd.47.  The apparatus of claim 58 wherein the joint characteristic is proportional to the joint tension rate. .Iaddend. .Iadd.48. The apparatus of claim 58 further comprising means for determining, after the onset of tightening, a parameter proportional to the torque rate of the fastener. .Iaddend. .Iadd.49. The apparatus of claim 58 wherein the determining means comprises means for combining the determinable joint characteristic and the torque rate proportional parameter. .Iaddend. .Iadd.50. The apparatus of claim 58 wherein the determinable joint characteristic is the joint tension rate, said apparatus further comprising means for determining, after the onset of tightening, the torque rate of the fastener and the determining means comprising means for combining the joint tension rate 
     
     
        and the determined torque rate. .Iaddend. .Iadd.51.  A method of tightening a multiplicity of substantially identical joints having components including at least one threaded fastener to a final desired atress value below the yield point of all joint components that can be correlated with stress, including: tightening the fastener with an instructable tool;   sensing torque at various angles of advance during tightening below the yield point of all joint components that can be correlated with stress;   calculating, while tightening below the yield point of all joint components that can be correlated with stress, the stress appearing in the fastener at least at one instant of tightening below the yield point of all joint components that can be correlated with stress from the sensed values of torque and angle;   determining the value of a tightening parameter sufficient to tighten the fastener to the final desired stress value below the yield point of all joint components that can be correlated with stress from the calculated stress;   instructing the tool to tighten the fastener to the determined parameter; and   terminating tightening in response to the attainment of the determined parameter. .Iaddend. .Iadd.52. Apparatus for tightening seriatim a multiplicity of substantially identical joints having components including at least one threaded fastener to substantially the same final desired stress value below the yield point, comprising:   a powered instructable tool for tightening the fastener;   means for sensing torque at various angles of advance during tightening below the yield point of all joint components that can be correlated with stress;   means for calculating the stress appearing in the fastener at least at one instant of tightening below the yield point of all joint components that can be correlated with stress from the sensed values of torque and angle;   means for determining a tightening parameter value sufficient to tighten the fastener to the final desired stress value below the yield point of all joint components that can be correlated with stress from the calculated stress; and   means for instructing the tool to tighten the fastener to the determined parameter value. .Iaddend. .Iadd.53. A method of tightening a multiplicity of substantially identical joints having components including at least one threaded fastener to a final desired stress value below the yield point of all joint components that can be correlated with stress, comprising:   tightening the fastener with an instructable powered tool;   sensing torque at various angles of advance during tightening;   determining the torque rate of the fastener from the sensed values of torque and angle;   calculating the stress appearing in the fastener at least at one instant of tightening below the yield point of all joint components that can be correlated with stress from the determined torque rate and from sensed torque;   determining the value of a tightening parameter sufficient to tighten the fastener to the final desired stress value below the yield point of all joint components that can be correlated with stress from the calculated stress;   instructing the tool to tighten the fastener in response to the determined parameter; and   terminating tightening in response to the determined parameter. .Iaddend.   
     
     
        .Iadd.54.  Apparatus for tightening a multiplicity of substantially identical joints having components including at least one threaded fastener to a final desired stress value below the yield point of all joint components that can be correlated with stress, comprising: a powered instructable tool for tightening the fastener;   means for sensing torque at various angles of advance during tightening;   means for determining the torque rate of the fastener from the sensed values of torque and angle;   means for calculating the stress appearing in the fastener at least at one instant of tightening below the yield point of all joint components that can be correlated with stress from the determined torque rate and the sensed torque;   means for determining the value of a tightening parameter sufficient to tighten the fastener to the final desired stress value below the yield point of all joint components that can be correlated with stress; and   means for instructing the tool to tighten the fastener in response to the   
     
     
        determined parameter. .Iaddend. .Iadd.55.  Apparatus for tightening a threaded fastener in a joint including the fastener, the apparatus comprising: a tightening tool for imparting input characteristics including torque and rotation to the fastener to tighten the fastener, the tool being capable of terminating the tightening of the fastener in response to an instruction incorporating a directly measurable tightening related parameter which can vary from one to another of ostensibly alike joints in tightening fasteners therein to the same final tension;   means for sensing at least one of the input characteristics;   means for determining from the sensed input characteristics, after the onset of tightening and while below the yield point of all joint components that can be correlated with stress, that value of the tightening related parameter which is representative of the amount of tightening required to tighten the fastener to the selected final tension; and   means for transmitting to the tool an instruction that will cause the tool to terminate the tightening of the fastener in response to the reaching of the determined value of the tightening related parameter. .Iaddend. .Iadd.56. Apparatus for tightening a threaded fastener in a joint including the fastener, comprising:   a power instructable tool, capable of terminating tightening in response to an instruction which varies from one fastener to the next, for imparting input characteristics including torque and rotation to the fastener;   means for sensing at least one of the input characteristics;   means responsive to the sensing means for determining after the onset of tightening and while below the yield point of all joint components that can be correlated with stress, a tightening parameter value, variable from one fastener to the next, sufficient to tighten each fastener to the same final desired stress value; and   means for terminating tightening of the fastener in response to the determined tightening parameter value. .Iaddend. .Iadd.57. A method of tightening a threaded fastener in a joint including the threaded fastener, comprising:   determining, prior to tightening the fastener, at least one joint characteristic;   applying torque to the fastener for tightening the same;   determining, after the onset of tightening and while below the yield point of all joint components which can be correlated with stress, a tightening parameter based on the determined joint characteristic, which tightening parameter varies from one joint to the next; and   terminating tightening in response to the tightening parameter. .Iaddend.   
     
     
        .Iadd.58.  Apparatus for tightening a threaded fastener in a joint including the fastener and having a determinable joint characteristic, comprising: means for applying torque to the fastener;   means for determining, after the onset of tightening and while below the yield point of all joint components that can be correlated with stress, a tightening parameter based on the joint characteristic, which tightening parameter varies from one joint to the next; and   means for terminating tightening in response to the tightening parameter.   
     
     
        .Iaddend. .Iadd.59.  Apparatus for tightening seriatim a multiplicity of substantially identical joints having components including at least one threaded fastener to substantially the same final desired stress value, below the yield point of all components that can be correlated with stress, appearing in the fastener, comprising a powered instructable tool, capable of terminating tightening in response to an instruction which varies from one fastener to the next, for applying torque to the fastener and tightening the same; means for sensing the torque applied to the fastener at various angles of advance; means responsive to the torque and angle sensings for determining, while tightening at a value below which any of the aforesaid joint components are alterable in configuration by the application of a load thereto, a tightening parameter value, variable from one fastener to the next, sufficient to tighten each fastener to the final desired stress value; and means for instructing the tool to terminate tightening of each fastener in response to the determined tightening parameter value. .Iaddend.