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**Tightening Effect Detection and Problem Analysis in Engine Parts Assembly**
Cars are made up of numerous components, and bolted connections are among the most common. Manual tightening often leads to inconsistent torque application, which can affect assembly quality. To ensure precision, tightening machines are widely used, especially in critical engine assembly processes. These machines offer controlled and consistent torque, ensuring reliable performance. However, even the most accurate equipment can have issues, so it’s essential to verify the tightening effect after the process.
This paper discusses current methods for detecting tightening effectiveness, focusing on practical cases involving engine part tightening. It highlights two commonly used techniques: the double-tightening method and the sensor serialization method. Both have their advantages and limitations, and understanding these is crucial for accurate quality control.
**Common Methods for Tightening Effect Detection**
The two primary control methods used in tightening machines are torque control and torque-rotation angle control. Despite this, most detection is still based on torque readings. The double-tightening method involves using a high-precision torque wrench to re-tighten a bolt after the initial tightening. This method is simple and cost-effective but can introduce errors due to static friction during the second tightening.
On the other hand, the sensor serialization method uses a high-precision torque sensor connected to the tightening shaft. This allows for real-time measurement during the tightening process, reducing error and providing more accurate results. While more complex and expensive, it is preferred for calibration and detailed torque characterization.
**Torque Errors and Challenges with Complex Tightening**
The double-tightening method has known inaccuracies. For rigid fasteners, the detected torque may be 25% higher than the actual value, while soft connectors can show a deviation of -20% to -5%. These errors make the method suitable only as a reference, not for final verification.
Sensor serialization, being a dynamic method, offers greater accuracy. However, it requires specialized equipment and careful setup. The key advantage is that it measures torque during the tightening process, minimizing the impact of static vs. dynamic friction.
**Common Issues Encountered During Tightening**
1. **Discrepancy Between Manual and Machine Readings**
- If manual torque readings are higher than machine values, it could be due to operator error or improper use of tools like pointer wrenches.
- When manual readings are lower, it might be due to factors like time elapsed after tightening, material differences, or improper surface conditions.
2. **Torque Reaches Upper Limit, Angle Doesn’t Match Target**
This often occurs when threads are damaged, foreign objects are present, or washers cause additional friction.
3. **Torque Below Lower Limit, Angle Is Met**
This usually indicates insufficient bolt strength or incorrect thread size.
4. **Other Practical Concerns**
- Process specifications can sometimes be too strict, leading to unnecessary rejections.
- Different workpiece materials (e.g., aluminum vs. steel) can result in different torque readings, even when the machine shows consistent values.
For example, in one case, tightening aluminum alloy and steel covers showed different manual readings, even though the machine displayed the same torque. This was due to differences in surface friction, highlighting the importance of material properties in torque interpretation.
In conclusion, while tightening machines provide consistent control, manual verification remains necessary. Understanding the limitations of each detection method ensures better quality assurance and avoids misinterpretations. Continuous discussion and improvement in tightening practices are essential for maintaining high standards in automotive manufacturing.
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