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Engine Systems

Arduino Torque RecorderWoodward, INC

January 2012

Clayton Rayment

Engine Systems

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Problem

• Currently, operator error from torque on assembly lines causes some products to ship with bolts that are not tightened, incorrectly tightened, or are missing alltogether.

• Although cases mentioned above are rare (once every 3 years) we need a solution to eliminate the problem.

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Proposed Solution

• The Arduino Torque Recorder will combat this problem, and help ensure product quality for the customers by counting the level and number of torques and exporting them to a computer.

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Current Torque Solution

• Currently Woodward uses Atlas Copco torque drivers.

• Some of these torque drivers have been in service for 15 years.

• New Atlas Copco torque drivers have torque counting built in, however the old drivers do not.

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Development

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ATR Development

Atlas Copco Status

Station Set-up

Cost Low Cost Solution

Station ID

Serial Output

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Atlas Copco Status

• Status programmable on with 3 relays

• Relays programmed to indicate “High” “Ok” “Low” torques

• Data taken into ATR with relay bounce control

• Data translated and packaged for export over serial

• Data exported to workstation computer via serial connection.

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Engine Systems

Station Setup

• Currently stations are not identified

• No way to match torques to stations

• ATR stores station data in EEPROM memory

• Station data is exported with the torque data

• Torque values in the database can be matched with a station.

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Engine Systems

Cost

• Currently there are 100 Atlas Copco torque units in use, each costing $16,000

• New Atlas Copco torque drivers would cost $20,000 each

• To replace all units would cost approx. $2.0M not including time and labor

• Stations would be shut down for a long period of time

• The ATR is a low-cost solution costing approx. $50 per unit

• To upgrade all units would cost $5,000 not including time and labor

• Stations would not be shut down very long

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Project Technical Challenges

Problems:• False Signals

• Relay bounce

• User Interface User configuration

• Information Storage

Solutions:• Pull-up resistor enabled

Floats signal high Signal indicated by grounding

• Delay added in the code to ensure relay is active

• Low-level terminal GUI added User given options to

configure station information

• Information about the workstation is stored in the onboard EEPROM

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Arduino Torque Recording

• Solves multiple manufacturing line and quality control issues

• Data stored on a WISE database

• ATR can be configured to each workstation

• One ATR can monitor up to 3 Atlas Copco Machines

• Low cost solution – Delays $2.0M investment in new Atlas Copco torque drivers

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