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Arduino Torque Recorder Woodward, INC

The Arduino Torque Recorder is a low-cost solution to eliminate operator errors and ensure product quality by counting and recording torque levels. It can replace expensive Atlas Copco torque drivers and store torque data on a WISE database.

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Arduino Torque Recorder Woodward, INC

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  1. Arduino Torque RecorderWoodward, INC January 2012 Clayton Rayment Engine Systems

  2. 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. Proprietary Information●●●

  3. 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. Proprietary Information●●●

  4. 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. Proprietary Information●●●

  5. Development ATR Development Atlas Copco Status Serial Output Station ID Station Set-up Cost Low Cost Solution Proprietary Information●●●

  6. 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. Proprietary Information●●●

  7. 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. Proprietary Information●●●

  8. 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 Proprietary Information●●●

  9. 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 Proprietary Information●●●

  10. 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 Proprietary Information●●●

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