CONTROL DEVICE AND METHOD FOR SETTING UPPER AND LOWER LIMIT CURVES FOR ONE OR MORE TOOLS ARRANGED TO APPLY FASTENERS

[0001] The present invention generally relates to the field of control devices for one or more tools arranged to apply fasteners in a production process. In particular, the present invention relates to such control devices able to set limit curves to detect not okay (NOK) fastener application operations.

[0002] In industrial assembly factories, tools are used for applying fasteners to objects for the purpose of joining different pieces of material together during a production process. Examples of such tools are tightening tools for applying threaded fasteners (such as screws and nuts) and riveting tools for applying rivets.

[0003] In such production processes, it is important to detect fastener application operations performed by such tools that do not live up to the desired quality standard. Such operations are normally referred to as not okay, NOK, fastener application operations. Just to mention a few examples, such NOK fastener application operations may be operations involving a fastener of incorrect dimension, having wrong thread coating or that was slanted upon insertion, or operations when a so called stick slip occurs. The cause of a stick slip is a complex dynamic phenomenon between many physical parameters that together results in the joint starting to act like an oscillating spring and thus, the torque value oscillates at a high frequency.

[0004] In order to detect such NOK fastener application operations, trace data from the operations of a tool are collected. Such trace data normally includes values indicative of application force (e.g. torque or clamp force) versus values indicative of displacement (e.g. angle) or time and can be displayed as a graph.

[0005] Further, during a pre-production configuration process, limits for these values are normally set, typically manually by a production technician. In the succeeding production process, it is then detected if the trace data of an operation exceeds these limits. If that is the case, that fastener application operation is classified as a NOK operation and it is typically recorded as such in the production management system as well as displayed to the operator of the tool. The operator then needs to re-do the fastener application to obtain an OK result.

[0006] A disadvantage of today's solutions for setting such limits is that they typically need to be set manually. Further, it might be hard to balance the trade-off of setting the limits generous enough to not make false NOK detections, yet strict enough to not miss out operations that are supposed to be detected as NOK. Failing in finding this balance results in a less accurate NOK operation detecting process.

[0007] It would be advantageous to achieve a control device and a method of overcoming, or at least alleviating, the above mentioned drawbacks. In particular, it would be desirable to enable a control device and a method that facilitates setting limits for the purpose of detecting NOK fastener application operations. It would also be desirable to enable a more accurate NOK fastener application operation detecting process.

[0008] To better address one or more of these concerns, a control device and a method having the features defined in the independent claims are provided. Preferable embodiments are defined in the dependent claims.

[0009] Hence, according to a first aspect, a control device for one or more tools arranged to apply fasteners in a production process is provided. The control device is configured to, in a production configuration process:

• • [0010] obtain a set of trace data for a plurality of test fastening application operations performed by at least one of said one or more tools on one type pf joint, the trace data including, for each fastener application operation, values indicative of application force versus values indicative of displacement or time or a derivative thereof;
  • [0011] from said set of trace data, derive maximum values indicative of application force, or the derivative thereof, for each one of a plurality of the values indicative of displacement or time, and calculate a first polynomial based on these maximum values;
  • [0012] from said set of trace data, derive minimum values indicative of application force, or the derivative thereof, for each one of a plurality of the values indicative of displacement or time, and calculate a second polynomial based on these minimum values;
  • [0013] based on said first polynomial, set an upper limit curve; and
  • [0014] based on said second polynomial, set a lower limit curve;
    the control device being further configured to, in the production process following said production configuration process:
  • [0015] determine that a fastener application operation performed by any one of said one or more tools is not okay (NOK) if at least some of its trace data exceeds the upper limit curve and/or falls below the lower limit curve.

[0016] According to a second aspect, a method for a control device for one or more tools arranged to apply fasteners in a production process is provided. The method comprises, in a production configuration process:

• • [0017] obtaining a set of trace data for a plurality of test fastening application operations performed by at least one of said one or more tools on one type of joint, the trace data including, for each fastener application operation, values indicative of application force versus values indicative of displacement or time or a derivative thereof;
  • [0018] from said set of trace data, deriving maximum values indicative of application force, or the derivative thereof, for each one of a plurality of the values indicative of displacement or time, and calculating a first polynomial based on these maximum values;
  • [0019] from said set of trace data, deriving minimum values indicative of application force, or the derivative thereof, for each one of a plurality of the values indicative of displacement or time, and calculating a second polynomial based on these minimum values;
  • [0020] based on said first polynomial, setting an upper limit curve; and
  • [0021] based on said second polynomial, setting a lower limit curve;
    the method further comprising, in the production process following said production configuration process:
  • [0022] determining that a fastener application operation performed by any one of said one or more tools is not okay (NOK) if at least some of its trace data exceeds the upper limit curve and/or falls below the lower limit curve.

[0023] The inventors have realized that by calculating polynomials based on the maximum and minimum values indicative of application force (for each one of a plurality of the values indicative of displacement or time), or a derivative thereof, for several test fastener application operations, upper and lower limit curves for NOK operation detection can be automatically created. The area between the upper and lower limit curves may be referred to as an envelope of allowable values. Hence, with the present aspects, an envelope defining the limits between OK/NOK values can be automatically created. Since the envelope is based on polynomials calculated based on maximum and minimum values of several actual test fastener application operations on one type of joint, it will ensure a balanced trade-off between the generosity and strictness of the limits, whereby the accuracy of NOK operation detection is improved. By using polynomials, the envelope (i.e. the upper and lower limit curves) will not follow all the irregularities of a single fastener application operation. Instead, smooth curves are provided for limiting OK from NOK values.

[0024] Further, by generating upper and lower limits in the form of curves, it is possible to detect NOK operations wherein not just the final maximum values are evaluated, but possibly also values throughout one, several or all of different steps of the operation. That enables detecting more types of NOK operations, such as stick slip, wherein the torque oscillates during the torque build up phase while the final end torque might be within acceptable limits.

[0025] The polynomials may be calculated based on the value indicative of the application force over displacement/time, or on a derivative (of the first or second order) of the value indicative of the application force over displacement/time. Both of these may be used as a basis for detecting OK/NOK fastener application operations.

[0026] In the present specification, the term “values indicative of application force” means values of a parameter that in some way reflects/represents the force applied by the tool to the fastener. For example, in case the tool is a tightening tool, such a parameter may be a torque as sensed by e.g. a torque sensor of the tool, a motor current (which is representative of the torque) or a clamp force as sensed by e.g. an ultrasonic sensor of the tool. As another example, in case the tool is a riveting tool, such a parameter may e.g. be the motor current (which reflects the force applied by the tool in the rivet). Other parameters may also be envisaged.

[0027] Further, in the present specification, the term “values indicative of displacement or time” means values of a parameter that in some way reflects/represents the progression of the operation. In the case of a tightening tool, that parameter may e.g. be the angle as sensed by an angle sensor. In case of a riveting tool, that parameter may be the time from the start of the riveting operation. Other parameters may also be envisaged.

[0028] Further, in the present specification, the term “one type of joint” means joints that have the same characteristics. For example, the test fastener applications may be made on the same corresponding single joint in several equal assemblies. Alternatively, the test fastener applications may be made on several joints in one (or several equal) assemblies, as long as these joints have the same characteristics in terms of e.g. stiffness (softness/hardness), friction etc. For example, the joints may join the same pieces of material and include the same type of fastener. The point is that the collected trace data of OK fastener application operations preferably should follow roughly the same path, at least for each step of the fastener application operations, in order to generate adequate polynomials.

[0029] For example, the upper and lower limit curves may be set to equal the first and second polynomials, respectively. Alternatively, a (slight) marginal to the polynomials may be added. Preferably, the upper and lower curves may be set to follow the first and second polynomials, respectively.

[0030] According to an embodiment, the number of degrees of the first and second polynomials may be at least 2, preferably at least 3, and most preferably at least 4.

[0031] According to an embodiment, the number of degrees of the first and second polynomials may be at maximum 6, preferably at maximum 5.

[0032] Having too few degrees of the polynomials will make them less adaptive, while having too many degrees will make them more sensitive, which might end up in curves having a too oscillating character. The inventors have found that around 4 to 5 degrees of the polynomials is perhaps the most optimal trade-off in this respect.

[0033] According to an embodiment, the first and second polynomials may be calculated using regression analysis, such as by using the least square method. Hereby, an efficient way of approximating the polynomials that best fits the maximum and minimum values is provided.

[0034] According to an embodiment, the control device may be further configured to, subsequent to obtaining the set of trace data of the test fastener application operations, and prior to the steps of deriving the maximum and minimum values:

• • [0035] if the obtained set of trace data comprises trace data considered to represent not okay (NOK) test fastener application operations, remove that trace data from the set.

[0036] The present embodiment is advantageous in that test trace data of NOK operations is removed/discarded before the maximum and minimum values are derived. Hence, the polynomials will be adapted solely to OK test operations, which will improve the accuracy of the resulting upper and lower limit curves.

[0037] The removal of the trace data of the NOK test fastener application operations may e.g. be made upon command of a user/operator (e.g. via input from a user interface), or automatically e.g. by using a machine learning model for identifying the NOK test fastener application operations.

[0038] According to an embodiment, the control device may be further configured to, in the production process:

• • [0039] during a fastener application operation performed by at least one of said one or more tools, continuously monitor whether at least some of the resulting trace data exceeds the upper limit curve and/or falls below the lower limit curve.

[0040] Hence, it is possible to detect that an ongoing fastener application operation is not turning out at as desired before the complete operation is terminated.

[0041] According to an embodiment, the control device may be further configured to:

• • [0042] trigger (preferably immediate) interruption of the fastener application operation in response to said resulting trace data exceeding the upper limit curve and/or falling below the lower limit curve.

[0043] Hence, the fastener application operation can be interrupted as soon as its trace data goes outside the envelope of allowed values. Thus, the evaluation of the trace data is not awaited with until after termination of a complete operation. The present embodiment is advantageous in that damage to the material to which the fastener is applied as well as to the fastener itself can be prevented or at least reduced.

[0044] According to an embodiment, the tool may be a tightening tool or a riveting tool.

[0045] According to an embodiment, the control device may be further configured to:

• • [0046] divide said set of trace data into at least two sets representing at least two different steps of the fastener application operation;
  • [0047] calculate first and second polynomials for each one of said at least two steps; and
  • [0048] set the upper limit curve and the lower limit curve for each step based on the, for each step, calculated first and second polynomials, respectively.

[0049] That is, for each one of the two sets of trace data, maximum values indicative of application force may be derived to calculate the first polynomial, and minimum values indicative of application force may be derived to calculate the second polynomial. Hence, different first polynomials may be provided for the different steps and different second polynomials may be provided for the different sets. In other words, each one of several steps of the fastener application operations will have individual upper and lower limit curves. Thereby, the upper and lower limit curves of each step will be better tailored to the test trace data of that step.

[0050] Examples of steps of a tightening operation may be the steps of: run down (up to when the fastener head meets the work piece), snug (when the pieces of material of the work piece are being compressed), torque build up (upon completion of the compression and when the torque builds up in the joint) and brake (when applied torque is interrupted).

[0051] According to an embodiment, a system is provided. The system comprises one or more tools arranged to apply fasteners in a production process; and a control device as defined according to the first aspect.

[0052] According to an embodiment, a computer program is provided comprising instructions which, when the program is executed by a computer (such as a control device), cause the computer to carry out the method as defined according to the second aspect.

[0053] According to an embodiment, a computer-readable storage medium is provided comprising instructions which, when executed by a computer (such as a control device), cause the computer to carry out the method as defined according to the second aspect.

[0054] It is noted that embodiments of the invention relates to all possible combinations of features recited in the claims. Further, it will be appreciated that the various embodiments described for the control device are all combinable with the method as defined in accordance with the second aspect of the present invention.

[0061] All the figures are schematic, not necessarily to scale, and generally only show parts which are necessary in order to elucidate the embodiments, wherein other parts may be omitted. Like reference numerals refer to like elements throughout the description.

[0062] A system 1 according to an embodiment will be described with reference to FIG. 1. The system 1 comprises at least one tool 2 for applying fasteners 8 to a work piece 7 in an industrial production process. The tool 2 may e.g. be a tightening tool (as illustrated in FIG. 1) for applying threaded fasteners 8 or a riveting tool (not shown) for applying rivets.

[0063] The system 1 may further comprise a control device 6 configured to control the tool 2. The control device 6 may be in communication with the tool 2, e.g. by wire or wirelessly. The control device 6 may be a remote single unit (such as a computer and as illustrated in FIG. 1), distributed in several units (such as cloud based), and/or comprised in the tool 2. The control device 6 may comprise a memory for storing coded instructions and processing means for executing the coded instructions.

[0064] The system 1 may optionally further comprise a display 5 for displaying information of the fastener application operations performed by the tool 2. The display 5 may be a separate unit (as illustrated in FIG. 1) or incorporated in the control device 6 and/or in the tool 2.

[0065] In industrial manufacturing, a pre-production configuration process may be performed in order to set up the system 1 for the upcoming production process. In such a pre-production configuration process, the equipment to be used and processing steps that are to be performed may be tested and configured for the specific assembly to be performed.

[0066] In the present example, upper and lower limit curves may be defined in such a pre-production configuration process for the purpose of being able to detect not okay (NOK) fastener application operations performed by the tool 2 later on in the production process. Such upper and lower limit curves may also be redefined/updated during a subsequent production configuration process, e.g. if a new batch of fasteners is to be used that has a higher friction compared to previous batches. An example of how these upper and lower limit curves may be set will be described in more detail in the following.

[0067] FIG. 2 shows a graph 10 of trace data 15 of a set of test fastener application operations performed by the tool on one type of joint during the production configuration process (which may be a pre-production configuration process or a subsequent production configuration process). The trace data 15 of each operation may be displayed as a curve illustrating how a parameter T indicative of the force applied to the fastener by the tool (such as torque) varies with the progression of the operation. The progression of the operation is represented by a parameter a indicative of displacement (such as angle) or time.

[0068] The trace data may alternatively (or as a complement) be displayed as the derivative of the parameter T with respect to displacement or time a (not shown).

[0069] The control device may be configured to obtain this trace data 15 from the tool and optionally display it (such as in the form of the graph 10 illustrated in FIG. 2) on the display to an operator.

[0070] If the obtained set of trace data 15 includes any test operation that is considered NOK, the trace data of that operation may be removed, e.g. by the operator or by means of a machine learning model.

[0071] Then, the control device may be configured to derive, for each one of a plurality of displacement or time values (such as angle) α, maximum values T_max and minimum values T_min of the application force (such as torque) from the set of trace data 15. In FIG. 2, merely a few maximum values T_max and minimum values T_min are illustrated for the sake of simplicity, however, it will be appreciated that maximum values T_max and minimum values T_min for many more displacement or time values α may be derived, such as for hundreds or thousands of displacement or time values α depending on the sample rate of the trace data.

[0072] The plurality of displacement or time values α for which the maximum and minimum values T_max and T_min are derived may e.g. represent a certain part of, or the complete, fastener application operations. Such a certain part may e.g. correspond to a certain step of the fastener application operation. In the example illustrated in FIG. 2, the plurality of displacement or time values α for which the maximum and minimum values T_max and T_min are derived may represent a torque build up step 13 of a tightening operation.

[0073] The control device may further be configured to calculate a first polynomial based on the maximum values T_max and a second polynomial based on the minimum values T_min. For example, a method based on regression analysis, such as the least square method, may be used to calculate the polynomials.

[0074] The first polynomial is then a basis for setting an upper limit curve 11 and the second polynomial is a basis for setting a lower limit curve 12. For example, the upper and lower limit curves 11, 12 may equal the first and second polynomials, respectively (as illustrated in FIG. 2). Alternatively, the upper and lower limit curves 11, 12 may be set slightly offset from the first and second polynomials. As can be seen in FIG. 2, the upper and lower limit curves 11, 12 smoothly approximates an envelope following the maximum and minimum values T_max and T_min. Preferably, the number of degrees of the first and second polynomials may be between 2 and 6, such as 4 or 5.

[0075] Optionally, the upper and lower limit curves 11, 12 may be editable by a user before finally set.

[0076] In the succeeding production process, these limit curves 11, 12 may be used for detecting NOK fastener application operations. This will be explained in the following with reference to FIG. 3.

[0077] In the production process, the control device is configured to obtain, preferably continuously, trace data 16 of operations performed by the tool. If it is detected that this trace data 16 goes outside the envelope as defined by the upper and lower limit curves 11, 12, it is determined that the operation is a NOK operation. The trace data 16 may be monitored continuously during the operation with respect to the limit curves 11, 12, and the operation may be interrupted as soon as trace data 16 falls outside the envelope. Alternatively, the trace data 16 may be compared with the limit curves 11, 12 after the complete operation is ended.

[0078] In the example illustrated in FIG. 3, trace data 16 of a tightening operation that includes a stick slip is illustrated. As can be seen, the trace data 16 oscillates 17 outside the envelope as defined by the limit curves 11, 12. Therefore, that operation will be classified as a NOK operation by the control device.

[0079] For example, the control device may be further configured to display the outcome of the OK/NOK classification of the operation on the display and/or record/save it to the production management system.

[0080] According to an embodiment, the control device may be configured to divide the trace data of an operation into several sets, each one corresponding to a pre-defined step of the operation. In the example illustrated in FIG. 4, a tightening operation is divided into the steps: run down 21, snug 22, torque build-up 23 and brake 24. Here, maximum and minimum values T_max and T_min are derived for a plurality of displacement or time values α defined for each phase 21, 22, 23, 24. The limits between the different steps may be defined not as numeric displacement or time values, but rather as when particular conditions are met.

[0081] For example, the snug step 21 may be defined as ended when the torque starts to rise. Then, one first polynomial and one second polynomial are calculated for each one of the steps 21, 22, 23, 24 based on these maximum and minimum values T_max and T_min. Upper limit curves 211, 221, 231 241 and lower limit curves 212, 222, 232, 242 for each step may then be set accordingly.

[0082] The trace data curves may be aligned for each step 21, 22, 23, 24. However, this is mere a display issue, when calculating the polynomials the relevant displacement or time values for the specific step in question is used to derive the maximum and minimum values.

[0083] A method 100 according to an embodiment will now be described with reference to FIG. 5. The method 100 may be performed by a control device, such as the one described with reference to FIG. 1.

[0084] The method 100 comprises, in a production configuration process 101:

• • [0085] a) obtaining a set of trace data for a plurality of test fastening application operations performed by at least one of said one or more tools on one type of joint, the trace data including, for each fastener application operation, values indicative of application force versus values indicative of displacement or time or a derivative thereof;
  • [0086] b) optionally, if the obtained set of trace data comprises trace data considered to represent not okay (NOK) test fastener application operations, removing that trace data;
  • [0087] c) from said set of trace data, deriving maximum values indicative of application force, or the derivative thereof, for each one of a plurality of the values indicative of displacement or time, and calculating a first polynomial based on these maximum values;
  • [0088] d) from said set of trace data, deriving minimum values indicative of application force, or the derivative thereof, for each one of a plurality of the values indicative of displacement or time, and calculating a second polynomial based on these minimum values;
  • [0089] e) based on said first polynomial, setting an upper limit curve; and
  • [0090] f) based on said second polynomial, setting a lower limit curve.

[0091] The method 100 further comprises, in the production process 102 following the production configuration process 101:

• • [0092] g) determining that a fastener application operation performed by any one of said one or more tools is not okay (NOK) if at least some of its' trace data exceeds the upper limit curve and/or falls below the lower limit curve. Optionally, the fastener application operation may be determined as OK otherwise.

[0093] Optionally, the method 100 may further comprise:

• • [0094] h) triggering interruption of the fastener application operation in response to said resulting trace data exceeding the upper limit curve and/or falling below the lower limit curve; and/or
  • [0095] i) notifying an operator and/or saving in a production management system the results of the determination in step g).

[0096] It will be appreciated that the embodiments described for the control device are all combinable with embodiments of the method.

[0097] The person skilled in the art realizes that the present invention by no means is limited to the embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims.

[0098] Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.