What is a Smart Screwdriver?
Many consumer goods are assembled with small screws by hand which can be prone to human error. The smart screwdriver is a solution from SMAC Moving Coil Actuators that eliminates this manual tedious hand-eye work as well as replace imperfect pneumatic screwdrivers.
The SMAC Smart Screwdriver is meant for a broad range of screw sizes, including 1.4 millimeter or smaller, like those found in watches, eyeglasses, cameras, consumer electronics, cell phones, power tools, etc. The Smart Screwdriver is very small and could be attached to a larger robotic arm for special applications, providing high quality every time. Furthermore, this solution could be used in reverse to automatically disassemble a device, quickly, efficiently, and carefully.
Common Problems
Misaligning
A misaligned essential screw could result in stopping an assembly line for some manufacturers. There is little or no feedback on the work until the device goes to QA. If QA misses the critical screw, it could lead to defective products, angry customers, recalls. In short, a small screw could cost big money!
Cross-Treading
A common problem with screws and lug nuts is cross-threading. This means the threads on a lug nut or screw are not aligned with the threads on the stud while screwing them together. To avoid cross-threading, an assembler will start lug nuts or screws by hand by turning the screw the wrong way until he feels a bump and hears the screw falling into position. The assembler would then turn the screw several rotations before using a wrench or screwdriver to “snug” it into place. This process has been difficult to automate until recently and has been primarily performed by human operators.
How does a smart screwdriver application automate the process?
To begin, a fast approach is performed which finds the surface with SMAC’s patented Soft-Land capability. Second, it turns counter clock-wise and the screw moves up and drops as the first thread is found. This thread matching technique prevents cross-threading. The linear rotary actuator then begins rotating clock-wise. A snug torque can be applied. This is useful when there are numerous screws holding a part on the clamping surface and they need to be snugged evenly. Lastly, a final torque is applied.
Throughout, the Smart Screwdriver is monitoring the torque and pitch verification. Good, cross/no-threads, shallow, and the precision of the thread are detected during feedback of position & torque off both axes.
Smart Screwdriver vs Pneumatic handheld auto-feed screwdriver
Using a pneumatic handheld auto-feed screwdriver to install screws is significantly more productive than the labor-intensive process, Nevertheless, simple pneumatic screwdrivers are not an ideal solution either. Workers using pneumatic tools with compressed air and dials to estimate the amount of torque for the screw can strip or misalign the threads if an incorrect torque or angle is used.
SMAC’s cost- effective smart screwdriver solution performs the same work as a pneumatic auto-feed tool electronically. There is no compressed air, no mechanical parts, and no need for oil or recalibration. In addition to being maintenance free the Smart Screwdriver also has a high degree of programmability. This gives the assembler the confirmation when the screw is correctly inserted, when linear height, degrees of rotation and the desired torque have been reached. The smart screwdriver monitors the linear position and force, rotary torque and degree of rotation while at the same time driving the screw. These parameters are all entirely programmable with the ability to have feedback sent to a PLC or database in real time. This ability to perform the task and verify simultaneously, eliminates the need for costly and time consuming down the line quality check.
Tri-Phase Automation/IMAC Motion Control is a SMAC distributor in Wisconsin and Illinois. Contact Us and we can help get you get started with this innovative solution.