Multi-pinion gear digital beam torque wrench

A position sensor assembly for use in a system in which a first beam moves relative to a second beam, comprising:

• a first position sensor portion mounted on the first beam, including:
• a first pinion gear;
• a second pinion gear operatively engaged with the first pinion gear;
• and
• a position sensor engaged with the second pinion gear to sense an amount of displacement of the first beam relative to the second beam;
• and
• a second position sensor portion mounted on the second beam, including:
• a rack gear operatively engaged with the first pinion gear of the first position sensor portion.

A torque wrench, comprising:

• a main beam having a distal end and a proximal end;
• a ratchet head disposed at the distal end of the main beam;
• a handle assembly disposed at the proximate end of the main beam;
• an indicator beam having a first end fixedly secured to the main beam at a first location on the main beam, and a second end;
• a position sensor assembly disposed at a second location on the main beam to detect an amount of flexure of the main beam relative to the indicator beam in response to a torque applied to the handle assembly, the position sensor assembly including:
• a rack gear secured to one of the main beam or the indicator beam;
• a pinion gear mounted on a first axis secured to the other one of the main beam or the indicator beam, wherein the flexure of the main beam causes movement of the rack gear relative to the first pinion gear;
• and
• a position sensor disposed away from the first axis to generate an electrical signal indicative of the amount of flexure of the main beam relative to the indicator beam based on the movement of the rack gear relative to the pinion gear.

A torque wrench, comprising:

• a main beam having a distal end and a proximal end;
• a drive element disposed near the distal end of the main beam;
• an indicator beam having a first end fixedly secured to the main beam at a first location on the main beam, and a second end;
• a position sensor assembly at least partially disposed at a second location on the main beam to detect an amount of displacement of the main beam relative to the indicator beam, the position sensor assembly including:
• a straight rack gear secured to one of the main beam or the indicator beam, wherein the straight rack gear includes a plurality of teeth aligned along a substantially straight line;
• a pinion gear in geared connection with the rack gear and secured to the other one of the main beam or the indicator beam;
• a spring having a first end coupled to the first beam, and a second end, wherein the spring pushes the pinion gear against the straight rack gear;
• and
• a position sensor engaged with the pinion gear to sense an amount of displacement of the main beam relative to the indicator beam.