System and method for optimizing a production process using electromagnetic-based local positioning capabilities

A system for optimizing a fastener installation process within a work cell, the system comprising:

• a handheld torque wrench adapted to install a threaded fastener into a work piece, the handheld torque wrench having a rotatable shaft that rotates about an axis of rotation;
• an electromagnetic marker connected to the handheld torque wrench such that the axis of rotation passes through the electromagnetic marker, wherein the electromagnetic marker is adapted to emit calibrated magnetic fields in close proximity to the handheld torque wrench within the work cell;
• a stationary array of electromagnetic receptors positioned in the work cell external to the handheld torque wrench and adapted to measure the emitted magnetic fields, and to generate a raw positional signal in response thereto;
• a processing core in communication with the array of receptors, wherein the processing core is adapted for processing the positional signal to thereby calculate a position value and an attitude value in the form of yaw, pitch, and roll for the electromagnetic marker;
• a fastener control unit (FCU) that selectively updates a performance setting of the handheld torque wrench;
• a graphical user interface (GUI);
• and
• a host machine in communication with the processing core, the FCU, the GUI, and the electromagnetic marker, wherein the host machine is operable for:
• displaying, via the GUI, an expected position from a calibrated sequence;
• continuously monitoring a present position of the handheld torque wrench using the position value and the attitude value;
• calculating a present position of the threaded fastener using the present position of the handheld torque wrench;
• comparing the present position of the threaded fastener to the displayed expected fastener position in a calibrated fastener sequence;
• and
• executing at least one control action, including temporarily disabling the handheld torque wrench, when the present position of the threaded fastener is not equal to the expected fastener position, and updating the performance setting of the handheld torque wrench via the FCU when a current performance setting of the handheld torque wrench is not equal to an expected performance setting of the handheld torque wrench.

A method for optimizing a fastener installation process within a work cell, the method comprising:

• emitting a calibrated magnetic field via an electromagnetic marker positioned within the work cell;
• sensing the calibrated magnetic field via an electromagnetic receptor array, wherein one of the electromagnetic marker and the electromagnetic receptor array is connected to a handheld torque wrench;
• generating a raw positional signal using the receptor array;
• processing the raw positional signal using a processing core to thereby convert the raw position signal into a position value and an attitude value of the electromagnetic marker in the form of yaw, pitch, and roll;
• and
• continuously monitoring a present position of the handheld torque wrench within the work cell, via a host machine, based on the position value and the attitude value;
• comparing the present position of the handheld torque wrench to an expected position in a calibrated sequence;
• displaying, via a graphical user interface (GUI), an expected position from a calibrated sequence;
• comparing a current performance setting of the handheld torque wrench to an expected performance setting from the calibrated sequence;
• and
• executing a control action, including temporarily disabling the handheld torque wrench, when the present position of the handheld torque wrench is not equal to the expected position in the calibrated sequence, and updating the performance setting of the handheld torque wrench via a fastener control unit when the current performance setting is not equal to the expected performance setting.