FIELD

This relates to a system and method for use in tightening one or more fasteners; to systems and methods for monitoring and/or managing connection integrity; associated connections assemblies; and energy capture and/or production devices comprising the connection assemblies.

BACKGROUND

Mechanical members are utilised in a vast array of applications and in a wide variety of industries. Typical examples of such mechanical members include mechanical fasteners, with bolts, studs, and tie-bars being particularly common examples. Other examples of mechanical members include cables used to secure and/or stabilise structures.

In many applications, particularly those of a safety critical nature, the mechanical members are tensioned to a prescribed load or to prescribed strain. In the case of mechanical fasteners, for example, tensioning ensures that the coupling between the mating faces of the components to be coupled is maintained. The tension applied to the fasteners is typically selected to be in excess of the expected separation force acting on the mating faces in use, and provides a greater degree of confidence that the coupling will function as expected.

There are a number of different methods for applying tension to mechanical members. One method of applying tension to mechanical fasteners such as bolts or studs involves the use of a tensioner device (also known as a bolt or stud tensioner), whereby a hydraulic cylinder is used to apply tension to the mechanical fastener to induce stretching of the fastener. A mechanical retainer, typically in the form of a nut, is then located on the stretched fastener, the nut maintaining the strain when the hydraulic load is removed. The tensioner device is then removed. In an alternative tensioner device, often known as a hydraulic nut, the hydraulic cylinder and the nut form a single assembly. Whereas bolt or stud tensioners are removed after use, the hydraulic nut remains in place, forming a permanent installation. Despite their widespread use, conventional tensioner devices and techniques nevertheless involve a number of drawbacks.

For example, in practice the use of these conventional tools tends to create micro-cracking within the threaded section of the bolt. The repeated application of torque can result in a higher risk of these micro-cracks becoming larger. In extreme cases, this can lead to major failure (for example, snapping) and therefore loss of integrity within the joint.

SUMMARY

Aspects of the present disclosure relate to a system and method for use in tightening one or more fasteners; to systems and methods for monitoring and/or managing connection integrity; associated connections assemblies; and energy capture and/or production devices comprising the connection assemblies.

According to a first aspect, there is provided a system for use in tightening one or more fasteners, the system comprising: a controller configured to receive an input signal comprising measurement data relating to the pre-load of one or more of the fasteners, the controller configured to determine from the received input signal a torque or an adjustment in torque required to be applied to the one or more fasteners; a torqueing device configured to apply torque to the one or more fasteners, wherein the controller is configured to provide an output signal indicative of the torque or adjustment in torque required to tighten the one or more fasteners to the torqueing device, and wherein the controller is configured to execute an artificial intelligence algorithm such that at least one of the received input signal, the output signal or the determined torque or adjustment in torque is obtained autonomously.

In use, the system may be provided to automatically and/or autonomously tighten one or more fasteners by adjusting the tension on one or more of the fasteners as required, the applied torque or adjustment in torque to be applied being determined by the controller based on measurement data obtained by the controller from the fasteners.

Beneficially, the system, amongst other things, addresses the issue of fastener slackening, by facilitating the quick and efficient tightening of one or more fasteners automatically and/or autonomously. This may have particular application for fasteners used within energy capture and/or production facilities, such as wind turbines, e.g. wind turbine tower foundations, subsea energy capture and production facilities, nuclear energy production facilities and/or within any heavy industrial engineering sectors, in which access to the fasteners (for example to obtain measurements relating to the tension of the fasteners, fastener integrity or to carry out required maintenance) may otherwise be challenging or impossible. This in turn may, for example, provide for improved safety and reduced costs. Additionally, the system beneficially reduces the risks of micro-cracking, which is typically associated with conventional tightening methods. For example, by reducing the likelihood of over-torqueing a fastener.

The controller may be coupled to or operatively associated with the torqueing device.

The controller may be configured to provide an output signal configured to activate a heating element provided in the one or more fasteners, in response to the received input signal.

In use, the controller may be configured to provide an output signal configured to activate the heating element when the controller determines that an adjustment in torque is required on the one or more fasteners. The output signal configured to activate the heating element may be provided prior to the output signal indicative of the adjustment torque required.

The controller may be configured and/or operable to heat the one or more fasteners for a pre-determined time. The predetermined time may be stored in memory and implemented via the system software. Trials and/or research may be provide the necessary data input for the system software.

In use, when the heating element is at full temperature (e.g. consistent with bolt diameter and/or material) then the system software may trigger a signal for the torqueing device, in particular one or more motors of the torqueing device, to engage and to turn the one or more fasteners a specific pre-set angular displacement, thereby rotating the one or more fasteners to a new position, e.g. further down the bolt thread. Once this has been achieved then the motor may be stopped. The one or more fasteners may be allowed to cool to ambient temperature and the tension will rise to the installed tension as before.

The controller may also be configured to provide an output signal comprising a warning to an operator, for example a warning signal via a user interface. The output signal comprising a warning to an operator may be provided in advance of the output signal indicative of the adjustment in torque required. This may provide the opportunity for manual intervention prior to a torqueing event.

The controller may be configured to determine from the received input signal the amount of torque or adjustment in torque required on the one or more fasteners. The controller may then be configured to operate the torqueing device to apply this amount of torque to the one or more fasteners. The controller may be configured to compare the input signal comprising measurement data relating to the pre-load on the one or more fasteners with a stored or previously calculated value of pre-load.

The controller may be configured to receive an input signal or signals comprising measurement data relating to environmental and/or operational conditions of an application, arrangement, assembly or device within which the system is in use. The input signal or signals comprising measurement data relating to environmental and/or operations conditions may be utilised by the Al algorithm executed by the controller. The Al algorithm may use this measurement data to adapt or devise operational strategies for the controller.

The system may comprise one or more fasteners. The one or more fasteners may be configured to provide a clamping force and prevent axial movement between two parts.

The one or more fasteners may comprise at least two inter-engaging components. For example, the fastener may comprise a first component and a second component. The first component may comprise a main body. The first component may comprise a threaded portion. The first component may be, for example, a bolt, a stud or the like. The second component may comprise a body having a threaded portion, wherein the second component may be configured for threaded engagement with the threaded portion of the first component. The second component may comprise for example, a nut or the like.

The main body of the first component may comprise a channel configured to receive a heating element. The channel may extend through the main body of the first component. The channel may not extend into the threaded portion of the first component. Accordingly, only the main body of the first component may be configured to be directly heated by the heating element.

The second component may be configured for the application of torque. For example, the second component may comprise an outer face. The outer face may be configured to facilitate the application of torque to the second component.

The outer face may be toothed, geared or provided with ridges.

This may facilitate improved accuracy when applying torque to the fastener, for example allowing for minute adjustments in angular displacement of the second component.

The outer face may be planed. For example, the outer face may comprise six planes to make the outer face shape hexagonal. It will be appreciated that any number of planes may be provided to give the outer face any required shape, for example, 4, 5, 6, 7, 8, 9, 10, ... n planes.

The system may comprise a plurality of fasteners. For example, in use, fasteners may be provided at areas known to experience or have been assessed to experience increased stress. For example, in use in a wind turbine tower foundation base, fasteners may be provided at 3, 6, 9 and 12 o’clock positions. Additional fasteners may be provided at 30 degrees points, for example, 1, 2, 4, 5, 7, 8, 10, 11 o’clock positions.

Each of the one or more fasteners may comprise a heating element. The heating element may comprise an induction heating element. The use of an induction heating element may provide for rapid and accurately controlled heating such that, only a selected portion of the fastener is heated. For example, the main body of the first component may be heated and the threaded portion of the first component may remain unheated during use.

The heating element may be configured to heat the main body of the fastener first component. The heating element may be configured to cause elongation of the main body of the first component when in use. The heating element may be configured to elongate the main body of the first component to a pre-determined length when in use. This may facilitate ease of removal of the fastener when required. This may also allow for the fastener second component to be torqued while not under stress. The provision of a heating element and heating the fastener reduces the need to unnecessarily torque the second component in the same location along the threaded portion of the first component during separate applications of torque. Accordingly, the likelihood of thread elongation and damage to the fastener first component may be minimised.

The controller may be configured to provide an output signal configured to activate a heating element provided in each of the one or more fasteners for a selected time. The selected time may be calculated by the controller based on the time required to achieve a required elongation of a portion of the fastener and/or the time required to heat the portion of the fastener to a required temperature. The selected time may be stored within the controller and/or calculated by the Al algorithm executed by the controller.

The system may further comprise a sensor arrangement.

The sensor arrangement may comprise an acoustic sensor configured to measure the pre-load on the one or more fasteners. The acoustic sensor may comprise or take the form of an ultrasonic sensor configured to measure the pre-load on the fastener.

The sensor arrangement may comprise a plurality of sensors. The type and number of sensors may be selected based upon the application within which the fastener is used. For example, the sensor arrangement may comprise any combination of sensors configured to acquire data relating to environmental conditions and/or operational conditions. For example, the sensor arrangement may comprise a blade accelerometer, tower accelerometer, pressure sensor, wind direction sensor, wind speed sensor, acoustic sensor, temperature sensor, humidity sensor, water sensor, sensor diagnostic monitor, and seismometer.

The sensor arrangement may comprise a sensor or sensors configured to obtain measurement data relating to the condition of the one or more fasteners. The sensor arrangement may comprise an ultrasonic sensor or an array of ultrasonic sensors configured to detect flaws, for example mechanical faults, in the fastener. For example, a phased array of ultrasonic sensors may be provided for non-destructive testing of the condition of the fastener.

The provision of one or more of the above sensors may allow for the system to obtain data relating to the environmental and/or operational conditions of the particular application within which the system is applied. The measurements and data obtained from the sensor arrangement may be used as the foundations for an artificial intelligence algorithm within the control system. For example, the system may be used within a wind turbine tower and the system may allow for the optimisation of the wind turbine operation by ensuring the fasteners throughout the wind turbine structure are tightened when required. The provision of one or more of the above sensors may allow for the system to optimise the fastener pre-load based on operational conditions.

The sensor arrangement, e.g. one or more acoustic sensors, may be configured and/or operable to output an output signal indicative of a reduction in fastener tension exceeding a predetermined threshold.

Alternatively or additionally, the sensor arrangement, e.g. one or more acoustic sensors, may be configured and/or operable to output an output signal indicative of a reduction in fastener tension equal to or exceeding the design limit of the fastener.

The controller may be configured and/or operable to receive the output signal from the sensor arrangement and output an alarm signal or otherwise initiate an alarm indicative of one or more of: the reduction in fastener tension exceeding a predetermined threshold; the reduction in fastener tension equal to or exceeding the design limit of the fastener.

In use, the controller may monitor the fastener arrangement and output an alarm signal or otherwise initiate an alarm in the event of a reduction in fastener tension exceeding the predetermined threshold and/or the reduction in fastener tension equal to or exceeding the design limit of the fastener. The continue may continue to output the alarm signal even when past the lowest acceptable design limit. The controller may monitor the fastener arrangement continuously, e.g. 24 hours a day.

Alternatively, the controller may monitor the faster intermittently, e.g. at a predetermined sample rate.

The system may comprise a torqueing device associated with each of the one or more fasteners. The torqueing device may be configured to be controlled by the controller to angularly displace the one or more fastener by a calculated amount. The calculated amount of angular displacement may be calculated by the controller based on the input signal.

The torqueing device may be configured to engage with the fastener. For example, the torqueing device may be configured to engage with the fastener second component and to apply torque to the fastener second component by angularly displacing the fastener second component.

The torqueing device may comprise a hydraulic torqueing arrangement.

The torqueing device may comprise a mechanical torqueing arrangement. The torqueing device may comprise a motor and gear arrangement. The fastener may comprise the gear arrangement. The motor may turn the gear thus resulting in angular displacement of the fastener. The motor may comprise a direct current motor. The torqueing device may comprise a plurality of motors and gears, for example, two motors and two gears.

The controller is configured to determine from the received input signal a torque or an adjustment in torque required on the one or more fasteners. The controller may be configured to compare the input signal comprising measurement data relating to the pre-load of one or more fasteners pre-load with a pre-set value of pre-load. The pre-set value of pre-load may be selected by the controller based on the requirements for the fastener and/or application of the fastener. The pre-set value of pre-load may be selected by an operator and programmed into the controller. The pre-set value of preload may be determined by and programmed by the Al program. If the measured preload is less than the pre-set value, this may indicate that the one or more fasteners are slack and may require tightening. The controller may be configured to calculate the angular displacement of the one or more fasteners required to reach the pre-set value of pre-load. The controller may be configured to calculate the angular displacement of the one or more fasteners required autonomously.

The system may comprise, may be coupled to or operatively associated with a sensor arrangement configured and/or operable to measure angular displacement of the one or more fasteners. The sensor arrangement may comprise one or more angular displacement transducers.

The controller may be configured to provide an output signal configured to activate and deactivate a torqueing device. The controller may be configured to provide an output signal configured to activate a torqueing device and then deactivate the torqueing device when the one or more fasteners have been torqued by the required amount. The one or more fasteners may then cool to ambient temperature and the preload will increase to the pre-set pre-load value. Beneficially, this may prevent a threaded portion of the one or more fasteners from becoming galled or damaged during repeated torqueing events over time.

The controller may be provided with real-time human override capabilities. The controller may be configured to adjust in response to a control command from an operator. Accordingly, the controller may provide for autonomous operation while also permitting manual intervention where required.

The controller may comprise a controller user interface or control panel. The controller user interface may be provided at a remote location, for example a mobile device or a lap top computer. Alternatively or in addition, the controller user interface may comprise an in-situ control system user interface, for example a control system interface located at the same facility as the fastener. The controller user interface may display output signals relating to the operation of the system and relating to the input signals received by the system. The controller user interface may provide for real-time monitoring of the system when in use, by an operator.

The system may comprise, may be coupled to or operatively associated with a processing system. The processing system, or part of the processing system, may form part of the system. The processing system may, for example, form part of the controller. The processing system, or part of the processing system, may be coupled to or operatively associated with the system. For example, the processing system may be located at one or more remote location. The remote location may comprise or take the form of a mobile device such as tablet, mobile phone or the like. Alternatively or additionally, the remote location may comprise or take the form of a control room. Alternatively or additionally, the remote location may comprise or take the form of a data store, such as an online data store.

The processing system may comprise a processor, such as a central processing unit, a data store, a memory. The processing system may be configured to receive input signals data from a sensor arrangement. The processing system may be configured to receive instructions from a user interface. The processing system may be configured to process input signals received and develop and implement operating instructions for the controller. The controller may comprise a plurality of processors. The plurality of processors may form, comprise or be comprised in a distributed or server/client based processing system.

The controller may comprise a network module. The network module may be connectable to a network and/or data carrier. For example, a WiFi network, Bluetooth, the internet.

The system may comprise a communication arrangement. The communication arrangement may be configured and/or operable to provide communication between the controller and the torqueing device. The communication arrangement may be configured and/or operable to provide communication between the controller and the sensor arrangement. The communication arrangement may be configured and/or operable to provide communication between the controller and the processing system.

The communication arrangement may comprise or take the form of a wireless communication arrangement. The wireless communication arrangement may comprise a radio frequency communication arrangement. The communication arrangement may comprise or take the form of a transmitter or transceiver. The communication arrangement may comprise or take the form of a wired communication arrangement. The wired communication arrangement may comprise or take the form of an electric wire and/or optical fibre communication arrangement. The Al algorithm may be capable of automatically devising operating instructions for the controller. These instructions may include optimal strategies for monitoring and maintaining fastener tightness, for example to maintain a connection integrity. Accordingly, the system for use in tightening one or more fasteners may also be configured to monitor the integrity of one or more connections formed by the one or more fasteners. In use, the Al algorithm may be capable of automatically devising optimal operational strategies which can either by implemented automatically by the controller or passed to a human operator for approval. The controller may be capable of learning operator decisions on the proposed operating strategies and operator defined changes to any proposed steps. The controller may be capable of monitoring outcomes of any changes to automated operational strategies and using this data to automatically improve the existing strategies. The controller may identify human decisions resulting in the deterioration of operating conditions and use this data to avoid such decisions being reused and flag them during future operations.

The controller may be configured to communicate data from the input signals to a data historian system. In use, this function enables data analysts to review and become more aware of any trends in fastener slackening, and/or operational conditions.

The system may further comprise an energy capture and/or energy production device. The energy capture device may comprise a wind energy capture device. For example, a wind turbine. The energy capture device may comprise a tidal energy capture device. The energy production device may comprise a nuclear energy production device. The system may be configured for use in tightening one or more fasteners, wherein the one or more fasteners are used to form connections within the energy capture and/or energy production device.

In use, the one or more fasteners may be provided at areas known to experience or have been assessed to experience increased stress within the energy capture and/or production device. Beneficially, the system may allow for the autonomous tightening of the one or more fasteners within the energy capture and/or production device and therefore mitigate against the risk of failure of connections within the energy capture and/or production device and/or optimise operational efficiencies of the energy capture and/or production device. The system may be configured and/or operable to operate in real time or substantially real time.

According to a second aspect, there is provided a method for tightening one or more fasteners, the method comprising: obtaining measurement data relating to the pre-load of one or more fasteners; the measurement data forming an input signal for use by a controller; determining based on the input signal a torque or an adjustment in torque required to be applied to the one or more fasteners; providing an output signal to a torqueing device indicative of the torque or the adjustment in torque required, wherein the controller is configured to provide the output signal, and wherein the controller is configured to execute an artificial intelligence algorithm such that at least one of the obtaining, determining or output signal takes place autonomously.

Beneficially, the method provides for quickly and efficiently addressing the issue of fastener slackening, whilst reducing the risks from over-torqueing of a fastener. This may have particular application for fasteners used within energy production facilities, such as wind turbines, wind turbine tower foundations, subsea energy production facilities, nuclear energy production facilities and within any heavy industrial engineering sectors, where access to fasteners may be challenging or impossible.

The method may further comprise providing an output signal configured to activate a heating element provided in each of the one or more fasteners. The method may comprise heating a portion of each of the one or more fasteners prior to an adjustment of the torque on the one or more fasteners.

The method may comprise adjusting the torque on the one or more fasteners. The output signal indicative of the adjustment in torque required may comprise an output signal to operate a torqueing device. The controller may therefore be configured to operate a torqueing device to apply torque to the one or more fasteners, in response to the determined adjustment in torque. The method may further comprise providing an output signal comprising a warning to an operator. For example, a warning signal via a user interface. The method may comprise providing the output signal comprising a warning prior to the output signal indicative of an adjustment in torque required. This may provide the opportunity for manual intervention prior to a torqueing event.

The controller may be configured to determine from the received input signal the amount of adjustment in torque required on the one or more fasteners. The method may comprise operating a torqueing device to apply this amount of torque to the one or more fasteners. The method may comprise comparing the input signal comprising measurement data relating to the pre-load on the one or more fasteners with a stored or previously calculated value of pre-load and determining the amount of adjustment in torque required.

The method may comprise obtaining an input signal or signals comprising measurement data relating to environmental and/or operational conditions of an application, assembly, arrangement or device within which the fastener is in use. The input signal or signals comprising measurement data relating to environmental and/or operations conditions may be utilised by the Al algorithm. The Al algorithm may use this measurement data to adapt or devise operational strategies for the controller.

According to a third aspect, there is provided a system for use in monitoring and/or managing connection integrity, wherein the connection is formed by one or more fasteners, the system comprising: a controller configured to receive an input signal comprising measurement data relating to the pre-load of one or more fasteners, the controller configured to determine from the received input signal if a torque or an adjustment in torque is required on the one or more fasteners, wherein, if a torque or an adjustment in torque is required, the controller is configured to provide an output signal indicative of the torque or adjustment in torque required for use in tightening the one or more fasteners, and wherein the controller is configured to execute an artificial intelligence algorithm such that at least one of the received input signal, the output signal or the determined torque or adjustment in torque required is obtained autonomously. In use, the system may be used to autonomously monitor the tightness of fasteners making up a connection, and where required adjust the torque on the fastener.

Beneficially, the system may ensure that connections within a particular application, assembly or device are maintained and this in turn mitigates against the risk of mechanical failures as well as improving operational efficiencies.

The system may comprise receiving an input signal or signals comprising measurement data relating to environmental and/or operational conditions of an application within which the system is in use. The input signal or signals comprising measurement data relating to environmental and/or operations conditions may be utilised by the Al algorithm. The Al algorithm may use this measurement data to adapt or devise operational strategies for the controller. For example, the controller may be configured to obtain input signals comprising measurement signals relating to the preload on the one or more fasteners at selected intervals, or in response to operational conditions, as determined by the Al algorithm. The controller may be configured to obtain input signals comprising measurement data relating to the pre-load on the one or more fasteners in response to an operator command.

The system may comprise providing an output signal configured to activate a heating element provided in each of the one or more fasteners, if an adjustment in torque is determined to be required. The system may be configured to provide an output signal configured to activate the heating element prior to the output signal indicative of the adjustment in torque required for use in tightening the one or more fasteners

According to a fourth aspect, there is provided a method of monitoring and/or managing connection integrity, wherein the connection is formed by one or more fasteners, the method comprising: obtaining measurement data relating to the pre-load of one or more fasteners, wherein the measurement data is an input signal for use by a controller; determining based on the input signal if a torque or an adjustment in torque is required on the one or more fasteners; and if a torque or an adjustment in torque is required, providing an output signal indicative of the torque or adjustment in torque required, wherein the controller is configured to provide the output signal, wherein the controller is configured to execute an artificial intelligence algorithm such that at least one of the obtaining, determining or output signal takes place autonomously.

The method may comprise receiving an input signal or signals comprising measurement data relating to environmental and/or operational conditions of an application within which the system is in use. The input signal or signals comprising measurement data relating to environmental and/or operations conditions may be utilised by the Al algorithm. The method may comprise, the Al algorithm using this measurement data to adapt or devise operational strategies for the controller. For example, the method may comprise the controller obtaining input signals comprising measurement signals relating to the pre-load on the one or more fasteners at selected intervals, or in response to operational conditions, as determined by the Al algorithm. The method may also comprise obtaining input signals comprising measurement data relating to the pre-load on the one or more fasteners in response to an operator command.

The method may comprise activating a heating element provided in each of the one or more fasteners, if an adjustment in torque is determined to be required. The method may comprise providing an output signal configured to activate the heating element prior to the output signal indicative of the adjustment in torque required for use in tightening the one or more fasteners

According to a fifth aspect, there is provided a connection assembly comprising: one or more fasteners, wherein each of the one or more fasteners comprise a heating element arranged to heat a portion of the fastener; a sensor arrangement arranged to provide measurement data relating to the pre-load on the one or more fasteners; a torqueing device, wherein the torqueing device is arranged for the application of torque to the one or more fasteners; a controller, wherein the controller is configured to: receive an input signal comprising the measurement data relating to the pre-load of one or more fasteners; determine from the received input signal a torque or an adjustment in torque required on the one or more fasteners; provide an output signal to activate the heating element; and provide an output signal to activate the torqueing device to apply torque to the one or more fasteners, wherein the controller is configured to execute an artificial intelligence algorithm such that at least one of received input signal, the output signals or the determined adjustment in torque required is obtained autonomously.

In use, the connection assembly may provide for autonomous tightening of the one of more fasteners and this ensure that the integrity of the connection is maintained. This may have particular benefits for connections within the energy industry, for example connections formed within wind capture equipment, tidal energy capture equipment and nuclear energy generators where the mechanical connections may be subject to high operational stresses.

According to a sixth aspect, there is provided an energy production and/or energy capture device, wherein the energy production and/or capture device comprises at least one connection assembly according to the fifth aspect.

The energy capture device may comprise a wind energy capture device. For example, a wind turbine. The energy capture device may comprise a tidal energy capture device. The energy production device may comprise a nuclear energy generator.

A plurality of connection assemblies may be provided. The connections assemblies may be provided at connections within the energy production and/or capture device known or shown to experience large operational stresses.

According to seventh aspect, there is provided a processing system configured to implement one or more of the previous aspects. The processing system may comprise at least one processor. The processing system may comprise and/or be configured to access at least one data store or memory. The data store or memory may comprise or be configured to receive operating instructions or a program specifying operations of the at least one processor. The at least one processor may be configured to process and implement the operating instructions or program.

The at least one data store may comprise, and/or comprise a reader, drive or other means configured to access, optical storage or disk such as a CD or DVD, flash drive, SD device, one or more memory chips such as DRAMs, a network attached drive (NAD), cloud storage, magnetic storage such as tape or magnetic disk or a hard-drive, and/or the like.

The processing system may comprise a network or interface module. The network or interface module may be connected or connectable to a network connection or data carrier, which may comprise a wired or wireless network connection or data carrier, such as a data cable, powerline data carrier, Wi-Fi, Bluetooth, Zigbee, internet connection or other similar connection. The network interface may comprise a router, modem, gateway and/or the like. The system or processing system may be configured to transmit or otherwise provide the audio signal via the network or interface module, for example over the internet, intranet, network or cloud.

The processing system may comprise a processing apparatus or a plurality of processing apparatus. Each processing apparatus may comprise at least a processor and optionally a memory or data store and/or a network or interface module. The plurality of processing apparatus may communicate via respective network or interface modules. The plurality of processing apparatus may form, comprise or be comprised in a distributed or server/client based processing system.

According to an eighth aspect, there is provided a computer program product configured such that when processed by a suitable processing system configures the processing system to implement one or more of the previous aspects.

The computer program product may be provided on or be comprised in a carrier medium. The carrier medium may be transient or non-transient. The carrier medium may be tangible or non-tangible. The carrier medium may comprise a signal such as an electromagnetic or electronic signal. The carrier medium may comprise physical medium such as a disk, memory card, a memory and/or the like.

According to ninth aspect, there is provided a carrier medium, the carrier medium comprising a signal, the signal when processed by a suitable processing system causes the processing system to implement one or more of the previous aspects.

It will be well understood by persons of ordinary skill in the art that whilst some embodiments may implement certain functionality by means of a computer program having computer-readable instructions that are executable to perform the method of the embodiments. The computer program functionality could be implemented in hardware (for example by means of a CPU or by one or more ASICs (application specific integrated circuits)) or by a mix of hardware and software.

Whilst particular pieces of apparatus have been described herein, in alternative embodiments, functionality of one or more of those pieces of apparatus can be provided by a single unit, processing resource or other component, or functionality provided by a single unit can be provided by two or more units or other components in combination. For example, one or more functions of the processing system may be performed by a single processing device, such as a personal computer or the like, or one or more or each function may be performed in a distributed manner by a plurality of processing devices, which may be locally connected or remotely distributed.

For the purposes of the present disclosure, it should be understood that the features defined above or described below may be utilised, either alone or in combination with any other defined feature, in any other aspect, embodiment, or example or to form a further aspect, embodiment or example of the disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings in which:

Figure 1 shows a diagrammatic view of a system for tightening one or more fasteners;

Figure 2 shows an example of a fastener for use in the system shown in Figure 1 ;

Figure 3 shows an example of another fastener for use in the system shown in Figure 1 ;

Figure 4 shows an example of another fastener for use in the system shown in Figure 1 ;

Figure 5 shows an illustrative arrangement of the system shown in Figure 1;

Figure 6 shows another illustrative arrangement of the system; and

Figure 7 shows a schematic diagram of the interaction of the Al algorithm with other components of the system for use in tightening one or more fasteners.

DETAILED DESCRIPTION OF THE DRAWINGS

A system 100 for use in tightening one or more fasteners is shown diagrammatically in Figure 1. As shown in Figure 1 , the system 100 comprises a controller 50 configured to receive an input signal comprising measurement data relating to the pre-load of a fastener 10. The input signal is obtained from an acoustic sensor 40 which is configured to measure the pre-load on the fastener 10. The fastener 10 comprises a bolt 12 having a main body 16 and a threaded portion 18, as shown in Figure 2. The bolt 12 is provided with an induction heating element 20 which is arranged to heat the main body 16 of the bolt 12. The main body 16 of the bolt 12 can also comprise a temperature sensor 43. The controller 50 is configured to provide an output signal indicative of an adjustment in torque required. The output signal operates a torqueing device 60 which is arranged to torque a nut 14 which forms part of the fastener 10. The controller 50 is configured to execute an Al algorithm 55 which is configured to allow the controller 50 to autonomously obtain measurement data from the acoustic sensor 40, and operate the heating element 20 and torqueing device 60 such that the fastener 10 can be tightened when required.

Figure 2 shows an example fastener 10 comprising a bolt 12 and a nut 14 positioned at either end of the bolt 12, for use in the system 100. The fastener 10 is provided to clamp two parts 30, 32 to form a connection. The bolt 12 comprises a main body 16 and threaded portions 18. The nuts 14 are in threaded engagement with the threaded portions 18 of the bolt 12. The main body 16 of the bolt 12 is provided with a channel 19 within which a heating element 20 is arranged. In this case, an induction heating element 20 is shown. The induction heating element 20 is arranged such that in use, the main body 16 of the bolt 12 is heated, while the threaded portions 18 remain unheated. The heating element 20 comprises wiring 22 allowing for power to be delivered to the heating element 20 to activate the heating element 20 and heat the main body 16 of the bolt 12. The speed and accuracy of induction heating prevents damage to the threaded portions 18 of the bolt 12. The heating process is so rapid that, in use, there is no time for the heat generated by the heating element 20 to travel to the threaded portions 18.

A sensor arrangement is provided to measure the pre-load on the fastener 10. Figure 3 shows an example sensor arrangement which includes an ultrasonic sensor 40. The ultrasonic sensor 40 is provided on the bolt 12 and is arranged to send an acoustic signal 42 through the bolt 12 to measure the pre-load within the bolt 12. This measured pre-load is then compared against a predetermined pre-load associated with the bolt 12 by the controller 50. If the measured pre-load is less than the predetermined pre-load, this may indicate that the fastener 10 is slack and requires tightening. More than one ultrasonic sensor 40 can be provided on the bolt 12. Two ultrasonic sensors 40 are shown in Figure 4. The ultrasonic sensor or sensors 40 can fixed to the bolt head using adhesive. Accordingly, the ultrasonic sensors 40 can be retrofitted to a bolt if required

The fastener 10 can be tightened by system 100 as follows. The controller 50 will output a signal activating the induction heating element 20. Heat is applied to the bolt 12 via the induction heating element 20. The heat expands the main body 16 of the bolt 12 by a pre-determined length. The pre-determined length and the heating time required to achieve this length may be input to the controller 50 by an operator. Additionally, or alternatively, the pre-determined length and the heating time required to achieve this length may be provided to the controller 50 by the Al algorithm 55. When the bolt 12 has reached its pre-determined length, an acoustic signal 42 is then transmitted to the control system 50 from the ultrasonic sensor 40 provided on the bolt 12. The temperature sensor 43 can also be provided on the main body 16 of the bolt and the temperature sensor 43 sends an output signal comprising temperature data to the controller 50. The controller 50 can therefore also monitor the temperature of the bolt 12.

The nut 14 is then torqued, without being under stress or pre-load, by the torqueing device, generally denoted 60. In Figure 4, the torqueing device 60 is shown as comprising two high torque direct current (DC) motors 60 which are configured to engage with the nut 14 to drive the nut 14 to a calculated angular displacement relative to the original position. The nut 14 comprises teeth or ridges 14a facilitating the application of torque. The angular displacement of the nut 14 is calculated by the difference in pre-load setting to actual measured pre-load when taken by the controller 50. After the nut has been torqued to the required amount, the controller 50 will send an output signal to turn off the heating element 20. The bolt 12 will cool to normal ambient temperature and whilst doing so the pre-load increases to the pre-set value requested. Accordingly, the fastener 10 is tightened by the system 100 in a way that reduces the risk and the potential for generating micro stress cracking in the threaded portion 18 of the bolt 12, without any human intervention (if desired).

In one example application, the system 100 may be used to ensure connection integrity in wind turbine operations. Fasteners 10 for use in the system 100 are located at the four cardinal points of North, South, East and West around the periphery of the wind turbine tower foundation base 80 as shown in Figure 5 (this corresponds to clock positions 12, 3, 6, and 9 o’clock). In some applications, the remaining fasteners provided in the base 80 will be standard bolts 81. Alternatively, fasteners 10 for use in the system 100 can be installed at 30 degrees (for example, 1 o’clock, 2 o’clock etc.) from corresponding fasteners 10, as shown in Figure 6. The locations of the fasteners 10 for use in the system 100 are selected to cover critical connection areas of known or considered/assessed increased stress for example due to wind conditions and/or direction, and/or geotechnical movement within the wind turbine. Each of the fasteners 10 will be provided with the heating element 20, ultrasonic sensor 40 and motor arrangement 60 as described previously. The heating elements 20, ultrasonic sensor 40 and motor arrangement 60 of each fastener may be individually and autonomously controlled by the controller 50 comprising the Al algorithm 55. The system 100 is shown schematically in Figure 7. The control system 50 is configured to execute Al software 55 that is loaded with upper and lower limits of preload calibration as well as other functionality based on virtual assistant technology type of control via cloud computing as part of the Al algorithm 55. The Al algorithm 55 is configured to receive signals comprising measurement data from the heating elements 20, ultrasonic sensors 40 and motors 60 of each of the fasteners 10 and facilitates the calculation of the angular displacement of the nut 14 required. The Al algorithm 55 provides operating instructions for the controller 50 to obtain measurements from the sensor arrangement 40, to operate the induction heating element 20 and to operate the torqueing device 60. Accordingly, the system 100 can also provide for autonomous monitoring of a connection integrity and automatic tightening of the fasteners 10 within the connection, when required. The control system 50 comprises at least one processor and a data store or memory.

The system 100 is provided with a user interface 52. The user interface 52 may be provided on a handheld device, laptop or tablet. The user interface 52 provides an advance warning prior to initiating a torqueing event on a fastener 10. Human intervention on the monitoring and tightening process is enabled through the user interface 52 which communicates with the control system 50 and the Al algorithm 55. If the pre-load on a fastener 10 drops below a certain pre-set level, then this is when the Operator will be given an early warning of an upset condition about to take place. The early warning can be sent to a handheld device or tablet via cloud computing technology to any location in the world.

The Al algorithm 55 provides a supervisory operating strategy, wherein specific limits and operating strategies can be assessed and implemented for specific incidents from a stored software library of events. To that end, the Al algorithm 55 may also be configured to receive measurement data generated from other sensors 44 associated with a specific application within which the system 100 is operating. For example, these may comprise temperature sensors (ground and/or air), blade accelerometers, tower accelerometers, pressure sensors, wind direction sensors, wind speed sensors, humidity sensors, fastener temperature sensors, sensor diagnostic monitors, seismometers, ultrasonic sensors for non-destructive testing of the condition of the fastener(s). It should be appreciated that this list is not intended to be exhaustive. The Al algorithm 55 is capable of automatically devising optimal strategies for monitoring and maintaining connection integrity and fastener tightness. Accordingly, in use, the controller 50 is capable of automatically devising optimal operational strategies which can either by implemented by the controller 50 or passed to a human operator for approval. In addition to feeding into the Al algorithm 55, outputs from the various sensors 44 are interfaced to the software computer and then sent via cloud enabled transmission to the user interface 52 such that the Operator can be informed of actual real time reporting and monitoring.

The system 100 provides a real time technology solution for the management and integrity monitoring of fasteners, and the connections formed by these fasteners. In some applications, for example, when employed within a wind turbine tower, the system 100 can also provide overall tower system condition monitoring. The output from the system 100 can be used to determine a trending pattern of data for specific areas of integrity. This will aid in the decision-making process with regards to the most influential and pressing engineering issue. It can assist in providing essential insight into whether a fastener 10 is in a condition to be kept in situation or if it requires further assessment for replacement. The system 100 can also check and compliment for any form of cathodic protection by way of its ability to maintain a minimal temperature within the fasteners 10, if required by operation of the heating element 20.

The system 100 may offer a number of benefits beyond ensuring connection integrity. These may include power generation optimisation through an effective realtime proactive approach where connection integrity is monitored and maintained on a continual basis; minimisation of the operational costs incurred compared to conventional fastener tightening approach; improved reliability of the integrity management process, with a major emphasis on its predictive aspects; the justification of the decisions taken by the system at every step of the computer-devised fastener management process; learning of each fastener management scenario and of its effects on power production optimisation, including those scenarios where a manual override of system decision takes place; advisory forecasting of the net effects of system decision overriding based on previous learnt scenarios and on the result of the automated system prediction model; use of a learnt scenario to automatically adjust the fastener management strategy; compliance to Net Zero aspirations. It should be understood that the examples provided herein are merely exemplary and that various modifications may be made thereto without departing from the scope defined by the claims.