In the tight, intricate spaces of aero-engine and airframe assembly, engineers often face a formidable challenge: how to install high-strength bolts where there’s barely room to maneuver. Enter L. Wensheng and his team from the Tianjin Key Laboratory of Fastening Technology, who have developed a compact bolt installation tool that could revolutionize assembly processes in the energy sector.
The tool, detailed in a recent study published in *Mechanical Sciences* (formerly known as *Mechanika*), is a marvel of engineering design. Its thin-walled structure allows it to squeeze into spaces as narrow as 4 millimeters, while its coordinated drive of a ratchet-pawl mechanism and a hydraulic cylinder enables it to deliver impressive torque. “The key was to balance compactness with power,” explains Wensheng. “We needed a tool that could fit into tight spaces but still pack a punch.”
The team’s design process was meticulous, focusing on the thin-walled structure, force arm dimensions, and ratchet tooth profile. Dynamic simulation analysis verified the strength and safety of key components under a torque of 120 Nm, ensuring the tool’s reliability in demanding conditions. But the real test came in the lab. Experimental results showed the tool could deliver an average torque of 136.3 Nm, exceeding design expectations and fulfilling the requirements for high-strength bolt assembly in compact spaces.
The implications for the energy sector are significant. Aero-engines and airframes are just the beginning; this technology could be adapted for use in other industries where space is at a premium, such as offshore wind turbines or nuclear reactors. “This tool isn’t just about making assembly easier,” says Wensheng. “It’s about making it safer and more efficient, which ultimately drives down costs and improves reliability.”
The research also opens doors for future developments. As Wensheng notes, “The principles we’ve applied here could be adapted for other types of fasteners or even other industries. It’s a stepping stone to more innovative solutions.” With the energy sector increasingly focused on efficiency and safety, tools like this one could become indispensable.
In a field where every millimeter counts, Wensheng and his team have delivered a solution that could reshape assembly processes, making them faster, safer, and more reliable. And with the study published in *Mechanical Sciences*, the engineering community now has a blueprint for the next generation of compact, high-torque tools.