Extended and Unscented Kalman Filtering for Estimating Friction and Clamping Force in Threaded Fasteners

Abstract: Threaded fasteners tend to break and loosen when exposed to cyclic loads or potent temperature variations. Additionally, if the joint is held tightly to the structure, distortion will occur under thermal expansion issues. These complications can be prevented by identifying and regulating the clamping force to an appropriate degree – adapted to the properties of the joint. Torque-controlled tightening is a way of monitoring the clamping force, but it assumes constant friction and therefore has low accuracy, with an error of around 17% - 43%.This thesis investigates if the friction and clamping force can be estimated using the Extended and Unscented Kalman filters to increase the precision of the torque-controlled methodology. Before the investigation, data were collected for two widely used tightening strategies. The first tightening strategy is called Continuous Drive, where the angular velocity is kept at a constant speed while torque is increased. The second strategy is TurboTight, where the angular velocity starts at a very high speed and decreases with increased torque. The collected data were noisy and had to be filtered. A hybrid between a Butterworth lowpass filter and a Sliding Window was developed and exploited for noise cancellation.The investigations revealed that it was possible to use both the Extended and Unscented Kalman filers to estimate friction and clamping force in threaded fasteners. In Continuous Drive tightening, both the EKF and UKF performed well - with an averagequality factor of 81.87% and 88.38%, and with an average error (at max torque) of 3.54% and 4.09%, respectively. However, the TurboTight strategy was much more complex and had a higher order of statistical moments to account for. Thus, the UKF outperformed the EKF with an average quality factor of 93.02% relative to 24.49%, and with an average error (at max torque) of 3.50% compared to 4.19%