Beatrice Lang
Electric torque screwdrivers are used in assembly processes and require routine verification and auditing of their torque output. Torque is the force applied by the screwdriver, and it can be adjusted using an external torque adjustment knob. The torque output can be measured using a torque tester or torque sensor, and the screwdriver typically features a scale on the torque adjustment nut. This scale can be matched to a torque curve or chart to set the desired torque. Dial torque screwdrivers can also be used to measure torque, which is a versatile and low-cost option. They can monitor torque as it increases or decreases and display the peak torque applied. To calculate the torque, one can use a torque analyzer to take readings directly from the screwdriver and perform capability studies to calculate a capability index.
| Characteristics | Values |
|---|---|
| Measuring Torque | Continuous process |
| Testing | Should be part of the assembly process |
| Calibration | Set the torque and verify the repeatability of the tool |
| Torque Tester | Place a run down adapter in-line between the drive of the tool and the transducer |
| Torque Capacity | Testing equipment torque capacity should fit within the screwdriver's torque range |
| Torque Curve | Not an exact measurement, only a guideline |
| Adjusting Torque | Turn the knob left to decrease torque, right to increase |
| External Torque Adjustment Knobs | Allow a screwdriver’s torque to be set at any value between its maximum and minimum settings |
| Exact Torque Setting | Use a torque meter to set the screwdriver’s torque |
| Torque Verification | Dial indicating torque screwdriver is designed for torque evaluation and verification |
| Dial Screwdriver | Can be used in track or peak mode and is operational in both directions |
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What You'll Learn
Using a torque meter
A torque meter, also known as a torque sensor or torque transducer, is a device used to measure and record the torque on a rotating system. Static torque is easy to measure, but dynamic torque is more challenging and may require a transfer of electric, hydraulic, or magnetic effect from the shaft being measured to the static system.
Digital torque meters, such as the AWS Series and AWS-MTM Series, are designed for workstation torque testing and calibration of electric and air torque screwdrivers. They are highly accurate, user-friendly, and portable. The Sumake Series Torque Meters is another example of a digital torque meter with high accuracy and portability, designed for assembly environments. It is worth noting that run-down adapters (RDAs) can be used with torque meters to provide consistent and reliable torque readings by reducing the impact of irregular peaks that affect repeatability.
When using a torque meter, it is important to ensure that the torque capacity of the testing equipment fits within the torque range of the electric screwdriver. This involves placing a run-down adapter in-line between the drive of the tool and the transducer, and then performing run-downs to adjust the torque setting as needed. The screwdriver typically features a scale on the torque adjustment nut, which lists reference numbers that can be used to determine the approximate torque setting. Reviewing the torque reference charts in the operation manual can help with this process.
Additionally, it is recommended to verify the actual torque output on the fastening application when the power tool is placed into the assembly station. This can be done using a rotary torque sensor to audit the power tool's performance. Regular torque testing and auditing of electric screwdrivers are important to ensure product quality, safety, and reliability.
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Adjusting the torque curve
To begin adjusting the torque curve, follow these steps:
- Identify the model of your electric screwdriver. Different models may have varying procedures for adjusting the torque curve.
- Access the manufacturer's website or platform to select your specific model. Look for a "Features" tab or a similar section that provides detailed information about your screwdriver's features and adjustments.
- Locate the "Torque Curve" option within the "Features" section. Clicking on this link should direct you to a new window or page that displays the torque curve specific to your screwdriver model.
- Refer to the scale on the nose or torque adjustment nut of your screwdriver. This scale represents the torque settings and allows you to match it to the appropriate setting on the torque curve.
- Adjust the torque setting as needed. You can increase or decrease the torque by turning a knob or adjuster on the screwdriver. Turning it right usually increases the torque, while turning it left decreases it.
- Test the screwdriver's torque output after each adjustment. This can be done using a torque tester or sensor, ensuring that the testing equipment's torque capacity aligns with the screwdriver's torque range.
- Fine-tune the torque setting until you achieve the desired torque output for your assembly application. It may take several adjustments and tests to reach the optimal torque setting.
Remember that the torque curve is a guide, and the actual torque output may vary slightly. Additionally, it is essential to routinely verify and audit the torque output of your electric screwdriver to compensate for any drift in torque accuracy over time.
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Testing and auditing
Torque Testing and Measurement
Torque meters, also known as torque sensors or torque transducers, are commonly used to test and measure the torque output of electric screwdrivers. These devices measure and record the torque on a rotating system. Digital torque meters, such as the AWS Series, AWS-MTM Series, and Sumake Series, are specifically designed for workstation torque testing and calibrating electric torque screwdrivers. They offer high accuracy, portability, and ease of use.
Calibration and Verification
Calibration is essential to ensure the reliability of electric torque screwdrivers. Over time, these tools can drift out of calibration, affecting their accuracy and performance. Regular torque verification should be conducted to mitigate risks associated with improper calibration. Torque analyzers allow quality engineers to quickly verify the torque output and ensure the screwdriver remains within tolerance.
Assembly Process Integration
Torque Auditing Programs
Manufacturers should incorporate a "Torque Auditing" program as part of their quality control processes. Torque auditing ensures product quality, safety, and reliability. It helps prevent issues such as insufficiently fastened parts or excessive torque that can lead to failures. Regular torque auditing can be performed daily, weekly, or monthly to maintain the integrity of the manufacturing process and the final product.
Torque Reference Charts and Manuals
When testing and auditing electric torque screwdrivers, it is essential to refer to the operation manual and torque reference charts. These documents provide essential information on the torque settings and reference numbers specific to the tool. By following these guidelines, users can ensure they are working within the safe torque range of the screwdriver.
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Using a dial torque screwdriver
Dial torque screwdrivers are designed for precision tightening and torque evaluation. They are versatile tools that can be used for torque auditing, R&D torque testing, and product evaluation. The torque can be measured as it is applied (in track mode) or when the maximum torque value has been hit (in peak mode).
The dial screwdriver is used in two common torque verification tests: the first movement test and the loosening test. In the first movement test, the fastener is tightened, marked, and then force is slowly applied in the tightening direction until the first movement in the fastener is noted. The reading is a good indication of the original torque applied to the joint and is the best way to determine residual torque.
The loosening test is similar, but instead of tightening the fastener, the torque is applied in the direction that loosens it. The torque reading is recorded when the fastener breaks loose. This torque value is approximately what was applied to the joint.
A recognised method for using a dial torque screwdriver is to perform a destructive test with a calibrated torque-measuring instrument on the actual material and fastener to be joined. An evaluation is usually conducted with ten parts, ten fasteners, and a torque-measuring tool. The fastener is tightened to the point of failure, repeated several times, and then another series of tests is begun where the joint is torqued to 75% of the failure point.
Dial torque screwdrivers are a low-cost, versatile tool that can be used for a wide range of applications. They can be used to monitor torque as it increases or decreases and display peak torque applied on a fastening application.
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Calibration
To calibrate an electric torque screwdriver, first select the model you want to calibrate. Then, find the "Features" tab and click on the "Click here for torque curve" link to find the torque curve for your screwdriver. Note that the torque curve is only a guideline, and you will need to adjust the torque setting as needed for your specific application.
When calibrating, use a torque tester or torque sensor with a run-down adapter. Ensure that the torque capacity of the testing equipment fits within the torque range of the screwdriver. Place the rundown adapter between the drive of the tool and the transducer. Adjust the torque setting as needed by turning the knob on the driver—turn it left to decrease torque and right to increase torque.
Additionally, the screwdriver typically features a scale on the torque adjustment nut, which lists reference numbers. You can use this scale to match the torque curve setting required for your assembly application. It is important to test and verify the torque output of the screwdriver regularly to ensure it stays within tolerance.
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Frequently asked questions
Torque is the force applied by a rotating object, in this case, an electric screwdriver.
Measuring torque can be done with a torque tester or a rotary torque sensor. A torque tester requires a run-down adapter to be placed in line with the tool and the transducer. A rotary torque sensor can be used to audit the screwdriver's performance.
Adjusting the torque on an electric screwdriver can be done by using the external torque adjustment knob. This will allow you to set the torque at any value between the maximum and minimum settings. The torque curve for your screwdriver can be found under the "Features" tab on the screwdriver's product page.
It is important to routinely verify and audit the torque output of an electric screwdriver as assembly tools can drift out of tolerance over time. A torque meter can be used to set exact torque settings, and a torque cover can protect the setting from accidental modification. Additionally, a dial indicating torque screwdriver can be used for torque auditing and testing, and can monitor torque as it increases or decreases. The screwdriver can also come with an external grid and torque chart to approximately set the torque, or a scale on the nose of the screwdriver can be matched to the torque curve setting.
