In the manufacturing and assembly world, tightening, controlling, or measuring torque on fasteners is imperative for production efficiency. An inadequately torqued fastener can vibrate or work loose; conversely, if the tension is too high, it can snap or strip its threads. Faced with these problems, manufacturers realize that precise torque control can distinguish between a safe, reliable, and economical product and a complete disaster.
Anybody who has to tighten a threaded fastener and needs to control, monitor, or measure torque needs sophisticated torque tools. Suppose manufacturers want to save money, make their workplace safer, enhance product quality, or reduce liability exposure. In that case, only specialized high-quality torque tools will correctly complete the job.
The following ten tips for achieving precision torque control will give manufacturers vital information needed to streamline their production processes:
1. Determine Torque Requirements
When determining correct torque specifications, the engineer must consider the maximum load placed on the fastener, the strength of the material joined, and whether the joint is hard or soft. A hard joint connects materials directly. After encountering the material, the fastener rotates very few degrees to develop a full clamping force. Since a soft joint contains a gasket or involves compressible materials, it requires additional tightening after the fastener makes contact to achieve full clamping force.
One recognized method is to perform a destructive test with a calibrated torque control tool on the actual material and fastener to be joined. An evaluation usually involves ten parts, ten fasteners, and a calibrated torque control tool with a transducer. First, the fastener is tightened to the point of failure and then repeated several times to verify the consistency of the failure point. Another series of tests has begun, whereby the joint is torqued to 75% of the failure point. The tightening torque can be reduced to any degree necessary, depending on how the parts are used. If parts on a machine are subject to heavy vibration, 85% of the total force is essential for good torque control.
2. Pick the Right Torque Tool
Various tools are available to control and measure the torque applied to fasteners, from pneumatic screwdrivers and electric screwdrivers to large industrial torque wrenches, torque testers, torque sensors, and torque multipliers. These tools utilize calibrated torque setting mechanisms that may be factory pre-set or user-definable. When the specified setting is reached, the tool gives a visual, audible, or tactile signal.
The anticipated production output, the type of materials being joined, the amount of torque required, and the specified fasteners determine the selection of tools for any given application. Lighter materials such as wood or plastic may require only lightweight tools; likewise, heavy materials such as steel may require stronger or larger tools. Tools should also have wireless capabilities or connection ports for a cable if torque data must be gathered electronically.
3. Use Torque Testers
A torque analyzer is a fast and reliable method of calibrating torque tools to their proper settings. Torque testers can also be used for quick tests on the line or in the lab to determine whether torque tools are holding a given setting. They also allow quality control inspectors to calibrate torque sensors and verify torque on fasteners.
A quality torque analyzer should have enough memory to record several hundred readings and store calibration data for multiple torque sensors. Torque testing equipment calibrates torque screwdrivers, pneumatic screwdrivers, torque wrenches, electric screwdrivers, pulse tools, torque multipliers, and other torque tools.
4. Cooperation is Necessary
Orchestrating a successful torque program requires extensive teamwork in all production-related departments to ensure consistent adherence to torque specifications. Production planners, supervisors, engineers, quality control technicians, and assemblers must all work together to control the process efficiently. To avoid problems, consult everyone whenever changes relating to the use or type of fasteners are instituted.
5. Employee Training
Professional torque tool suppliers often offer personnel training sessions and workshops. Topics covered include basic torque theory, types of tools available, how to operate specific tools, preventive maintenance, safety concerns, and job-related ergonomics.
6. Employee Safety
Safety programs and high-quality tools can avoid worker fatigue and potential injuries. In critical applications where safety is an issue, the proper use of tools can decrease the incidence of expensive lawsuits and product recalls.
To avoid accidents, tools, and the work area should be inspected regularly. Worn components should be replaced, and unsafe conditions on the assembly line should be rectified before injuries occur. Reducing worker fatigue must also be considered to achieve production line consistency and reduce repetitive motion injuries. Torque control tools that improve ergonomics and reduce the effort required for consistent tightening are available.
7. Establish a Calibration Program
Calibration is fine-tuning the torque control process in a production environment. It should be checked periodically to determine whether torque tools are operating at their proper settings. Many tools don’t have a locking device, and users may easily change their torque settings, causing the tool to fall out of adjustment.
A regularly scheduled calibration program enables quality control personnel to correct divergence from proper settings, whether it’s due to average tool slippage over time or adjustments to the tool. Begin by initially setting a calibration interval based on the severity of the application and the tool manufacturer’s recommendations. If the applied torque values are out of range, cut the calibration interval in half and re-test the tools.
8. Preventive Maintenance
To maintain consistent accuracy, torque tools must be checked periodically for wear or defective parts. A properly structured preventive maintenance program optimizes tool performance and reduces unexpected downtime, thereby saving time and money in the long run.
Monitoring the number of cycles per day and total hours a tool uses is the most accurate way to establish proper maintenance intervals. It is recommended that tools be serviced after 100,000 cycles or if an inspection reveals old or dry grease, parts that show signs of excessive wear, or loose screws or bolts.
9. Torque Control Increases Quality Control
Precise torque control is a key to quality assembly and can ensure that products perform as expected. In many cases, companies spend a great deal of time and money on the disposal or repair of damaged parts during assembly, resulting from improper torquing. Worse yet, even if these products make it to market, manufacturers are faced with customer dissatisfaction if they fall apart due to loose screws or stripped threads.
10. Increase the Return On Investment
Tool suppliers should offer recommendations and answers to manufacturers’ torque control challenges. Will their tools enable assemblers to build quicker and with less wasted motion? Will they give quality control inspectors more time to check parts thoroughly? Will they reduce errors in the assembly process? And, will they save money and time for the company overall?
The Mountz torque tools s are designed to streamline assembly processes and enhance productivity in work areas and production cells. To see our full range of products, shop our store. Contact us anytime to ask a question. To inquire about price, request a quote. If you’d like to see our equipment in person, schedule an appointment. To get the latest torque-related news, follow us on LinkedIn.
