Torque sensors measure the torque output of hand and power tools, as well as calibrating torque tools. They work together with torque analyzers, which interpret the results. These tests are intended to verify the calibration of hand, electric, and pneumatic torque screwdrivers and nutrunners. Companies which rely on torque tools can reduce lost product and product liability by regularly testing tools with torque sensors. By keeping torque tools in calibration, companies reduce the risk of product failure before or after a product leaves the factory by preventing over- or under-tightened fasteners.
Different types of torque sensors are best suited for different torque tools. In order to find the ideal sensor for your tools, here’s some information on three of the most common types of torque sensors available today: torque reaction sensors, rotary torque sensors, and torque screwdriver sensors.
What is a Torque Reaction Sensor?
Torque reaction sensors are engineered for both measuring torque and calibration torque tools. They directly measure the torque a tool applies to their transducer before it stops. Since torque tools are designed to limit the amount of torque their user can apply, testing can easily verify the accuracy of a torque tool’s output. By comparing the intended torque selected on the tool to the actual torque measured by the reaction sensor, users can verify that the tool works correctly.
Torque reaction sensors can be used to measure output from hand, electric, and continuous-drive pneumatic torque tools. To ensure proper readings, run down adapters should be used when measuring power tools. Run down adapters compensate for the impact and irregular peaks produced by power tools.
As laboratory grade instruments, torque sensors are also used for tool verification. The versatile sensor can be used in both a calibration lab or on the production floor. Since a torque sensor can calibrate a wide range of torque tools, its use expands upon the testing capabilities of a torque analyzer.
Depending on their size, torque reaction sensors can measure a broad range of torque outputs, from the minuscule to the mighty. However, some torque applications require a high degree of specificity in extremely low torque ranges. For these applications, low torque reaction sensors are preferred.
What is a Rotary Torque Sensor?
Rotary torque sensors are used mainly for measuring the output of power tools, including electric, pulse, and continuous pneumatic tools. Rotary torque sensors are mounted in-line on the tool’s driver. The tool is then used to tighten a fastener in a representative joint. This allows users to measure a tool’s torque output against the friction conditions and angles found in the actual fastening application.
If a tool with an attached rotary torque and angle sensor is used to loosen a fastener instead of tighten it, it provides a different measurement: the breakaway torque of that fastener. This can aid in product research and development, as well as in product quality verification.
Brushless rotary torque sensors have advanced internal mechanisms which don’t rely on brushes. This reduces the amount of maintenance they need and allows them to measure pulse tool torque output more accurately. However, they cannot measure torque values as high as traditional rotary torque sensors, which are a preferred choice for more powerful tools. Both brushless and traditional rotary torque sensors have torque and angle model options designed for torque verification and measurement applications.
What is a Torque Screwdriver Sensor Used For?
Torque screwdriver sensors are used primarily for torque evaluation and verification of fasteners in their joints. These tools help ensure product quality by enabling technicians to verify the accuracy and repeatability of significant numbers of products. This process can give insight into tool calibration since an increase in the number of poorly tightened fasteners indicates that tools may be out of alignment.
Rather than sending products back through the line for rework if fasteners are found to be incorrectly tightened, technicians can simply use their screwdriver sensor to apply the proper torque. By watching the amount of torque they apply on their connected torque analyzer, technicians can accurately tighten the fastener they’re working on.
The Types of Torque Sensors Summarized
Torque reaction sensors, rotary torque sensors, and torque screwdriver sensors all play an important role in maintaining product quality in modern manufacturing. Quality torque sensors will connect easily with compatible torque analyzers, enabling quick setup and easy use. Investing in torque calibration equipment like torque sensors saves companies money by reducing lost product rates and preventing costly lawsuits or recalls related to improperly tightened fasteners.
Mountz has been a pioneer in torque application and measurement for over fifty years. Our torque sensors have been tried and tested over decades and are certain to meet your torque testing needs. 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.