Impact wrenches speed up assembly by driving threaded fasteners with powerful twisting force. But as we covered previously, their very nature prevents reliably hitting a tightening target. This is why using separate torque testers for verification matters greatly.
Taking real-time torque measurements during an impact wrenches run introduces even more quality control. Portable torque testers can integrate with computer systems for collecting data on every fastening. The operator gets live precision feedback on when to stop for optimal tension.
In this article, we will explore the case for active torque monitoring in impact tools applications. An overview includes:
- Impact gun accuracy challenges
- Principles of torque testing
- Using torque sensors for real-time data
- Analyzing fastening data trends
- Why choose Flexible Assembly solutions
The Quest for Torque Accuracy
Impact wrenches contain a hammer and anvil mechanism that delivers substantial twisting force to the socket. Pulling the trigger spins up the hammer which intermittently hits the anvil, channeling torque into the fastener. This allows driving screws, nuts and bolts with great speed and power for increased productivity.
However, the pulsing nature of impacts makes consistently achieving an exact torque target impossible. Yes, pneumatic impact guns have a general torque range they work within. But subtle factors like air pressure, lubrication, wear and grip alter the peaks and valleys of force with every strike. Much like how each blow from a hammer on a nail varies.
This random torque delivery causes scatter outside of acceptable tolerances on critical applications like cylinder heads or structural equipment. Factory calibration helps but still allows +/- 15% or more variation. Consider aerospace and machinery with torque specs allowing only 4-5% total variance – impacts alone clearly miss this precision need.
Enter Torque Testers
Dedicated torque diagnostic tools exist to measure actual twisting force as each fastener gets tightened. torque testers, multi-tools and sensors quantify exactly how much torque gets transmitted during a run down.
Common torque testing devices provide:
- Highly accurate +/- 3% or better precision
- Preset torque audible/visual alarms
- Digital capture of every measurement
- Analysis of mean, peaks, coefficients of variation
- Graphical and tabular data presentation
- Compatibility with data monitoring platforms
Skilled technicians use the real-time readings from instruments like these to decide when to stop the Impact Wrenches. Tightening ceases immediately at the target torque rather than relying on guesswork. Managers gain visibility of all fastening data for auditing work quality or catching outliers early.
Integrating Live Torque Data
Connecting a portable torque tester directly into the air feed line of an impact gun takes real-time monitoring a step further. Now the operator receives instant torque measurements from a sensor tool while tightening proceeds.
Changing torque values appear on screen as they tighten each screw or bolt. Software tracks the data, giving maximums, averages and coefficients of variation during the run down. Alarm lights and sounds indicate when the optimal torque level gets achieved per the specs.
This closed-loop setup with live data prevents over or under-tightening right at the point of assembly. Precision guide lights cue the worker exactly when to stop based on measured values instead of estimates. Absolute control of torque delivery in the exact moment surpasses manual testing periodically.
Analyzing Trends and Capability
The torque audit trail from a instrumentation sensor also helps assess the capability of each impact gun over time. Software can chart historical torque readings for each tool showing the mean, range and deviation trends.
Any significant shift up or down indicates service needs for the impact driver. Supervisors monitoring the charts spot high variation creeping in requiring calibration. Data proves when pneumatic impacts start functioning suboptimally before bad assemblies occur.
Statistical process control also applies to the tightening results on specific applications. Production managers investigate trends on torque plots to optimize quality at each workstation. They verify proper torque gets applied according to manufacturer ranges without overdoing it. Torque audits confirm no weak or loose joints exist that might fail in the field.
Why Choose Flexible Assembly Solutions
Understanding and controlling true torque values matters deeply for critical equipment. As described here, torque testers deliver the precision needed to maximize fastening quality and safety. That is why Flexible Assembly Systems offers highly advanced torque diagnostic solutions covering all assembly needs.
Contact Flexible Assembly Systems today online to discuss deploying torque instrumentation to enhance quality, throughput and process control for your assembly applications. Our torque testing products lead the industry for portability, accuracy and reliability.
