During the assembly of parts using an electric torque screwdriver there are many things to consider to achieve proper torque control. Is the joint hard or soft? The material that is being used? Is the screw lubricated or treated with a locking patch? One factor that’s often overlooked when using an electric screwdriver is the RPM setting of the tool.

Will changes in RPM have a net effect to the torque applied to a joint?
The answer in short is yes. RPM settings can be a contributor as to the torque applied to a joint.  There are a number of variables to consider. A best practice is to document the settings and ensure they are not altered after all has been set and validated. It is important to ensure the same settings are used when validating calibration and making correlations.

A few of the variables are as follows:
- Higher RPM, less energy is applied at the joint as the force is present for a shorter period of time.
- Higher RPM may result in increased inertia, although the net differences are dependent on the mass of the force being generated.

- Lower RPM, more energy is applied at the joint, as the force is present for a longer period of time.
- Lower RPM can result in less inertia, although the net differences are dependent on the mass of the force being generated.
 
In some scenarios, the net differences may be negligible, while in other scenarios, the net differences may be more significant. Due to these and other variables, it is best to check the residual torque at the joints and develop a formal and consistent plan for setting and validation.

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A helicopter manufacturer had a critical torque application during the routine maintenance process of their aircraft. The rotor of the helicopter requires servicing after every 20 hours of flight. Some of these aircraft are serviced in very remote locations, where air or power is not readily available or reliable. Ensuring proper torque control is achieved for the rotor assembly nut is a critical element for maintaining the continuous safe operation of the helicopter.

The director of maintenance contacted Mountz Inc. and explained the application requirements. He inquired about cost effective torque control options that were available to ensure the quality and safety needs of their critical fastening application were satisfied.

The impact wrench lacks torque control and is destructive by nature with its “hammering” design. These tools are not ergonomically friendly for a technician and require a high maintenance budget. Also with some locations being remote, access to power would not be possible. Therefore, an impact wrench was not an option.

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A pulse tool has the speed of an impact wrench with nearly the repeatability of a clutch based shut-off tool. Containing precision-machined parts the pulse unit is a sealed chamber that is filled with a formulated hydraulic fluid. Pulse blades with a custom designed precision roller push the fluid inside the rotating chamber generating hydraulic pressure that produces torque. Air power is the power source that spins the anvil and resistance against the fastener causes the pulse unit to activate.

The Flex Power pulse tool requires regular maintenance to ensure the tool operates at optimal performance. The type of routine maintenance and the frequency is dependent on the application and how the tool is used. The pulse tool requires preventive maintenance like oil changes and have the parts inspected periodically. Regular oil changes will increase the life cycle of the tool, reduce maintenance costs and allow the tool operate properly.

When is service required? There are several factors that influence the maintenance schedule:
1) Type of application
2) Torque testing the setting within the torque range of the pulse tool
3) The number of cycles the tool is used daily, weekly and monthly.

The video provides a visual aide and tips for servicing Mountz Inc. Flex Power pulse tools.

Mountz Inc.’s Flex Power pulse tools are designed for safe, reaction free operation for various industrial assembly applications. Durability, power, speed, low noise decibels, minimal vibration and low torque reaction are key reasons for selecting a safe ergonomic pulse tool. For fastening applications a pulse tool will increase productivity, provide excellent ergonomics, reliability and quality.

Designed for high production environments, electric screwdrivers with a high performance brushless motor design provides durability and reduces the standard maintenance costs for standard electric screwdrivers. Management in power tools ensures product quality, cost savings and a reduction in overall failures.

Standard Electric Screwdrivers (with Brushes)
These ordinary models use brushes and over time there’s wear on expandable parts (carbon brushes, commutators, switches and other contact points. The heat generated by the motor in brushed screwdrivers can shorten the operating life of the screwdriver. These screwdrivers require regular maintenance and part replacement, depending the amount operating time and environment it’s used in.

Brushless Electric Screwdrivers
Screwdrivers with brushless motors have an extremely long operating life with no need for regular maintenance or replacement of expendable parts (carbon brushes, rotor, switches and other contact points). Heat generated by the motor is reduced and screwdriver performance is always at the maximum level resulting in reliable product quality. The brushless screwdriver ensures product quality, cost savings and a reduction in overall failures.
Carbon Brushes

Carbon brushes are the first item replaced after 6 months (based on tightening of 5,000 screws per day). Approximately 0.6g of worn carbon granules are scattered inside the screwdriver case and into the air after each carbon brush replacement. (More Info)

A manufacturer of heavy-duty trailer suspensions was looking for a way they could verify torque and tension on suspension bolts used on current products and on new products that were in development. The manufacturer was experiencing quality control issues, which were causing production delays and rework expenses. Upon further investigation, the quality control manager traced the issued back to improper torque control being the root cause of the problem. The quality control manager started seeking solutions.

The manufacturer needed the capabilities to check up to around 1,000 foot-pounds, but the quality control manager also wanted a torque tool that did not require their testing technicians to pull the full 1,000 foot-pounds of force. He was seeking a tool with low energy input with a high torque output to help reduce any technicians suffering from potential work-related injuries.

Based upon previous experience of using Mountz torque tools, the quality control manager contacted Mountz Inc. After reviewing the application with the quality control manager, Mountz offered a couple solutions to resolve the manufacturer’s torque issue. The quality control manager selected the Mountz hand torque multiplier as the only option to resolve their critical torque application issue.

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