Built for high production environments, FlexPower pulse tools provide durability, power and speed for most industrial assembly applications. To maintain consistent accuracy, the torque output for pulse tools must be verified periodically. You should also validate the actual torque being applied to the fastener by auditing the joint application. The goal for auditing is to verify adequate torque was delivered to the fastener and detect any loose fasteners or joint relaxation.
You need to validate the proper pulse tool is being used for the assembly application. Although a pulse tool has a specified torque range, the type of joint the tool is being utilized on is a key component. A pulse tool is a discontinuous tool and added adapters or extensions create a dampening effect, thus lowering torque values.
Pulse tools increase productivity and enhance product quality through precision torque control and user comfort. Regular tool calibration ensures repeatable accuracy and adherence to international standards. A pulse tool is a power tool that must be properly calibrated and maintained. Torque testing ensures the pulse tool is operating at peak performance and can highlight any potential tooling problems before they arise perhaps due to tool wear or broken components.
Setting the torque output of a pulse tool requires a torque tester or torque sensor. Here are some quick tips for setting the torque output of a Mountz pulse tool.
The ability to audit joints such as flanges with gaskets is important for critical applications where leakage or rupturing of the connection can have disastrous, costly or environmental implications. Auditing is a preventative quality measure and is a required part of an ISO or other quality management system.
Auditing large bolts is very difficult. Use of a proper auditing tool can make life easy for an auditor.
Torque is an inexact science with a lot of differing variables. Resolving or isolating these variables is the key to improve torque errors and fastening procedure. This is done with data. Auditing provides data to help make improvements to quality.
The Mountz Bolt Auditing System for large bolted applications consists of a HSD torque multiplier with embedded strain gauges to measure torque as well as an angle encoder to measure angle. The multiplier is connected to the TorqueMate® PTT-2000 torque tester designed specifically for torque and angle analysis and data collection. The PTT-2000 Bolt Audit Model is capable of both torque and angle measurement and has the ability to store up to 5000 readings. In addition the system includes PC based Windows software to configure the PTT for torque measurement tests. The stored data can be downloaded to a PC for use with quality control software or for analysis in Excel. A barcode scanner can be used with the system to enhance its function. The system provides two main modes for Auditing; the first is an ” Enhanced First Movement” mode the second is a Torque vs. Angle Audit mode. These modes provide different information depending on the application requirements.
Torque measurement is paramount for many manufacturers. Simply running a fastener or bolt down until it’s snug and tight and assuming the torque control process is complete, is no longer sufficient. Measuring torque doesn’t stop once the assembly process is complete. As part of the overall quality control process, manufactures should include a “Torque Auditing” program. A method to detect loose fasteners or any signs of joint relaxation. Torque auditing validates the fastening process, the torque tool, the product design and the materials used for the application.
A single fastener, inaccurately or incorrectly tightened, can lead to the failure of a product, which impacts the bottom line.
Key reasons for conducting a torque audit:
- Substantiates assembly procedures reflect actual practice (what we say is what we do)
- Reveals the consistency with the assembly process (from person to person, or day to day)
- Uncovers inaccuracies with the assembly process so it can be quickly corrected
- Promotes ongoing corrective actions
- Process improvement
A torque sensor is a finely tuned instrument designed for testing and monitoring torque applications. Designed for torque evaluation and verification, a torque sensor is a laboratory grade instrument that is commonly used for quality control, R&D and calibration applications. A torque sensor is used in conjunction with a torque analyzer. For low torque auditing applications, a torque screwdriver sensor is an option. For higher torque needs, a torque wrench sensor is the instrument of choice.
The Torquemate® FTA-100 is a new torque tester by Mountz, Inc. designed for torque testing and calibrating torque tools. The digital torque tester provides exceptional accuracy for measuring torque on various torque tools including pulse tools, hand screwdrivers, torque wrenches and power assembly tools. The small size and portability of the torque analyzer makes it ideal for checking torque tools on production floor daily or weekly to ensure the tools aren’t falling out of calibration.
The versatile and cost effective torque calibration instrument features the ability to count pulses, which is a key element for the setting the torque on a pulse tool as well as evaluating the maintenance schedule for a pulse tool. The FTA-100 unit displays both the peak torque reading and the number of pulses performed during a preset time frame to reach the final torque value.
Featuring an intuitive operating system the FTA-100 provides an auto filter frequency selection system based upon type of tool being used in peak mode. The easy-to-use menu structure allows engineers and calibration technicians to quickly perform torque tests and adjust settings as needed on the torque tester. The torque analyzer features an Over Current Protection (OCP) system that protects the unit from damage or malfunction.