Fastening error can never be eliminated if proper technique and tools are not used. Audit discussion must begin with an understanding that a process is under control, until such time as variances in expected result are found. That does not imply that there should be a lack of auditing; in fact, the contrary is true.
The critical question must be asked: If proper joint design and proper torque application still do not guarantee that effective tension has been achieved, how can we know if the installed fastener meets the specification intended by the designer?
The answer is in Auditing, a process used to validate, inform and confirm. Depending on how the word is used as a noun or a verb, the term audit has similar definition and meaning.
(n) the inspection or examination of a building or other facility to evaluate or improve its appropriateness, safety, efficiency, or the like: An energy audit can suggest ways to reduce home fuel bills.
(v) to make an audit of (a building or other facility) to evaluate or improve its safety, efficiency, or the like.
Even the most sophisticated fastening systems require torque calibration to ensure their accuracy or repeatability. Therefore, auditing is a necessary interrogatory to gain information about how a job was performed even when the process is being controlled perfectly. Clearly auditing is a preventative quality measure to help eliminate possible failure. Without an audit process we leave open the possibility of errors, failures or other additional costs.
Experience, Quality and Reliable
In the manufacturing and assembly world, tightening, controlling, or measuring torque fasteners is imperative for production efficiency. An inadequately torqued fastener can vibrate or work loose: conversely, if the tension is too high, the fastener can snap or strip its threads. Faced with these problems, manufacturers are realizing that precise torque control can spell the difference between a safe, reliable, and economical product and complete disaster.
Anybody who has to tighten a threaded fastener and needs to control, monitor, or measure torque needs sophisticated torque tools. If manufacturers want to save money, make their workplace safer, enhance product quality, or reduce their exposure to liability; only specialized high-quality torque tools will get the job done properly.
1. Pick the Right Torque Tool
A wide variety of torque tools are available to control or measure the torque applied to fasteners, from electric screwdrivers to large industrial torque wrenches, torque analyzers, torque sensors, pneumatic screwdrivers 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 a 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. If torque data must be gathered during the assembly process or quality process, tools should also have connection ports such as USB, RS-232 and other cabling connections.
2. Establish a Torque Calibration Program
Calibration is fine-tuning the torque control process in a production environment. Torque calibration 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. When this happens, the tool falls out of adjustment.
A regularly scheduled calibration program enables quality control personnel to correct divergence from proper settings, whether it’s because of normal slippage over time or because of adjustments to the tool. Begin by setting a calibration interval initially based on 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.
Many industries like as medical, aerospace, nuclear and others continuously calibrate their torque measuring equipment to comply with government regulations. For companies that prefer to have torque calibration capabilities in-house when their calibration requirements become extensive and costly, the Mountz Calibration Wheels and Calibration Segment Arms are the only quality calibration equipment to select for your calibration lab.
The accurate measurement of torque applied to rotating drives and fastening applications is an important criterion for evaluating production efficiency and quality assurance in manufacturing and assembly. There are many process monitoring applications that require rotary style torque sensor be used to capture and record traceable measurement results.
A rotary torque sensor is a finely tuned instrument designed for testing and monitoring torque applications. Designed for torque evaluation and verification, the rotary torque sensor is a laboratory grade instrument that is commonly used for quality control, R&D and calibration applications. The torque sensor connects to a torque tester or torque meter.
This special class of torque sensors require the ability to rotate but be able to measure the torque applied to a joint. Historically rotary torque sensors provided this feature by using brushes, to contact the shaft measuring torque, in a similar manner to the operation of electric motors.
1. Some additional torque is required to overcome the friction of the brushes.
2. There may be problems associated with “brush bounce” in applications of pulse tools with significant vibration.
3. More maintenance is required, especially in high usage applications, because of brush wear.
4. Additionally, high RPM operation will lessen the force on the brushes due to centrifugal force precluding operation at very high RPM
The TorqueLab®, LTT-Series, is a torque tester that offers portability, expandability and documentation control. Meeting the demands to test multiple torque ranges for various torque tools used in production, maintenance and calibration labs, the LTT features the EZ-Plug & Play technology, which is an auto-recognition system for Mountz torque sensors. The torque tester is designed for torque calibration, joint testing, auditing or for force and load measurement or verification of load cells.
The EZ-Plug & Play feature of the LTT facilitates and expedites the process of setting up and running tool tests, as well as the transfer, analysis and storage of test data for ISO/SPC documentation purposes. The combined hard-software manufacturing solution offers tool testing, graphing capabilities and a graphical menu for easy navigation.
As an advanced torque controlling, monitoring and documentation solution, LTT enables operators and engineers to ensure product quality, safety and reliability promptly in a variety of manufacturing environments. The LTT torque tester can calibrate hand screwdrivers, pneumatic tools, torque wrenches, and power tools to avoid over tightening problems such as stripped threads and under tightening problems, which can increase liability and risk of recall.