A heater manufacturing company was experiencing improper torque control, which was costing them money in rework time and product being damaged by the assembly tools that they were using on the production floor. The heater manufacturer assembles floorboard heaters and in-wall bathroom heaters for residential construction. A deformation with the coated sheet metal used to house the heating element in the floorboard unit occurred during the fastening process.
The production manager started a root cause analysis program to eliminate this costly production problem. They started to test the process and determine what was causing the issue. Using a torque analyzer system they did some destructive testing. They wanted to first determine “at what torque value” that was applied during the fastening process would cause the deformation in the product’s coated sheet metal.
Once the proper torque value was determined for the product, they next examined the pneumatic tools being used in the assembly process. The pneumatic torque screwdrivers were set once every six months or at the time of purchase at a preset torque value. This torque value, however, was derived from a chart supplied by the fastener manufacturer, which was at 80% of the fastener yield value. The torque value did not account for the material the fastener was clamping together, which was causing product deformation, paint chipping, increased rework, and decreased their productivity.
The Loading Bench by Mountz Inc. is a laboratory grade instrument designed to enable accurate torque wrench calibration with less physical effort. The Loading Bench simulates torque application conditions with minimum effort and enhanced safety for the calibration technician assuring a more accurate calibration. The calibration instrument enables quick and easy torque wrench calibration and presetting, independent of human influence or transducer side and end load factors. The Mountz Inc. Loading Bench is designed to calibrate torque wrenches in accordance with International Standards ISO6789:2007.
The drive system of the Loading Bench assures the load application eliminates potential operator induced test errors. Built for durable use, the Loading Bench reduces the operator effort required to attain and sustain torque during the calibration process. The Loading Bench features a large handle wheel, which operates in clockwise and counterclockwise directions to allow smooth manual loading.
A torque wrench is considered a measuring tool and must be properly calibrated and maintained on a preventative maintenance and calibration schedule. The adjustable design of the Load Bench allows it to accommodate various size torque wrenches that can be tested with the unit. The gearbox design of the Loading Bench allows for high torque to be applied with minimum effort required from the calibration technician.
Torque tools go out of calibration with use. Calibrating a torque tool is a fine-tuning process of bringing the tool back within its tolerance. Torque testers can also be used for quick tools tests on the line or in the lab to determine whether torque tools are holding a given setting.
A regular torque tool calibration and re-calibration guarantees the operator repeatable accuracy and adherence to international standards. Torque testing also ensures torque equipment is operating to peak performance and can highlight potential tooling problems before they arise perhaps due to tool wear or broken components.
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