Torque control system evolution & revolution

1. Achieving Fastened Joints Excellence
China Pneumatic Corporation
Bolting Strategy
for
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2. Bolting Strategy
1. Type of Joints
2. How to Measure Torque?
3. A Novel Torque Control Method for Bolting
4. Ultimate Solution for Bolting Works
5. Other Development of Remote Control Technology
6. Torque Control System Overview
7. Key Features of the Torque Controller
8. Torque Controller Overview
9. Specifications of Torque Controllers
10. Torque Controller Touch Panel Menu Examples
11. Specifications of Torque Transducers
12. Alternative for Impact Wrench Torque Control
13. Appendix
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3. Steel, aluminum, plastic and wood, etc. create different joints and therefore they can support different
tightening forces.
It’s important to know what material the joint is made of when choosing the fastener and the torque tools.
Joints can be hard or soft
• The joint is soft when tightening torque is reached with a rotation of at least 720° (about 2 rotations);
• The joint is hard when tightening torque is reached with a maximum rotation of 30°.
Type of Joints
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4. China Pneumatic Corporation offers a complete solution for torque control, calibration and
measurement of all torque tools and bolt joints.
There are three facets of torque measurement required for the assembly process.
1. Torque Measurement Prior to Assembly
2. Torque Measurement During Assembly
3. Torque Measurement After Assembly
How To Measure Torque
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5. Torque measurement tools, like torque Tester and torque transducer are used prior to the assembly
process. The equipment is used for tool setup or conducting tool capability studies.
 For tool setup, the tool crib or lab will want to set the torque tool according the torque specification
required for the application.
 For tool capability studies, technicians need to ensure that the torque tool can provide the necessary
torque and repeatability that's required for a potential application.
The equipment used for conducting this type of measurement would be:
Torque Tester / Torque Analyzer
Torque Transducers
Torque Simulator
Torque Controller or Monitor
Torque Measurement Prior to Assembly
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6. For pneumatic and electric assembly tools that are being used in the production area, many manufacturers like to
audit the tool and verify the actual torque being applied to the fasteners and/or if the tool is starting to fall out of
specification.
A ZIPP Torque Transducer coupled to a Torque Controller is the ideal torque control tool for assembly line. It
enables operators monitoring the real tightening torque applying to the fasteners during the whole tightening
process.
By connecting the Torque Transducer between a pneumatic torque tool with a socket to the fastener, an operator
can easily set up the workable torque range for the selected flow level on the tool under functional high and lowest
working air pressure, set the target torque within this range, the Controller will regulate the air pressure to the
correspondent torque value automatically and simultaneously, actuate the tool, the Torque Transducer will keep
transmitting the strain signal to the Controller wirelessly, As soon as the sensed strain signal reach the target torque,
the Controller will shut off the air supply immediately and display the result on the screen along with audible alert
by buzzle or light.
By means of the Torque Transducer and the Controller, it will make the torque control smartly. No more rely on
accurate and costly torque control mechanism of the pneumatic torque tools, in spite of the improper posture to
hold the tool or loosening power resulted in the hydraulic fluid warming up or various kind of hard or soft joints
during tightening process, the Controller will tune the air pressure automatically to compensate the power loss to
reach the target torque until it failed due to the limitation of the air supply.
The equipment used for conducting this type of control would be:
Torque Transducers (TTE)
Torque Controller (TCA)
Torque Measurement During Assembly
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7. As a final check, it’s required to verify the torque after an assembly process, so they can verify if adequate torque was delivered
to the fastener and detect any missed or loose fasteners, or joint relaxation.
To perform this verification, there are three common methods that have been established to provide an accurate reference to
the applied torque.
1) First Movement Test - Once the fastener has been tightened, employ the use of torque measuring tool. Mark the tightened
fastener and surrounding. Along the tightening direction, begin to slowly apply torque to the fastener until the first
movement on the mark is noted. The reading recorded is a good indication of the original torque applied to the joint. This is
the best way to determine residual torque.
Our wireless Torque Transducer can be driven by any torque wrench performs just like a digital torque wrench to do this
test with superior 10 times resolution to detect the angular movement at 0.1o of the tightened bolt to display the torque
value most close to the applied torque in the tightened bolt.
2) Loosening Test - This is a similar process to the first movement test described above, except instead of tightening the
fastener, the torque is applied in the direction that loosens the fastener. At the point the fastener breaks loose, the torque
reading is recorded. The torque value to loosen the fastener is the approximate torque that was applied to the joint.
3) Marking Test- Once the fastener tightened, mark clearly the surface of the fastener, nut or bolt. Then, loosen the fastener
and retighten it until the marks on both the joint and fastener are aligned. The torque required to return the fastener to its
original location is the reference to the original torque applied to the fastener.
There are three techniques for monitoring bolt tension, i.e. manual inspection, Ultrasonic Bolt Tension technology, and the
Sensing Bolt Tension Monitoring System.
The equipment used for these measurements would be:
Any manual Torque Wrench / Torque Transducers (TTE) / Torque Monitor (TFM)
Torque Measurement After Assembly
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8. In bolting works, the most difficult part is how to control the tool to fulfill it to the target torque for different type
of joints, such as the hard joint, medium and soft joint.
People get used to do torque calibration for the toque tool on the torque tester before doing the bolting on the
joint ( soft or hard ) and then, check the torque again by using a torque meter to see if it meets the target torque.
Most of the torque control methods can be awkward and inefficient
China Pneumatic Corporation provides a novel solution by using a wireless torque transducer (TTE) along with a
Torque Controller(TCA), apply the unique patented algorithm to make the torque control easy and handy.
It needs no more accurate and costly torque tool, no modification required to the torque tools and even no matter
what brand of tool you have in hand, as long as its power will not decay within hours. Through simple and easy
torque setting process in minutes, just determine the target torque you require within the preset torque range, the
Controller will shut off the power supply as soon as it reach the target value. In case, the tool power decay due to
the fact of the joint condition, improper posture to hold the tool or heating up of the hydraulic fluid (often
happened with impulse tools), the smart programmable Controller will compensate the power loss automatically
by itself and make it meet the target torque until its upper limit. In words, this combination-TTE and TCA will help
the operator to control the bolting toque within the range of its torque capacity. The accuracy of the tightening
torque will be determined mainly by the torque transducer and the controller instead of the sophisticated torque
control mechanism of the torque tool.
A Novel Torque Control Method for Bolting
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9. In coal mines, bolt loosening in the cage guide is affected by the harsh environmental factors and cage hoist vibration, leading
to significant threats to work safety. It is crucial, to this effect, to successfully detect the status of multipoint bolts of guide
structures. We propose a system to monitor bolt status in harsh environments consists of a Sensing Bolt, a Transmitting Socket,
a Transmitter (Repeater) and a Controller or Monitor. A proof-of-concept model was demonstrated with programmable
software.
The Sensing Bolt consists of a MCU, a strain gauge, an amplified circuit, a RF module and a Battery. The strain signal produced
during the bolt tightening process. It will be magnified and transmitted to the Controller or Monitor via the Transmitting
Socket to enable the Controller monitor the real time clamping force and shut of the torque tool as soon as it reach the target
value for precise control. Bolting sequence control is essential for most of the assembly works which can be programmed in
advance in the Controller to guide the operators all through the tightening process .
After the Sensing Bolt tightened, it can be programmed to send the strain signal in time interval via the Transmitters which to
be mounted at reasonable transmission distance until reach to a Monitor for monitoring the status of the bolt.
The ID of each Sensing Bolt and the memory embedded will memorize the production information about the bolt, such as the
manufacturer, the batch of production, the material and the grade of the bolt, etc. and the bolting record, such as the operator
ID, the date of bolting and the torque applied to the bolt or the real clamping force of the joint for great traceability. It will also
identify loosen bolt location and reporting them in the software. Confirmatory test results revealed that the system indeed
successfully detects bolt loosening and comparative test results provided valuable information regarding the unique
effectiveness of the proposed system.
The equipment used for conducting this type of measurement would be:
Sensing Bolt / Transmitting Socket / Torque Controller
Ultimate Solution For Bolting Works
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10. Ultimate Solution for Bolting Works
Includes: Controller, Monitor, Transmitting Socket , Sensing Bolt and Transmitter
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11. Transmitting Socket & Sensing Bolt
Thanks the development of the Transmitting Socket and Sensing Bolt, the real time bolt axial tension
force can be controlled precisely during bolting process and traceable or monitored remotely for quality
assurance and safety after work.
Type No. Features Structure
Transmitting
Socket
Socket embedded with a MCU, a RF module, an antenna and a battery for
transmitting the strain signal to the Controller wirelessly.
Sensing
Bolt
Bolt embedded with Strain Gauge, OP, RF,MCU and battery to transmit the
strain signal via the Sensing Socket wirelessly to the Controller (TCA) for
monitoring the clamping force during the tightening process.
All data relate to bolt production and bolting history especially the clamping
force can be recorded and traceable after bolted.
Remote monitoring the status of the bolt is programmable for the ease of
security management.
All related information (such Date, Torque, Operator.. etc.) stored within the
Sensing Bolts.
Data wireless transmitted through Transducer (TTE) to Controller (TCA) and
then uploaded to PC or Cloud Server afterwards.
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12. • Air Servo Motor + Controller enable air motors have similar functions
as electrical servo motors for speed, angle, torque and brake control
in broadly applications of automation under environments with
potentially explosive atmospheres.
• Torque Transducer with RFID Reader + Tagged Bolts for bolt production、
bolting process and bolting record traceability.
Other Development & Patented Remote Control Technology
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13. Torque Transducer with RFID Reader & Tagged Bolt
Type No. Function Characters
TB
Tagged
Bolt
• Bolt embedded with a passive RFID Tag.
• It’s an economic alternative of the Sensing Bolt.
• All data relate to bolt production and bolting history (information such as the bolt
manufacturer, date of production, operator’s ID, date of bolting and torque
applied, etc.) can be read and written for traceability.
Data transmitted wirelessly through Transducer (TTR) to the Controller (TCA) for
further uploading to PC and Cloud Server afterward. . A bolt adhered with a RFID Tag
( named as Tag Bolt), to be applied to the joints where the traceability of bolt production, bolting
process and bolting record are required. All relevant data will be written or read through an
antenna and RFID reader for Production History traceability also Self-Locking optional functions
prevent from wrong process sequence RFID reader/writer
Increasing reliability and accuracy for Tag Bolts torque process
TTR
Torque Transducer
with RFID Reader
To be applied with the patented Torque Transducer with RFID Reader (TTR) for
reading and writing relevant information effectively without interference
TTR Torque Transducer is an advanced patented design of TTE, integrated with a RFID
Reader
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14. Torque Control System Overview
More emphasis on Torque tools installation safety are required during recent decades. CPC has been dedicated
efforts to integrate torque control technologies for solving these issues for years.
Includes:
Controller, Wireless Torque Transducers, Wireless Torque Transducers with RFID Reader, Wireless BPM
Detector, Sensing Bolt, Tagged Bolt, Optional Wearable Control Device and APP access to Mobile Phones and
IoT connection to cloud server.
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15. • Patented control system with programmable software
make torque control easier and more accurate.
• Unique control algorithm for easy calibrating the tool
prior to assembly and achieving target torque accurately.
• Wireless Transmission - More operation space without
cable lines for better maneuverability.
• 10" Touch Panel Display - Easily read and input with
related control parameters.
• Intuitive Parameters Interface Designed – easy access
without difficulties for operators
• Various Modes of Control Interface – Suitable for most
pneumatic Torque tools applications.
• RF2.4G Wireless Transmission - Data transmitted more
faster and stable.
• Wireless Transducer with Plug-in Designed - Suitable and
flexible for most Torque tools used.
• Various Operation Functions - With Torque, Angle, Pulse
Count and Speed measurements.
• No more costly and accurate pneumatic torque tools
required in bolting works.
Key Features of the Torque Controller
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16. Torque Controller Overview
There are three types of Torque Controllers for option:
• TCA Type: Automatic torque sensing and compensation within the pre-calibrated working torque range during bolting process .
Designed for accurate torque control of impact wrenches and impulse type wrenches and precision
output torque measurement of pneumatic power driven tools.
• TCB Type: Shut off the air supply as soon as the tightening torque reach the target range. It’s required to adjust the working air
pressure to the correspondent target torque. Warning signal to alert Ok/NOK result.
• TCC Type: Mainly designed for Pneumatic Torque Multiplier, equipped along with the FRL unit, with preset Torque and
correspondent Working Air Pressure Chart, the Operator just need to regulate the air pressure until the torque value reach the
target torque. The regulated air pressure will be monitored during the whole tightening process. Since the output torque of the
pneumatic torque multiplier is related to the working air pressure, monitoring the variation of the working pressure is essential
to the accuracy of the torque control . If it is out of the preset pressure variation range during the tightening process, the
Controller will alert the operator, the result is NOK.
• Optional Operation Modes with following functions for above models:
Torque Records / Remote System Updated / Cloud Server Data Access / Multiple Languages Support
• TFM Type: It ‘s a kind of Monitor. Designed for accommodating with Torque Tester or manual torque wrench to function as a
digital torque wrench for torque control and calibration. It receives the strain signal wirelessly and display the torque value, the
rotating angle, the pulse count and the correspondent working air pressure simultaneously.
It’s also ideal for accessing the clamping force signal from the Sensing Bolt to
display the real time status of the joint.
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17. Specifications of Torque Controllers
Model No. TCA TCB TCC TFM
Air
Flow Rate
1000/2000
(Liter/min)
N/A
Pressure
Regulator
Automatic Manual Manual N/A
Torque
Control
Automatic Manual Manual N/A
Display
Screen
10”
Touch Panel
3.5”
OLED
Power Supply 110V~240V 6.0 V 3.7 V
Weights 3.3 Kg 2.0 Kg 0.5 Kg 0.11 Kg
Dimensions
(cm^3)
30x25x18 30x25x18 15x10x8 10x7x3
Languages: English, Chinese, Japanese, German, French, Spanish
Operation Modes: Torque Tester, Torque Transducer, Air Impulse Tool, Air
Impact Tool, Air Torque Multiplier, Torque Multiplier
Parameters: Torque Tolerance, Angle, Time, pulse count and Air Pressure
Upper/Lower Limitations
Communication: RF2.4G Wireless Transmission vs. Transducer
Data Access: Wi-Fi connected to PC or Cloud Server
Cable Output : RS-232 x2 or USB x2 connected vs. PC
Dimensions: 29.6 x 24.7 x 17.6 (cm) (L x W x H)
Housing Material: Steel
Color: Red
Operation Temperature : -10C to +60C
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18. Torque Controller Touch Panel Menu Examples
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19. Specifications of Torque Transducers
TTE Products Overview Main Features TTR Products Overview
• Designed to give excellent
performance with pulse tools
externally or internally for torque
control.
• RF2.4G wireless communication for
maneuverability in torque calibration
or bolting works.
• ±0.5% of reading from 20% ～100% of
full scale.
• Built-in Gyroscope and G Sensor for
Torque, Angle and Speed
measurements
• MCU: Automotive Grade Processor
• Frequency: 100 kHz
• Angle measurement: +/- 1%
• Auto Self-Detection (Abnormal Alerts)
• Power Saver with 5 Minutes Auto Shutoff
• Low Voltage Alerts
• Cable: USB
• Power Switch: Spring Type
• Power : 3.7V Rechargeable Lithium Battery
• Shell Material: ABS
• Color: Red
• Dimension: 90 x Φ44 (mm) (L x D)
• Temperature: -10C ° ～ + 60C °
• Except the same features as TTE , it
designed with patented built-in RFID
reader/writer used with Tag Bolts for
bolting history traceability from bolt
production, bolting sequence
monitoring and record.
• Optional programmable Error
proofing control to avoid wrong
bolting sequence
• Increasing reliability and accuracy for
Tag Bolts torque process
Model Capacity Driver Inlet/Outlet TTE Structure Model Capacity Driver Inlet/Outlet TTR Structure
TTE-33001 10NM 3/8” Sq. or ¼” Hex. TTR-44010 100NM 1/2” Sq.
TTE-33005 50NM 3/8” Sq. TTR-44020 200NM 1/2” Sq.
TTE-44010 100NM 1/2” Sq. TTR-44050 500NM 1/2” Sq.
TTE-44020 200NM 1/2” Sq. TTR-66100 1000NM 3/4” Sq.
TTE-44050 500NM 1/2” Sq.
TTE-66100 1000NM 3/4” Sq.
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20. Alternative for Impact Wrench Torque Control
Products Overview Main Features
Nowadays, Torque Control usually utilized strain gauges to detect torque value.
It’s not good enough for the Impact wrenches since it will cause more severe vibration
during bolting process.
This patented apparatus ～BPM (Blows per Minute) Detector (BD) is developed as a
good accompaniment to the Torque Transducer in application.
It’s attachable to any Air Impact Wrench housing with Wireless transmission.
Prior to assembly, use BD along with a Torque Transducer (or a Torque Tester) to
calibrate the relationship curve of the Torque (TL/TH) and BPM counts (BL/BH) to the
correspondent operable low(PL) and high(PH) working air pressure of the tool on the
bolting objective to establish two linear curves(Torque-Pressure and BPM - Pressure).
And, have it memorized in BD or the Controller.
Start to do bolting with or without the Torque Transducer. The BD will detect the
vibration or BPM pulse count during the bolting process to judge if the tool is under
bolting condition. It will alert automatically if the working air pressure is out off the
predetermined range and alert by buzz or lighting as well as displaying NOK on the
screen.
It’s also ideal for using under space limited circumstance.
For more precise torque control, our patented control algorithm for regulating the
working air pressure to correspondent target torque by means of a pressure control
module will make it achieve satisfactory control accuracy .
RF2.4G Wireless
Transmission
Auto Self-
Detection
(Abnormal Alerts)
Power Saver with
5 Minutes Auto
Shutoff
Vibration
Frequency
Measurement
Low Voltage Alerts
USB Power
Charged
3.7V Rechargeable
Lithium Battery
Torque
Setting
Bolt
Tightening
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21. APPENDIX
Aim at Industry 4.0～the current trend of automation and data exchange in manufacturing technologies and
the presentation of affordable and high performance products for more applications, China Pneumatic
Corporation has been devoted in the development of electronic / mechanical integration for conventional
pneumatic tools for years.
Thanks the modern advanced technology in sensors, Wi-Fi and MEMS, it enables us to have it integrated
conveniently and successfully with patented control algorithm to develop the unique Torque Control System,
the ultimate solution for bolting works, the programmable controller with traceable bolt production, bolting
process ( including the bolting sequence ) and bolt tightening record as well as the fastened joints quality
verification system for hydraulic fastening system, etc. with significant benefit for reducing verification time,
work efficiency and higher quality assurance.
RFID Reader integrated with the Torque Transducer and the Tagged Bolts have related data inputted or read
from production history of bolt manufacturing, distribution until bolting status will be all traceable
completely. Continuous and reliable remote monitoring of bolt status will ensure highest bolting quality as
well as safety to cease controversy accordingly.
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22. China Pneumatic Corporation
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