Bolt Tightening Solutions for Industrial Assembly Applicable to any air driven impact tools regardless of brand and type, design and mechanism

1. Assembly Technology
Bolt Fastening
Bolt Tightening Solutions for Industrial Assembly
Applicable to any air driven impact tools regardless of brand and mechanism
www.zipptork.com

2. 1
ZIPPTORK
Smart Series
Torque Controller & Wireless Rotary Torque Transducers
Torque Controller
TCA
Wireless Rotary Torque Transducer
TTES TTEH

3. Contents
1. Introduction ………………………………………………………. 1
2
5
6
7
8
10
13
16
2. Features of ZIPPTORK products ………………………….
3. Products Combination for Various Applications ..
4. Common problems & remedies of bolting works
5. Ordering Information …………………………………………
6. Specifications ……………………………………………………..
7. Dimension ………………………………………………………….
8. Applications ………………………………………………………..
9. Appendix …………………………………………………………….

4. 1
1. Introduction
ZIPP Fastening Technology group presents fastening solutions for the
industrial assembly market in threaded fastener bolting, solid rivet
squeezing, blind rivet/rivet nut riveting and lock bolt fastening, etc.
This system takes advantage of our patented transducer and wireless
transmission technologies. We have data collection and reporting the
same as DC nut runner controllers. With the torque controller and
wireless torque transducer, we can control impact wrench, pulse tool
and any direct drive air tools from any manufacturer or design.
An Innovative Revolution of Impact Wrench Torque Control
Make the torque control easy and affordable
No more precision and costly torque-controlled tool required
Regardless of air tool brand, manufacturer, design and grade
Applicable to
Air Pulse Tools
Air Clutch Tools
Air Impact Wrenches
Air Impact Ratchet Wrenches
Air Geared Wrench / Torque Multipliers
Any Air Driven Continuous & Discontinuous Torque Tools

5. 2
2. Features of ZIPPTORK products
2.1 Torque Controller - TCA
With patented control algorithm and device for controlling the
output torque of air impact wrenches, air impact ratchet
wrenches, air pulse tools as well as geared torque multiplier
regardless of brand or manufacturer and the type of impact
mechanism. It is designed for the best practice of quality, safety,
performance and efficiency of bolting tasks.
Key Features
Easy set-up in minutes
Dynamic torque control accuracy：+/- 10%
Patented control algorithm and device - applicable to any air
driven impact or pulse tool regardless of brand and type of
impact mechanism
Automatic air flow rate measurement and selection for the
broadest torque control range
Optional programmable function for bolting sequence control
while applying with the tagged bolt or sensing bolt
Built in Torque Fastening stage & Tightening Sequence control
Optional function with preset parameters up to 5 tools for the
ease of assembly works
Versatile operation modules for option:
◆ Air impact wrench ◆ Air pulse tool
◆ Geared wrench / torque multiplier ◆ Torque wrench
◆ Torque tester ◆ Clutch tool
Closed loop control with wireless transducer for bolting joints
under different Joint hardness
Open loop control without the transducer for unified type of
joints in mass production bolting tasks
Multiple control methods;
Dynamic: ◆ Torque Control ◆ Torque +Angle Control
Static : ◆ Torque Control ◆ Torque +Angle Control
Torque Control Methods:
◆ Torque Transducer
◆ Key-in Torque + Air Pressure Sensor
Remote operation or monitoring with PC or cellphone
Operation record traceable in USB or exported to cloud server

6. 3
2.2 Wireless Rotary Torque Transducer - TTES
Unique wireless feature sets a new standard for accurate static
torque measurement and dynamic torque control of all
continuous and discontinuous drive air tools even the impact or
pulse tools regardless of brand and its mechanism with proven
satisfactory control accuracy and durability.
TTES type Transducers fit in-line between the air driven torque
tool and the sockets. Used with the TCA Controller to do closed
loop control for excellent torque control accuracy with one
torque tool among several joints with different hardness to
compensate the torque loss instantly and automatically within its
allowable working torque range. It will also solve the problems of
torque control accuracy which are bound to be affected by the
rising hydraulic fluid temperature of the air pulse tools or the
posture how the operator holding the tool during continuous
operation.
Key Features
Torque measurement accuracy: Tnom +/- 5%
Static tightening angle measurement accuracy: Anom +/- 5%
Static angular movement & torque verification accuracy: +/- 5%
Applicable to any air driven impact or pulse tools regardless of
brand and the type of impact mechanism for torque calibration,
measurement, control, and verification.
Both ends type in square or hexagon and size can be custom-
made
Records of tool G-value (Measured by Gravity sensor) in
operation, the working cycles and over-torque for the ease of
warranty judgement.
No slip ring design, more durable under shock and vibration for
long service life.
RF2.4G for transmitting torque and angle wirelessly and
effectively within 15M working distance

7. 4
2.3 Torque and Force Monitor - TFM
TTE used with a manual torque wrench and TFM, it can be
functioned as a digital torque wrench for static torque control
and torque verification.
Patented control algorithm enables the operator measures the
tightened torque at 0.1o angular movement of the tightened
bolt to verify the most real and accurate torque applied to the
bolt. This advanced feature provides advantage over all other
digital torque wrenches on the market.
2.4 Torque Sensing & Transmitting Socket – TTEH/TSSH
The patented socket designed for sensing the torque signal and
transmitting to the Torque Controller - TCA for real time closed
loop torque control. While applying to the innovative Tagged
Bolt-TB or Sensing Bolt - SB, not only the bolting sequence can
be programmed in the Torque Controller for selected rounds
and torque of bolting work by sequence, but also the bolting
data along with the operator ID can be recorded in the memory
of the tag of TB or flash memory in the SB and even uploaded
to peripherals or cloud server for tracking the relevant
responsibility of work to ensure the highest quality and
reliability.
Air Impact Wrench
Air Impact Ratchet Wrench
TCA
TTES
Air Pulse Wrench
TCC
TTEH Manual Torque Wrench
TFM

8. 5
3. Products Combination for Various Applications
TFM TCC
TTES+TF TM
TS PTM
TCA+TTES with Impact Socket or
TTEH
Applicable to any air driven
torque tools
TFM+TTES with Impact Socket or
TTEH + Manual Torque Wrench
Acts as a Digital Torque Wrench
for torque control or verification
TFM+TTES +Torque Multiplier For high torque bolting work
TCC + FRL Unit + PTM
For air geared wrench / torque
multiplier torque control
TFM +TTES +TS+TF
For torque calibration of air
driven pulse tools or clutch type
torque tools

9. 6
4. Common problems & remedies of bolting works
Item Problems Remedies
1
Hard to control output
torque resulted from
hydraulic fluid temperature
rise of air pulse tool and
causes the power decline of
the tool or the torque
created by abrupt impact of
impact mechanism driven by
air pressure and causes
considerably strong vibration
resulted from metal to metal
impact during continuous
operation
Take the advantage of ZIPPTORK Smart
Series Torque Controller-TCA & Wireless
Rotary Torque Transducer-TTE, the
sensed torque and angle signal will be
transmitted from the TTE to TCA instantly
and wirelessly while controlled by
patented algorithm to effectively control
any air driven impact or pulse tool with
satisfactory control accuracy within ±5%
～15%.
2
Bolt joints characteristics
resulted in difficult
controllability.
The patented control algorithm and
device of TCA will compensate the torque
loss automatically to achieve the target
torque range.
3
The torque control accuracy
always affected by the tool
impact mechanism and the
posture how the operator
holds the tool during
operation.
The closed loop control and patented
control algorithm make the TCA control
the torque accuracy effectively regardless
of the tool brand and impact mechanism
as well as the holding posture of the
operator.
4
Operator didn't follow the
bolting sequence to fasten the
bolts and led to uneven
clamping force on the joints
and even resulted in the
deformation or damage and
unable pass the high-pressure
leakage test.
Use the TCA and the Torque Sensing and
Transmitting Socket- TTEH/TSSH along
with the Tagged Bolt-TB or Sensing Bolt-
SB, the bolting sequence and stage of
bolting can be programmed in advance,
not only the operator will not mess up
the bolting sequence, but also the torque
can be controlled properly at each stage.
The bolting data can also be recorded for
great traceability to verify the
responsibility of works to ensure the
highest quality.
5
The Controller need to be pair
with specific torque tool.
TCA is applicable to any air driven torque
tool regardless of the brand and its
mechanism.

10. 7
5. Ordering Information
Torque Controller5.1
5.2 Wireless Rotary Torque Transducer
Torque Capacity TTES TTEH TSSH
20Nm
50Nm
100Nm
200Nm
500Nm
1000Nm
1500Nm
2000Nm
2500Nm
Customization
Max. Flow Rate TCA TCC
1000
2000
Torque Controller

11. 8
6. Specifications
6.1
Item TCA-1000 TCA-2000
Max. Flow Rate 1000L/min 2000L/min
Power Source AC110V~220V / 2A
Wire Connector
USB 1
RS232 1
RJ45 1
Wireless RF2.4GHz 2
Speaker 1
Light Tower Output Port 1
Buzzer 80dB
Transducer Charger Port 2
RF Antenna 2
Control
Mode
Air Pulse Tool V
Air Impact Wrench V
Manual Torque Wrench V
Control
Accuracy
Static Torque (%) ±5%
Static Angular
Movement (%)
±10%
Dynamic Torque (%) ±5%~±15%
Torque Controller

12. 9
6.2 Wireless Rotary Torque Transducer
Item TTE-4FS4MS-200 TTE-4FS4MS-500
Battery DC 3.7V/650mAh DC 3.7V/350mAh*2
Torque Range (Tnom) 10Nm-200Nm 25Nm-500Nm
Torque Resolution (Nm) 0.1Nm 0.25Nm
Static Torque Accuracy (CW) ±0.5% ±0.5%
Static Torque Accuracy
(CCW)
±0.5% ±0.5%
Static Angular Movement
Measurement (Anom)
0°- 360° 0°- 360°
Static Angle Resolution (%) 0.5° 0.5°
Static Angular Movement
Measurement(%)
±10% ±10%
Dynamic Torque Accuracy (%) ±10% ±10%
Maximum Torque (Nm) 220Nm 550Nm
Wireless Transmission RF 2.4GHz
Wire Transmission USB、RS232
Wired Charge USB
Operation Temperature (°C) 0 °C - 50 °C
Storage Temperature (°C) -10 °C - 60 °C
Net Weight (Kg) 0.22 0.47

13. 10
7. Dimension
7.1 Torque Controller-TCA

14. 11
7.2 TTES Series

15. 12
7.3 TTEH Series

16. 13
8. Applications
Aviation
Vehicle Service
Civil Engineering
Construction
Assembly Line
Torque Tools Torque Controller System Air
TTES
Torque Transducer
Socket
Bolt
TCA
Monitor + PPV
+ PCV +SV
TCC
Monitor +SV
TFM
Monitor
Pneumatic
Torque Wrench
Manual
Torque Wrench

17. 14
8.1 Manual Digital Torque Wrench
Use with the Wireless Rotary Torque Transducer - TTE and
Torque Multiplier, a manual torque wrench can be converted to
a digital torque wrench for doing wide range
Torque Control (Dynamic + Static)
Angle Control (Static)
Torque + Angle Control (Dynamic + Static)
Angle + Torque Control (Static)
Residual torque verification (Static)
Sound prompts when the torque is reached
TCA TFM
or

18. 15
Oil P
Imp
Wr
8.2 Air Pulse Wrenches / Air Impact Wrenches / Air Geared Wrenches
Use with the Wireless Rotary Torque Transducer - TTE, it's applicable to
air driven impact wrench, air impact ratchet wrench, air pulse tools and
torque multipliers, etc. regardless of the brand and manufacturer as
well as the impact mechanism for performing
Torque Control (Dynamic + Static)
Torque + Angle Control (Dynamic + Static)
System Air
TTES
Socket
Bolt
TCA
or
TCC
Air torque tools
Air pulse tool
Air impact wrench

19. 16
9.1 Bolting Strategy
To make torque control user friendly and affordable!
No more costly torque control tool required!
Calibrating torque tool capability prior to assembly
by applying
Torque Tester / Torque Transducer / Torque Simulator
Torque Controller / Torque Monitor
For checking the torque tool capability & calibrating the torque setting
Controlling torque during assembly
by applying
Torque Transducer & Torque Controller
For controlling the torque being applied to the bolt instantly and wirelessly
Verifying tightened torque after assembly
by applying
Torque Transducer & Torque & Force Monitor
For effectively verifying the bolt tightened torque accuracy with Angle/Torque Mode
Achieving the Ultimate in Bolted Joint Excellence
TFMTTE
TCA / TCBTCCTTE + Socket + BoltTTE
TCA / TCBTFMTSTTE + TFTTW
9. Appendix

20. 17
9.2 The Ultimate Solution
for
Achieving the Most Accurate Bolted Tightness
by applying
Sensing Bolt / Transmitting Socket / Transmitting Cap / Torque Controller
Ideal for the traceability of bolt production and assembly record, bolting sequence
control, real time bolt tightness monitoring and remote monitoring bolt tightness
status after assembly.
Assures the highest degree of safety and reliability of the bolted joint.
(1) What is the Sensing Bolt?
The Sensing Bolt is the bolt integrated with a MCU, an Amplified Circuit, a Strain Gauge, a
wireless module and a Battery. Designed for sensing the strain signal induced during bolt
tightening process until it reaches the corresponding clamping force.
With other complement patented designs, it features with;
1. Traceability of bolt production, i.e. the bolt manufacturer, the date of production, batch no.,
material code and bolt grade, etc.;
2. Apply with the patented Transmitting Socket and our programmable Controller or a
Dongle designed for use with customer's PC, a programmable bolting sequence
control can be fulfilled. The operator need to follow a SOP to pre-load each bolt clock-
wisely or counter-clock-wisely and follow the instruction to do 2 or 3 stages fastening
accordingly. The operator's ID will be recorded along with each bolt in every stage and
each time how much the clamping force induced. It's a kind of error proof to avoid
misplacement and improper sequence while bolting as well as clarify the controversy
about the job responsibility.
3. After the bolt fastened to the target clamping force, another patented Transmitting Cap
will be attached to the Sensing Bolt for keep receiving the power from the Transmitting
Cap and transmitting the strain signal wirelessly to peripheral devices within effective
transmitting distance 15-20M which to be placed at every 15-20M outwardly with
required units as a Repeater to the receiver endlessly for the ease of remote monitoring
the status of the Sensing Bolt. Higher power Transmitting Cap can be custom made
upon request.
It can be programmed to transmit the strain signal periodically and alert while the
variation of the clamping force over the limit of the predetermined threshold due to
vibration or other reason, such as stolen or disassembled intentionally.
((22)) Why the Sensing Bolt is required? In your application, if
1. Traceability of bolt production and bolt assembly record are required.
2. Bolt tightness control during the bolting process is required.
3. Bolting Sequence control is required.
4. Assembly quality assurance is required.
5. Easy clarification of bolting job responsibility to cease controversy is expected.
6. Bolt status remote monitoring is required.
Sensing Bolt will be the only choice and ultimate solution to surpass current bolting
technologies.
TC + SBTC-Transmitting CapTS + SBTS-Transmitting SocketSB-Sensing Bolt

21. 18
During Assembly
After Assembly
Example of Application Diagram for the Sensing Bolt

22. 19
9.3 An economical alternative to Sensing Bolt
by applying
Torque Transducer with RFID Reader / Tagged Bolt / Torque Controller
Ideal for the traceability of bolt production and bolted record as well as bolting sequence control
instantly and wirelessly
((11))What is the Tagged Bolt?
The Tagged Bolt is the bolt embedded with a RFID Tag. Designed for using along with the
patented Torque Transducer with RFID Reader. It features with;
1. Traceability of bolt production, i.e. the bolt manufacturer, the date of production,
batch no., material code and bolt grade, etc.
2. Torque as well as the bolting sequence are all controllable by the Torque
Transducer-TTE and the Controller-TCA while every bolting step and torque applied
to the Tagged Bolt-TB will be written and recorded in the Tag simultaneously.
((22)))Why the Tagged Bolt is required?
In your application, if
1. Traceability of bolt production and bolt assembly record are required.
2. Bolting Sequence control is necessary.
3. Assembly quality assurance is required.
4. Easy clarification for bolting job responsibility to cease controversy is expected.
Tagged Bolt will be your alternative and economic solution to assist in your bolting
quality assurance.
TCA / TCB / TCC / TFMTTR + Socket + TBTB-TaggedBoltTTR-TorqueTransducerw/RFIDReader

23. 20
Example of Application Diagram for the Tagged Bolt

24. 21
ZIPPTORK
Bolting Technology
ZIPPBOLT
The Ultimate Bolting Solution
SB TC+SB TB
+ + &
2
Inspection cover Clutch cover
99
9 55 8 1111 44
2
6 44
Criss-Cross Tightening
Sequence for
Circular Bolt
Patterns
121133
7 7 1144
10 66 22 33 10
5 3 1 8Spiral Tightening Sequence Starting in the
Middle for Non-Circular Bolt Patterns.
3
4
FEATURES
Programmable bolting sequence control.
Bolt production and bolting data logging traceability.
Real time clamping force control and remote bolt status monitoring.
PRODUCTS
●TCA - Torque Controller ●SB - Sensing Bolts
●TTEH - Torque Sensing & Transmitting Socket ●TB - Tagged Bolts
●TSSH - Torque Sensing & Transmitting Socket ●TGC - Tag Cells
●TC - Transmitting Cap
FEATURES
Innovative patented torque control device and algorithm.
Applicable to any air impact wrench, air impact ratchet wrench & air pulse wrench,
regardless of brand or impact mechanism.
Exceptional control accuracy with standard joints; air impact wrench +/- 10%, air pulse wrench +/- 5%.
PRODUCTS
TCA - Torque Controller
TTES - Wireless Torque Transducers
TTEH - Wireless Torque Transducing Socket

29. www.zippgroup.com
Distributed By
2018/March/TC/2000