The document details Zipp Assembly Technology's innovative solutions for torque control in industrial assembly, featuring torque controllers and wireless rotary torque transducers compatible with various air-driven tools. It emphasizes ease of use, accurate torque measurement, and integration with modern IoT technology for real-time monitoring and data collection. Key applications include bolting threaded fasteners, with robust features designed to handle common challenges in bolting works.

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

2. ZIPPTORK
Smart Series
Torque Controller & Wireless Rotary Torque Transducers
Torque Controller
TCA
Wireless Rotary Torque Transducer
TTES
(Square output)
TTEH
(Hexagonal output)
TCB
TTEB
(Driver Bit Adaptor)
TTEHR
(Hexagonal output)
With Reader

3. Contents
1. Introduction …………………………………………………..……… 1
2. Features of ZIPPTORK products ……………………..………… 2
3. Products Combination for Various Applications ……..… 5
4. Common problems & solutions of bolting works ….... 6
5. Bolting Issues with Power Torque Tools …………..…… 7
6. Torque Controller …………………………………………..……… 8
7. Wireless Rotary Torque Transducers ………………..……… 9
8. Bolting Strategy ……………………………………..……………. 12
9. Innovated Fasteners for Bolting Works …………..……… 13
10. Solve bolting issues with your power torque tool …... 14
11. Air line Installation Guide …………………………………..… 15

4. 1
1. Introduction
ZIPP Assembly Technology presents fastening solutions for the
industrial assembly market in bolting threaded fasteners, squeezing
solid rivets, riveting blind rivets and rivet nuts, and fastening lock
bolts, etc.
This system takes advantage of our combined patented control device,
control algorithm, and wireless rotary torque transducer, with the best
practice on IoT (Network of physical devices), making the controllability
and traceability of fastener assembly, fastening processes, and
fastening records possible and accessible.
An Innovative Revolution of Impact Wrench Torque Control
Making the torque control easy and affordable
No more precision and costly torque-controlled tools required,
regardless of air tool brand, manufacturer, design, and grade.
Applicable to
Air Clutch Tools
Air Impact Driver
Air Impact Ratchet
Air Pulse Wrenches
Air Impact Wrenches
Geared Wrench / Torque Multipliers
Any Air Driven Continuous & Discontinuous Torque Tools

5. 2
2. Features of ZIPPTORK products
2.1 Torque Controller – TCA/TCB
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 multipliers. Regardless of
brand or manufacturer and even the type of impact mechanism. It
is designed with stability, safety and accuracy in mind.
Key Features
Easy set-up in minutes
Dynamic torque controllable accuracy：± 5% ~ ±20%
Patented control algorithm and device～ applicable to any air
driven impact or pulse tool regardless of brand and type of
impact mechanism
Automatic air consumption rate measurement and selection for
the broadest torque control range ( TCA only )
Optional programmable function for bolting sequence control
while applying with the tagged bolt or sensing bolt
Built-in torque fastening stage & bolting sequence control
Built-in preset parameters and job sequences up to 10 tools for
the ease of assembly works
Versatile operation modes for option:
◆Air impact wrench ◆Air pulse tool ◆Torque wrench
◆Clutch tool ◆Geared wrench / torque multiplier
◆Torque tester
Multiple control methods;
Dynamic: ◆ Torque Control ◆Torque Control + Angle Monitor
Static: ◆ Torque Control ◆Torque Control + Angle Monitor
Torque Control Methods:
◆Closed loop control with wireless transducer installed on the
tool for bolting joints with various joint hardness
◆Open loop control without transducer installed on the tool but
with the torque measured from a reliable source and operates
under Key-in mode on TCA for the unified type of joints in mass
bolting tasks
Functions with remote configuration or monitoring with PC,
smart phone or tablet through Mobile APP are optional upon
request
Operation records traceable through USB, Ethernet or exported
to the cloud server through wired or wireless connections

6. 3
2.2 Wireless Rotary Torque Transducer – TTES/TTEH/TTEHR/TTEB
Unique wireless feature sets a new standard for accurate static torque
measurement and dynamic torque control for all continuous and discontinuous
air driven tools especially the impact or pulse tool, regardless of tool brand and
its designed mechanism with proven satisfactory control accuracy and
durability.
It fits in-line between the air driven torque tool and the sockets. Used with the
TCA Torque Controller and closed-loop control for excellent torque control
accuracy allowing the use of one torque tool among several joints with various
hardness.
It solves the problem of the torque loss that is caused by the variation in the
joint hardness while bolting or the rise in temperature of hydraulic fluid in pulse
tools or the posture of holding the tool during continuous operation and
compensates the dynamic torque automatically within its allowable working
torque range.
Key Features
Static torque control accuracy: ± 1% CW / ± 2% CCW
Static angle measurement range: 0∘～ 360∘
Patent pending shock reduction design to withstand violent vibration of
impact tools.
Applicable to any air driven impact or oil pulse tools regardless of brand and
the type of impact mechanism for torque calibration, measurement,
control, and verification.
Applicable to any power torque tool with built-in torque control mechanism
for monitoring the bolting status and up-logging the data to PC/Tablet for
data collection and further production management and job traceability.
The type and size of both ends can be custom-made.
The over-limit vibration level, the operation cycles, and the over-torque
information will be recorded for the ease of warranty judgment.
No slip ring design, more durable under shock and vibration for long service
life.
RF2.4G Hz for transmitting torque and angle signal wirelessly within 15M
working distance.
Power: 3.7V, rechargeable battery
Warranty: Within 100,000 cycles in use for any air torque tools or the
indicated vibration level of 15 or the maximum torque limit specified.

7. 4
2.3 Torque and Force Monitor - TFM
TTES/TTEH/TTEB can be used along with a TFM and manual torque wrench to work as
a digital torque wrench for static torque control and torque verification.
The patented control algorithm enables the operator to measure the tightened torque
at 0.5o
angular movement to verify the most real and accurate torque applied to the
bolt. This advanced feature provides advantage over all digital torque wrenches on
the market.
2.4 Torque Sensing & Transmitting Socket with Reader– TTEHR/TSSHR
The patented socket designed for sensing and transmitting the torque signal to the
Torque Controller – TCA/TCB 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 stages of bolting by sequence,
but also the bolting data along with the operator ID and the workpiece barcode can
be recorded in the memory of the tag of TB or flash memory in the SB. All information
can be uploaded to peripherals or cloud server for tracking the relevant responsibility
of work to ensure the highest quality and reliability of the joint.
2.5 Dongle – ZD
With the use of the Dongle attached to a PC/Tablet, any power torque tool with built-
in torque control mechanism, not only the bolting status throughout the process can
be monitored and all data such as the workpiece and operator ID as well as the time
and torque applied to the bolt will be up-loaded to PC/Tablet simultaneously for
further production management and job traceability.

8. 5
3. Products Combination for Various Applications
Air Impact /Air Impact Ratchet / Air Pulse Wrench
Wrench
Power Torque Tool with Torque Control Mechanism
Wrench
Criss-CrossTightening Sequence
for Circular Bolt Patterns

9. 6
4. Common problems & solutions of bolting works
Item Problems Solutions
1
Hard to control the target torque
accuracy due to the hydraulic fluid
temperature rise in pulse tool which
causes the torque to decline and torque
created by uncontrollable air impact
wrench mechanism which causes a
considerably strong vibration during
intermittent operation
Take advantage of ZIPPTORK Torque
Controller-TCA & Wireless Rotary
Torque Transducer-TTE, the sensed
torque and angle signal will be
transmitted from the TTE to TCA
simultaneously and wirelessly while
controlled by the patented control
device and algorithm to effectively
control any air driven impact or oil
pulse tool with satisfactory control
accuracy within ±5% ~ ±20%
2
Bolt joints characteristics - hard or soft
joint, cause unstable torque
controllability
The patented control algorithm and
device on Torque Controller-TCA will
compensate the dynamic torque loss
automatically to allow it to achieve
the target torque range
3
The torque control accuracy is always
affected by the tool impact
mechanism and the posture of how
the operator holds the tool during
operation
The closed-loop control and patented
control algorithm enables the Torque
Controller-TCA to control the torque
accuracy effectively regardless of the
tool brand and impact mechanism as
well as the holding posture of the
operator
4
The operator didn't follow the bolting
sequence to fasten the bolts and led to
uneven clamping force on the joints
Use the Torque Controller-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 has to obey the
bolting sequence, but also the torque
can be appropriately controlled at each
stage. The bolting data can also be
recorded for traceability to verify the
responsibility of fastened joints to
ensure the highest quality and
reliability of bolting
5
The torque controller needs to be
paired with specific torque tool
TCA applies to any air driven torque tool
regardless of the brand and its
mechanism

10. 7
5. Bolting Issues with Power Torque Tools
Q & A
 How to control the output torque of an impact wrench?
ZIPP's Torque Controller∼TCA/TCB + Wireless Rotary Torque Transducer∼TTES/TTEH with the
patented control apparatus and algorithm will enable you to control air Pulse tools torque with ±5%
accuracy and ±10% for air impact wrenches.
 How to do the bol ng sequence control & ghten the bolt in several run?
With the programmable Torque Controller∼TCA + Wireless Rotary Torque Sensing and Transmitting
Socket∼ TTEHR +Tagged Bolt∼TB, not only the bolting sequence, but also the torque to be applied in
several runs can all be programmed in advance.
 How to control the joint ghtness effec vely?
With the Torque Controller∼TCA/TCB + Wireless Rotary Torque Sensing and Transmitting
Socket∼TTEHR + Sensing Bolt∼SB, it will assure that homogeneous clamping force can be fulfilled.
 How to control the bol ng torque on re stud and monitor the status of the bolted joint as a TPMS?
With the Torque Controller∼TCA/TCB + Wireless Rotary Torque Sensing and Transmitting
Socket∼TTEHR + Sensing Bolt∼SB + Transmitting Cap∼TC, it will not only ensure that the clamping
force can be applied evenly on each bolt/stud, but also the joint status can be remote monitored by
the car computer.
 How to monitor the bolted joint status periodically & remotely?
With the Torque Controller∼TCA/TCB + Wireless Rotary Torque Sensing and Transmitting
Socket∼TTEHR + Sensing Bolt∼SB + Transmitting Cap∼TC + Gateway∼ZG, the joint status can be
monitored remotely and periodically.
 How to track the responsibility of the bol ng work after bolted?
Use the Wireless Rotary Torque Sensing and Transmitting Socket∼TTEHR with the features of the
Tagged Bolt∼TB & Sensing Bolt∼SB, not only the production record of the bolt, but also the bolting
process and its result will be recorded in the memory of each bolt for traceability to verify the
responsibility and cease the controversy if there is any.
 How to monitor the bol ng status of a power clutch type torque tool?
With the Wireless Rotary Torque Transducer∼TTES/TTEH/TTEB + Dongle∼ZD to PC/Tablet/PLC, the
boltng status of a power clutch type torque tool either electric or pneumatic can be recorded
simultaneously during work. The data can be collected for production control and time study to
improve the productivity.
 How to collect bolted data with the torque tool which has built-in torque limit mechanism?
Use the Wireless Rotary Torque Transducer∼TTES/TTEH/TTEB with a manual, electric or pneumatic
torque tool while bolting, the bolted data can be recorded immediately after bolted and
transmitted to the TFM or via a Dongle to a PC/Tablet, then, uploading to other peripheral devices.
 How to verifying the residual torque of a bolted joint?
Use the Wireless Rotary Torque Transducer∼TTES/TTEH/TTEB with a manual click wrench or any
torque measurement wrench, the data will be transmitted to the TFM or via a Dongle to a PC/Tablet
to verify if it's OK or not. It makes the audible click visible with torque data. The collected data
can be uploaded to peripheral devices for traceability.
Applying the most advanced bolting technology
TCA / TCB TFM TTES TTEH TTEB
SB TB
ZGZD
TC
Torque Controller Wireless Rotary Torque Transducer Dongle Sensing
Bolt
Tagged
Bolt
Torque Monitor

11. 8
6. Torque Controller
6.1 Specifications & Dimensions
Item TCA TCB
Model TCA-1000 TCA-2000 TCB-1000 TCB-2000
Max. Flow Rate 1000L/min 2000L/min 1000L/min 2000L/min
Touch Panel Size 10” 7”
Power Source AC 110V~220V /2A AC 110V~220V /2A
Wire connector
USB 1 1
RS232 2 1
RJ45 1 1
Wireless RF2.4G 2 2
Speaker 1 1
Light Tower Output Port 1 1
Buzzer 80 dB 80 dB
Transducer Charger Port 2 2
RF Antenna 2 2
Flow Rate Detection V X
Stage control V X
Operation Mode
Air Pulse Tool V V
Air Impact Wrench V V
Manual Torque Wrench V V
Air Torque Multiplier V V
Job Group V V
Control Accuracy
Static Torque (%) ±1% CW / ±2% CCW ±1% CW / ±2% CCW
Dynamic Torque (%) ±5%~±20% ±5%~±20%
Thread Size
Inlet 3/8” NPT 1/2” NPT 3/8” NPT 1/2” NPT
Outlet 3/8” NPT 1/2” NPT 3/8” NPT 1/2” NPT
Dimensions
Length(L) 370 mm 320mm
Width(W) 214 mm 205 mm
High(H) 266 mm 210 mm
Weight 9.5kg 8kg

12. 9
7. Wireless Rotary Torque Transducer
7.1 Specifications
Item TTES TTEH TTEB
Tnom 50Nm～2000Nm 5～20Nm
Power DC 3.7V / 1010mAh DC3.7V / 650mAh
Measured Torque Range 10% Tnom～Tnom
Torque Resolution (Nm) 0.1% Tnom
Accuracy (CW) ±1%
Accuracy (CCW) ±2%
Static Measured Angle Range 0o～360o
Angle Resolution (Degree) 0.5o
Maximum Torque (Nm) 110% Tnom
Wireless Communication RF 2.4 GHz
Cable USB、RS232
Charger USB-Type C (DC 5V/0.7A)
Operation Temperature (oC) 0 oC～50 oC
Storage Temperature (oC) -10 oC～60 oC

13. 10
7.2 Dimensions～TTES/TTEH/TTEB Series
Model
Specifications
(Tnom)
Designation Net Weight
A
mm
B
mm
C
mm
D E
mm
F G
mm
Kg Lb
TTE-50-FS3MS3 50 Nm 82.2 45.0 24.0 3/8” 12.5 3/8” 12.0 0.20 0.44
TTE-100-FS3MS3 100 Nm 82.2 45.0 24.0 3/8” 12.5 3/8” 12.0 0.21 0.46
TTE-180-FS4MS4 180 Nm 96.7 45.0 29.6 1/2” 18.0 1/2” 17.0 0.26 0.57
TTE-250-FS4MS6 250 Nm 103.7 45.0 29.6 1/2” 18.0 1/2” 17.0 0.35 0.77
TTE-500-FS4MS6 500 Nm 105.2 57.0 40.0 1/2” 18.0 3/4” 21.5 0.55 1.21
TTE-1000-FS8MS8 1000 Nm 126.7 57.0 54.0 1” 29 1” 27.3 0.85 1.87
TTE-1500-FS8MS8 1500 Nm 127.4 57.0 54.0 1” 29 1” 31.1 0.95 2.09
Model
Specifications
(Tnom)
Designation
Net
Weight
A
mm
B
mm
C
mm
D
mm
E
mm
F G
mm
H
mm
I
mm
Kg Lb
TTE-250-FS4FH18 250 Nm 93.7 45 26.0 27.0 20.0 1/2” 18.0 18.0 13.0 0.28 0.62
TTE-250-FS4FH24 250 Nm 96.7 45 30.0 34.0 23.0 1/2” 18.0 24.0 15.0 0.34 0.75
TTE-250-FS4FH17L 250 Nm 97.7 45 24.0 42.0 25.0 1/2” 18.0 30.2 17.0 0.35 0.77

14. 11
Model
Specifications
(Tnom)
Designation Net Weight
A
mm
B
mm
C
mm
D
mm
E
mm
F
mm
G
mm
Kg Lb
TTE-5-MH6FH6 5Nm 121 45 10 6.35 23.5 6.65 23.5 0.15 0.33
TTE-10-MH6FH6 10Nm 121 45 10 6.35 23.5 6.65 23.5 0.15 0.33
TTE-20-MH6FH6 20Nm 121 45 10 6.35 23.5 6.65 23.5 0.15 0.33

15. 12
Make torque control easy and affordable!
No more costly torque control tools required!
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
During Assembly
by applying
Torque Transducer & Torque Controller
For controlling and recording the torque being applied to the bolt instantly and wirelessly
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
8. Bolting Strategy

16. 13
9. Innovated Fasteners for Bolting Works

17. 14
10. Solve bolting issues with your power torque tool
ZIPPTORK
Bolting Technology
ZIPPBOLT
The Ultimate Bolting Solution
SB TC+SB TB
+ + &
Inspection cover Clutch cover
Spiral Tightening Sequence Starting in the
Middle for Non-Circular Bolt Patterns.
1
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 Bolt
●TTEH - Torque Sensing & Transmitting Socket ●TB - Tagged Bolt
●TSSH - Torque Sensing & Transmitting Socket ●TGC - Tag Cell
●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%～15%, air pulse wrench
±5%～10%.
PRODUCTS
TCA - Torque Controller
TTES - Wireless Torque Transducers
TTEH - Wireless Torque Transducing Socket
TCA TTEH/TTEHR TSSH/TSSHR

18. 15
11. Air line Installation Guide
Flow Rate For the tool with air consumption less than 500L/min
Controller Model TCA-1000, TCB-1000
Flow Rate For the tool with air consumption between 500L/min and 900L/min
Controller Model TCA-1000, TCB-1000
In order to reach the best performance for the system, please follow the air
line installation guide.
The air line installation guide of TCA-1000 for the tool with air consumption between 500L/min and 900L/min
Air Compressor
Air Pressure 100～120 Psi
Flow Rate 1500L/minute
The air line installation guide of TCA-1000 for the tool air consumption under 500L/min
Air Compressor
Air Pressure 100～120 Psi
Flow Rate 1000L/minute

19. 16
Flow Rate For the tool with air consumption between 900L/min and 1500L/min
Controller Model TCA-2000, TCB-2000
Flow Rate For the tool with air consumption between 1500L/min and 2000L/min
Controller Model TCA-2000, TCB-2000
The air installation guide of TCA-2000 for the tool with air consumption between 900L/min and 1500L/min
Air Compressor
Air Pressure 100～120 Psi
Flow Rate 2000L/minute
The air line installation guide of TCA-2000 for the tool with air consumption between 1500L/min and 2000L/min
Air Compressor
Air Pressure 100～120 Psi
Flow Rate 2500L/minute

20. 17
www.zippgroup.com
Distributed By
2018/July/TC/2000
Assembly Technology