Air Tool Torque Controller

(Also known as Pneumatic Torque Control Unit / Smart Torque Controller for Air Tools)

An Air Tool Torque Controller is an electronic or electro-pneumatic control system designed to precisely regulate, monitor, and record the torque output of pneumatic (air-powered) fastening tools such as impact wrenches, pulse tools, and clutch-type screwdrivers.

It bridges traditional Operational Technology (OT) with modern Information Technology (IT) by converting real-time torque and angle data from the tool into digital, traceable information for process control, quality assurance, and Industry 4.0 integration.

These controllers are essential in automotive, aerospace, heavy machinery, and industrial assembly, where accurate and repeatable torque is critical for product safety and consistency.

Working Principle

1. Air Input Control:
   The controller regulates compressed air pressure and flow to the connected tool.

   • Higher air pressure → higher torque.

   • Lower air pressure → lower torque.

2. Sensor Feedback:
   When used with a wireless or integrated torque transducer, the controller continuously measures torque, angle, and time.

3. Digital Control & Feedback Loop:
   The system adjusts air supply in real time to maintain the target torque, providing automatic shutoff, torque compensation, and data recording.

4. Data Integration:
   Torque data is transmitted to IIoT, MES, or SPC systems for traceability, analysis, and quality control.

Key Features

• Precise Torque Regulation: ±10% or better torque accuracy depending on tool and configuration.

• Programmable Control Modes: Torque, angle, or time-based control.

• Real-Time Monitoring: Displays live torque/angle curves, cycle counts, and OK/NOK results.

• Data Traceability: Stores fastening data for process validation and quality audits.

• Wireless / IoT Connectivity: Supports Bluetooth, Wi-Fi, or Ethernet for integration into smart factories.

• Multi-Tool Compatibility: Can control impact, pulse, or clutch-type pneumatic tools.

• User Interface: Equipped with a touchscreen or a software dashboard for setting torque parameters and viewing reports.

Applications

• Automotive and Truck Assembly Lines (wheel fastening, chassis, engine assembly)

• Aerospace Manufacturing (critical fastener control)

• Heavy Machinery Production

• Industrial Bolting and Maintenance

• Smart Factory and IIoT Systems

Advantages

• This technology converts conventional air tools into intelligent, data-driven fastening systems.

• This feature enables traceable and repeatable torque control, improving product quality.

• This process reduces operator error and rework through automated shutoff and validation.

• Integrates seamlessly with wireless torque transducers and smart sensors.