Passion and Innovation to achieve the excellence of bolting works
and
make the control more accurate, easier, yet cost-effective
- Makes pneumatic oil pulse torque tool can be controlled within ± 5%～±10%.
- The impact tool can be controlled within ±10%~±15 % accuracy.
- The cordless oil pulse torque tool can be controlled within ±10%~±15 %
- Makes cordless impact torque tool can be controlled within ±10%～±15%
- Makes the click-type torque tool visible and data recordable within ±5%.
- Revolutionize your power-driven torque multiplier with closed-loop control for torque and clamping force controllability within±5% in real-time.
- Make it feasible to verify the residual torque or clamping force of the high-torque bolted joint.
ZIPPTORK Bolting Strategy
- Torque control accuracy in the assembly line
For pneumatic or cordless impact torque tools used is within ±10%～±15%;”
The pneumatic or cordless oil pulse torque tools are within ±5%～±10%.
For pneumatic or cordless torque multiplier is within 5%.
ZIPPTORK torque controller, with its patented design and control algorithm, provides excellent control over the bolting operations carried out by air—or DC-driven impact or oil pulse torque tools.
Torque Controller (TCA/TCC) –
It’s applicable to any type of air-driven torque tool from any brand and automatically compensates for the torque loss due to the variation of joint hardness, the oil temperature rise of the pulse unit, and the operator’s improper posture while holding the tool during the process.
Wireless Torque Transducer (TTE / TTR) –
With a patented anti-vibration mechanism, it’s the first wireless torque transducer applicable to any torque tool for static or dynamic bolting works.
It’s to be mounted between the output end of the torque tool and the impact socket. During the bolting process, the sensed torque signal is continuously transmitted wirelessly to the torque controller or a monitor such as a tablet or Notebook via a Dongle. When the target torque is reached, the torque controller cuts off the power source, or the result with OK/NOK will be judged and displayed with a warning light or buzz.
Torque Controller (ECA) – For cordless impact or oil pulse torque tool
The control board is integrated into the tool handle and equipped with a wireless torque transducer, the control accuracy can be controlled within ±10%～±15%.
Signal Transmitter (Dongle)-
The Signal Transmitter receives the torque signal from the wireless torque transducer and transmits it to a Tablet to monitor the correctness of the torque applied by the pneumatic or cordless oil pulse torque tool and collect and transmit data.
Application Software (APP)-
Compatible with both Android and Microsoft operating systems to connect the dongle to a tablet or notebook.
- Bolt clamping force control –
Designed for applications where the clamping force of the bolted joint needs to be controlled. The control accuracy of the clamping force is within ± 5%～10%.
Wireless Clamping Force Transducer (FTE) –
It’s designed for adapting to any torque tool for precision clamping force control. The transducer is to be mounted on the output end of the torque tool. During the bolting process, the sensed clamping force signal is continuously transmitted to the torque controller or a monitor wirelessly, and when the target clamping force is reached, the power source is cut off by the torque controller or the result with OK/NOK will be judged and displayed with warning light or buzz.
Clamping Force Wrench (FW) –
Disruptive innovation overturns the design concept of traditional torque tools and replaces the torque control used in bolting works with the most advanced and accurate clamping force control.
Clamping Force Screwdriver (FS) –
Disruptive innovation has overturned the design concept of traditional torque tools and replaced the torque control used in bolting works with the most advanced and accurate clamping force control.
Loose-proof Sensing Washer (SW) –
Like the bolt washers used commonly, only with a force sensor to monitor the clamping force induced during the bolting process, the controller instantly cuts off the power source when it achieves the target clamping force and transmits the status to peripheral devices. It can be monitored wired or wirelessly and remotely, while reporting instantly when exceeding the settings. The patented anti-loose design enables the bolted joint to achieve the best state and excellent safety and reliability while ensuring it will not loosen due to vibration. Furthermore, in accordance with the preset time interval, it will activate or the passive rendering of tightness status to ensure the highest safety of the joint.
Anti-loose sensing washers are the best solution for high-precision bolting operations. Regardless of the grade of bolt specifications used and the torque tools used, the ZIPPTORK brand anti-loose sensing washers will meet your requirement to control bolt clamping forces and outperform similar products in the field.
- Bolting Sequence Control
Use a torque controller and a wireless torque transducer～TTR (Torque Transducer with Reader) or a wireless clamping force transducer (Force Transducer) coupled with an indicator, as well as the anti-loose sensing washers (SW), Tagged Bolt (TB), or an RFID Tag Cell (TGC). And so on. The bolting sequence can be programmed on the controller for 2～4 rounds of bolting sequence control. All relevant data throughout the process, such as the operator’s ID, Job ID, time of bolting, and the torque or clamping force applied to each joint in each round, will be collected and transmitted to a peripheral device or uploaded to a cloud server for further follow-up inspection of construction responsibilities after the work.
- Residual torque and clamping force inspection～Use TTT ( Torque Tension Tester )
a. Manual torque wrench～Use TTT + Tablet →
1. Verify that the torque applied to the specific size of the bolt and washer will produce the amount of clamping force and equivalent residual torque on the bolted joint.
2. To prove that the same amount of torque applied to the bolted joint with the same size bolt and washer, but only the pitch is different, a small pitch bolt will induce a higher clamping force on the joint.
3. To prove that the same amount of torque applied to the bolted joint with the same size and pitch bolt, but only the hardness of the washer is different, harder the washer, higher clamping force on the joint.
4. To prove that the same amount of torque is applied to the bolted joint with the same size bolt and washer, but only the surface condition of the bolt, such as rust, roughness, or oil contamination, is different, the clamping will be different.
5. To calibrate the torque ratio～TR of a torque multiplier.
6. To calibrate the static torque slope of a static torque transducer.
7. To calibrate the relationship curve among the Sensing Washer strain value, the clamping force, and equivalent residual torque on the joint.
8. To verify the torque tool accuracy of a digital torque wrench, a dial-type torque wrench, and a click wrench.
9. To do a bolt incoming inspection.
b. Pneumatic torque wrench torque capacity verification～Use TTE & TTT
- For tool manufacturers to verify the quality and stability of their tool production under specific air pressure and flow rate while tightening specific specifications of bolt (material plus grade, etc.) and washer (soft or hard), the tool’s capability (maximum output torque that can be achieved in seconds) and the torque or clamping force limits can be reached within certain seconds, to realize the quality and stability of the production lot and precisely set the tool capability specifications accordingly.
- In other words, the tool torque capacity can be specified clearly for production, such as the torque being measured under how much PSI working pressure, what size and length of the air hose, what specs of bolt and washer are tightened, and how many seconds it takes to reach the tool output torque limit as well as the residual torque limit.
- For the operator to understand the selected tools and the fasteners ( bolt & washer specs.) to be tightened to simulate the real residual torque, it can be achieved within his expectations for correctly adjusting the tool. While using the TTE to drive the fastener on the TTT, the graph shown on the monitor will tell if the tool can tighten the fasteners to the target torque within the time interval as expected. Or under what air pressure the tool can produce how much residual torque for efficient torque setting.
- If the TTE torque transducer is not used and uses the air pressure mode only, it can also be known through TTT and the monitor after driving the tool and fastener for 5 seconds. If the target torque is within the range, just use the air pressure and the corresponding time to tighten the fastener to the target. Use the same specification size bolt with sufficient length to do a simulation before bolting.
c. Cordless torque wrench torque capacity verification～Use TTE & TTT
1. For tool manufacturers to verify the quality and stability of their tool production under different voltage or current conditions, while tightening specific size of bolt (material plus grade, etc.) and washer (soft or hard), the tool’s capability (maximum output torque that can be achieved in seconds) and the torque or clamping force limits can be reached within certain seconds, to realize the quality and stability of the production lot and precisely set the tool capability specifications accordingly.
In other words, the tool torque capacity can be specified clearly for production, such as the torque measured under which power selection, what specs of bolt and washer are tightened, and how many seconds it takes to reach the tool output torque limit and the residual torque limit.
2. The design engineer should know clearly how much residual torque and clamping force can be induced on the selected fasteners, enabling him to specify how much torque should be applied properly to this joint in the job instructions.
3. Enable the sales personnel to understand clearly the tool capability, especially how many seconds it takes for the tool to reach its maximum output torque limit and how much residual torque can be achieved, to tell the difference among competitive items professionally in their sales talk about price/performance.
4. For the service or maintenance personnel to understand whether the quality of repaired tools meets the original level
5. For the operator to understand the selected tools and the fasteners (bolt & washer specs.) to be tightened to simulate the real residual torque, it can be achieved within his expectation for correctly adjusting the tool. While using the TTE to drive the fastener on the TTT, the graph shown on the monitor will tell if the tool can tighten the fasteners to the target torque within the time interval as expected. Or under each power selection, the tool can produce how much residual torque is needed for efficient torque setting.
6. If the TTE torque transducer is not used and uses the power selection mode only, it can also be known through TTT and the monitor after driving the tool and fastener for 5 seconds.
If the target torque is within the range, you can just use the power stage and the appropriate time to tighten the fastener to the target.
- If the bolt length used in the assembly line is too short to fit the depth of the TTT, find a bolt with the same specification size and sufficient length to do a simulation before bolting.
- High residual torque and clamping force-torque multipliers ～
- Our pneumatic torque multipliers – ATM-200, ATM-300, ATM-700
- Our pneumatic torque multipliers – ATM-200, ATM-300, ATM-700 plus TTA-10
- Our pneumatic torque multipliers – ATM-700 s RR4, RR9, RR16 s Hytech TM series
- Our pneumatic torque multipliers – ATM-700 plus TTA-10 plus RR4, RR9, RR16+Hytech TM series
- Hytech Series torque multipliers -TCT-500, 1000, 2000, 3000, 6000
- Hytech Series torque multipliers -TCT-500, 1000, 2000, 3000, 6000 + TTA-10
- Hytech Series torque multipliers -TCT-500 + RR4, RR9, RR16 for 1500NM, 3000NM & 6000NM
- Hytech Series torque multipliers -TCT-500 + TTA-10 + RR4, RR9, RR16 for 1500NM, 3000NM & 6000NM works
- Electric torque multipliers – ETM-5 00plus 1000, 2000, 3000, 6000
- Electric torque multipliers – ETM-500 plus 1000, 2000, 3000, 6000 plus TTA -10
- Electric torque multipliers – ETM-500 plus RR4, RR9, RR16 for 1500NM, 3000NM and 6000NM
- Electric torque multipliers – ETM-500 plus TTA-10 plus RR4, RR9, RR16 for 1500NM, 3000N,M and 6000NM works
Above, TTA-10 can all be changed to FTE to transform all torque transducers series into clamping force transducers series
- High Residual torque and clamping force verification～
For a long time, the industry has found it difficult to do adequate testing of high residual torque above 1000NM, usually only according to the air pressure or hydraulic pressure applied to calculate the equivalent torque, and no further inspection of the real amount due to a lack of applicable instruments to implement high torque verification after bolted..
Make the most of ZIPPTORK’s TTA torque transducers and torque multipliers by selecting the appropriate torque capacity, along with a dongle and tablet. To ensure accurate measurements, choose the right TTA torque transducer that has an angle sensing function and a torque multiplier with clearly marked torque and gear reduction ratios. By inputting the target torque, default angle displacement, and acceptable thresholds into the system, you can easily determine whether the assembly is qualified using our patented algorithm.
In addition, the inspector’s ID, job code, inspection time, and test results are displayed in real time and can be uploaded if necessary. This process clarifies responsibility for ensuring that the assembly meets quality standards.