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Recent months have seen significant new developments in torque technology. Specifically, the
use of the solid state gyro, best-use methodologies associated with it and the incorporation of
these advances into electronic tools is causing serious rethinking and re-engineering in quality
manufacturing circles and assembly operations.
In some respects, the application of the motion-sensing solid state gyro to torque plays out like a
solution looking for a problem. We can now sense motion and measure the number of degrees a
fastener rotates in real time. The question is, how to best harness the innovation? Several
different approaches have emerged. A few look good on the surface, but a disciplined drill down
reveals major weaknesses. This study examines the new torque technology, methods and
applications, and provides some useful conclusions.
The Torque challenge has been with us for some time. An under-torqued fastener can vibrate or
work loose. Conversely, if tension is too high, the fastener can snap or strip its threads. Precise
torque control can spell the difference between a safe, reliable and economical product and
complete disaster.
Some have argued that with the advent of precise, instrumented DC power tools the need to
measure or audit residual torque has become less important. Has it? The answer is no, and for
two reasons.
First, there are dozens of sources of error that could cause an instrumented tool, one that
indicated correct installation torque, to subsequently apply low actual joint torque. For example
something as simple as a cracked socket can throw off targeted applied torque. Or consider a
longer than normal extension. The longer extension absorbs more rotational energy intended for
the joint than a shorter extension, thus lowering actual applied torque. Power tools in particular
create variability by their very nature – high speed, constant motion, high volume. As the gears in
the right angle drive of a power wrench collect dirt and wear, increasing friction absorbs torque
and the sensor in the tool picks up less than accurate readings.
Material conditions can leave a fastener with insufficient torque even if the joint was originally
installed correctly. An example of this occurred when an over application of lubricant on a joint
assembly deposited grease between a washer and the work surface. The grease was too
viscous to be extruded completely from under the washer before the power tool reached cutoff
torque. Afterwards it continued to ooze out. A follow-up measurement of residual torque
indicated the joint was nearly one third below installation torque.
The second reason to measure residual torque precisely is the high cost of failure for many joints.
Improper torque in safety critical applications such as steering gears or braking assemblies can
result in tens of thousands of dollars in equipment damage, human injury, or even death. As we
continue to observe high levels of recalls attributable to improper torque in the auto and other
industries, it would seem the need to resolve torque issues carries more weight than ever.
Torque Technologies
There have been a number of competing torque measurement technologies and methodologies
in recent years that have attempted to take on the optimization challenge. Among them are peak
torque, the use of breakaway and restart inflection points, capture angle and angle restart.
Peak Torque
Assessing residual torque by means of a peak measurement strategy is perhaps the oldest and
most widely employed methodology today. Typically, peak torque wrenches use a simple non-
electronic indicating dial to measure peak torque. There are electronic versions as well. In order
for these devices to effectively and accurately measure residual torque, though, a significant
amount of operator training and practice is required. Proper operation requires the operator to
slowly and deliberately apply ever-increasing torque until the fastener just begins to move, and
then release pressure. This slow approach is an attempt to reduce the amount of overshoot after
the fastener starts to turn.
Overshoot
The tendency to overshoot is central to many of the problems associated with using a peak
reading device to measure residual torque. Contributing to the problem are individual differences
in human reaction time. An operator with quick reaction time tends to take lower readings than
an operator with slower reaction time. Slower reaction time results in greater overshoot. In
addition, since torque auditors typically take several hundred measurements in a shift,
inconsistencies can creep in. Fatigue can cause a weaker pull on the wrench or pressure to meet
a schedule can lead to a quicker pull and greater overshoot. On the curve below, an overshoot of
only about 150 milliseconds resulted in a peak reading more than 10% higher than the torque
applied at the start of fastener rotation.
Figure 1. Overshoot.
Fastener Peak
Movement Reading
Overshoot
While excessive overshoot creates false high readings using a peak reading device, releasing the
wrench before the fastener begins to turn causes false low readings. This all too common
occurrence is usually triggered when a “bump” or vibration in the work piece is mistaken for
fastener rotation. These false apparent indications of fastener rotation are more common when
the work piece is in motion as on an assembly line.
Even if it were possible to stabilize these sources of variance, the peak residual torque method is
inherently flawed. It measures torque at the point where the operator stops pulling on the
wrench. This may occur before the fastener turns, shortly after the fastener turns, or significantly
after the fastener turns. Lack of accuracy has a cost. Peak residual torque measurements are
The introduction of the solid state gyro has facilitated development of residual torque
measurement devices that incorporate the use of sensed angular displacement as a qualifier for
the capture of a torque value. Generally, the purpose of the gyro in these devices is to ensure
that the fastener has actually moved before capturing a torque value, and to eliminate the effects
of overshoot.
Today there are two widely used methods that capitalize on the use of a gyro in a residual torque
measurement system. One method is referred to as the “Capture Angle” or “Torque at Angle”
method, which captures torque at a preset degree of sensed angular rotation. The other method
is called Angle Restart.
Capture Angle
The capture angle method relies on the operator or engineer to determine a capture angle for
each joint type to be audited. The residual torque for any given joint is the reading taken after
some degree of sensed angular rotation that includes both windup and actual fastener rotation.
That predefined number of degrees has to come from somewhere. Typically an engineer makes
a best guess based on the materials used, their properties, the type of joint and anticipated
windup before fastener rotation begins. Going forward, torque capture angle is often adjusted
using some number of residual measurements and comparing them to in-line installation
measurements. The method is very much trial and error and fairly subjective.
Torque
20
15
The chart in figure 5 shows the torque 10
curve for a fastener on a brake line 5
Torque
shown in figure 6. Which is the correct 15
capture angle for this joint? 10
5
The charts in figure 7 track torque and 0
angle for a joint consisting of a lug nut on 0 2 4 6 8 10 12 14
160 250
140
120 200
100
Torque
Torque
150
80
60 100
40 50
20
0 0
0 1 2 3 4 5 6 0 1 2 3 4 5 6 7 8
Angle Angle
How are these different joints to be interpreted? Clearly a capture angle that is correct for one is
wrong or very wrong for another.
10
previous example, a joint signature of this 8
type is particularly problematic for the 6
4
capture angle method since small changes in 2
the capture angle or in a joint’s amount of 0
0 2 4 6 8 10 12 14
windup can significantly alter the reported
Angle
torque value.
Torque
5
Angle Restart
The torque rate differentiation method known as angle restart was developed specifically to
eliminate the false high and false low readings associated with peak measurement and to
eliminate the error inducing guesswork associated with the capture angle methodology. This is
done by monitoring the changes in angular torque and noting the difference in the curve slope
during windup and actual rotation. Angle restart torque is captured at the start of rotation where
the curve transitions from the windup slope to the rotation slope (see figure 10 below).
Rotation
Rotation
Windup
Windup
In other words, Angle Restart captures torque at the instant of fastener rotation.
Angle restart can be used to measure torque accurately and consistently independent of the joint
type. The operator does not need any engineering estimates to put him in the ballpark and there
is no need to guess a capture angle. Consequently, the possible chain reaction errors built
upon a bad guess go away. It is no longer possible to have error induced by a capture angle that
doesn’t match the start of fastener rotation.
There are several other advantages of measuring torque via the angle restart method. These
include:
6
5
4
Torque
3
2
1
0
0 1 2 3 4 5 6
Angle
Conclusion
Most manufacturers continue to face challenges relating to proper torque, and demand is
increasing. As the number and types of mechanized consumer and commercial products being
developed and offered in the world expands, so does the need to assess and manage torque
precisely and accurately. Current electronic, software-controlled DC power tools do not have a
means by which to measure and manage the joints that they create, and so by themselves offer
no solution.
Of the various torque measurement and management solutions discussed, it is clear that peak
torque introduces too much variability to be considered viable. The use of restart and breakaway
inflection points provides some improvement, but only in the hands of very experienced
operators, and only if there are ways to overcome inconsistencies.
Employing a solid state gyro to sense angular motion is a critical step in the right direction. This
technology was initially put to use in the capture angle method. Unfortunately this approach
doesn’t really help us pinpoint optimal torque. In fact the “capture angle” is something that has to
be estimated and inserted into the process before any torque auditing can actually begin. There
is a great deal of guesswork involved, considerable variability across joints and joint types, and
inconsistency between operators performing follow-up measurements. Thinking of this as a
sound and accurate torque method is dangerously deceiving.
The angle restart approach does away with the guesswork and variability because it employs a
technology that can be applied consistently to joints of all types. It measures residual torque and
provides a basis for setting optimum torque on each fastener independently. This is achieved by
means of a motion-detecting gyro used in conjunction with a sophisticated software algorithm that
allows the device to differentiate between the windup and rotation angular torque curves. This
advancement delivers significant precision and optimization advantages to the torque
management challenge and seriously raises the bar over other approaches.
40
Torque
30
0
fastener joint to effect installation. 1 144 287 430 573 716 859 1002 1145 1288 1431 1574 1717
Time
200
150
150
force. 100
50
20
10
captured after a given amount of sensed
angular rotation past a torque threshold. On the 5
Torque
before the start of actual fastener rotation. 100
50
Soft joint. A soft joint is a joint where additional fastener rotation results in little or no fastener
elongation, but the joint components are either pulled closer together, or are compressed
further.
Authors
Frank Skog is a Sr. Product Manger and Applications Engineer for ASI DataMyte, Inc. Mr.
Skog is recognized as an industry leader in the field of Torque Technology. He holds a
number of measurement-related patents, and is published regularly in top quality
manufacturing and assembly periodicals across the globe.
End