Torque measurement is crucial in manufacturing. Accurate measurements are essential to ensure safety, improve reliability and eliminate risks in both the assembly and quality auditing stages. Manufacturers not only have to adhere to and record specific torque tightening levels due to legislation, but this also helps to provide peace of mind for their customers and end-users.
Torque measurement is a critical element in a wide range of mechanical applications, from securing a car’s wheels to maintaining the structural integrity of aerospace machinery. Using specialised tools to measure and apply torque accurately helps ensure compliance with standards, enhance product quality and optimise performance across numerous industries.
The consistent application of the correct torque specification to critical fasteners maintains the integrity, performance and reliability of machinery and mechanical components, which is essential for industry success and safety.
What is torque?
Torque is a measurement used to indicate the amount of ‘clamp load’ and tension applied to a threaded fastener joint. It is not a direct measurement of the clamp load or tension; torque is simply an indicator.
A tightening process must be used to reach a target torque level and induce the correct amount of tension to hold an assembly together.
Why do we need torque measurement?
Torque is applied to a joint, such as a nut and bolt connecting two components, to apply the correct level of tension that holds the assembly together. The correct level of torque applied is critical to all joints. Too much tension can cause a bolt to become warped and fracture. Too little tension can cause the joint and assembly to become loose over time.
Why is torque measurement so important in manufacturing?
The combined tension applied in a series of fasteners, such as bolts, is essentially what holds an entire assembly together. However, tension cannot be reliably measured in a fast-paced production environment, but torque can.
Torque can be measured as the amount of force applied at a given distance from the axis of the fastener that is necessary to turn the fastener. As torque is applied, the tightening process produces the required level of tension within the joint.
The perfect level of torque for each given assembly is determined through research and development and testing prototypes. Once this specification is set, the fastener is tightened to this torque level to ensure it has the right amount of tension for a stable joint and a high-quality product.
Benefits of torque measurement
Beyond compliance with regulations, measuring torque has many benefits, such as preventing mechanical failures, enhancing safety and ensuring consistency in production.
One of the main reasons to measure torque is to prevent mechanical failures. Applying the correct amount of torque ensures that nuts, bolts and screws are tightened according to the manufacturer’s specified requirements. Incorrect torque can lead to either over-tightening or under-tightening, both of which can cause mechanical failures such as machine breakdowns or catastrophic accidents.
The correct application of torque is critical in industries where safety is paramount, such as automotive and aerospace. It ensures components like wheel nuts, engine parts and structural bolts are secured at the optimal tightness. This significantly reduces the risk of parts becoming loose during operation, thereby enhancing operational safety and reliability.
Maintaining a high standard of quality is essential in mass-production environments. Torque measurement ensures uniformity and precision in the assembly process, minimising variability in how components are assembled. This consistency is crucial for maintaining the reliability and quality of the final product, which in turn supports brand reputation and customer trust.
Types of torque measurement
There are several types of torque measurement techniques. Each one is suited to different applications depending on the requirements for accuracy, the nature of the torque (static or dynamic) and the environment in which the measurement needs to take place. Some examples include:
Static torque measurement
This is used when the item being measured is not in motion. It is commonly applied in scenarios where precision is essential, such as in the calibration of torque tools or when measuring the torque on pre-tightened bolts. Torque wrenches and torque sensors are commonly used for this type of torque measurement.
Dynamic torque measurement
This is used when the item being measured is in motion. Dynamic torque measurement is typically used for engines, gearboxes and motors. It is critical for assessing the performance and efficiency of rotating machinery. Rotary torque transducers and optical torque sensors are used to test and measure torque.
Strain gauge-based sensors
One of the most common and versatile methods for measuring torque is using strain gauges. These sensors convert the mechanical deformation under torque into electrical signals that can be quantified. They can be used in static and dynamic torque measurements and strain gauge torque transducers can deliver accurate results.
Tools for measuring torque
There are a variety of methods and tools for measuring torque. Some of the most commonly used tools include:
Which industries measure torque?
Torque measurement is invaluable to many manufacturing industries and is used widely across a host of industries, including:
- Automotive
- Aerospace
- Rail
- Marine
- Pharmaceutical
- Food & Beverage
- General Manufacturing, such as that of white goods and electronics
Every industry has its own requirements for monitoring, recording, storing and measuring torque. It is particularly important in industries that demand a precise, high-quality product finish with accurate and reliable data records, such as automotive and aerospace.
Why choose Crane?
Established in 1971, Crane Electronics has vast experience delivering bespoke torque measurement solutions. Crane offers a variety of different torque wrenches, data collectors and rotary torque transducers, which have helped revolutionise and shape the industry standard for torque measurement.
For more information about our ranges of torque measurement solutions or for any assistance with our products and services, please contact Crane Electronics on 01455 25 14 88 or email sales@crane-electronics.com.