Torque testing finds the hidden problems
Torque is the angular force required to turn something, whether it’s a fastener such as a nut or screw, or an assembly such as an electric motor. A failure or defect in the fastening operation of something as simple as a fastener or small part can impact the operation of an entire motorized assembly, which is why it is critical to call attention to hidden defects and other issues early in the production process.
In torque testing for manufacturing, the amount of force applied to move an object is measured and analyzed for comparison to a baseline. Any anomalies in torque characteristics can indicate a quality issue. With Sciemetric’s off-the-shelf technology, these anomalies can be used to trace the root cause of a variety of defects. Sciemetric's solutions can help you identify specific problem, including under- or over-fastened parts, bearing debris, lack of lubrication, out-of-tolerance components, and broken/missing parts.
Torque process monitoring and analysis systems
Sciemetric offers in-station part test and process monitoring and data acquisition systems that enable manufacturers to catch production problems. On many production lines, fastening and run-down operations are monitored only for verification that a specified torque was reached. Our solutions go far beyond this basic pass/fail determination to monitor and collect data from every millisecond of the process using digital process signatures. This provides much more granular and effective defect detection. If it takes longer than usual to reach a specified torque, if it takes more or less force, your team will know in real-time.
Sciemetric offers two solutions for monitoring and analysis of your torque testing operations: sigPOD and Sciemetric EDGE. Each solution applies the power and insight of Sciemetric digital process signature technology, combined with the hardware to suit your needs on the line. See below for more information on which solution is right for you.
The sigPOD is powerful process monitoring platform that offers an in-station display to be able to easily view and analyze your basic test data using PSV right at the station.
The sigPOD is preferred if your application requires several channels of synchronous data collection for complex tests. This would apply to areas of your line where you may be monitoring multiple parameters along with your torque operation. This would include multifunction tests like engine cold test and other functional engine testing, where multiple sensors would be monitoring at once to get a full picture.
The Sciemetric EDGE is an innovative platform for process monitoring and control. Its compact, modular design allows it to be easily integrated onto your line and offers remote access control.
The Sciemetric EDGE is preferred for standard two-channel torque applications, offering simple integration and blazing fast cycle times. The Sciemetric EDGE platform includes advanced data analytics using Sciemetric Studio accessed on industrial PC on the factory floor or in the field to maintain efficiency of your operations.
Torque process defect detection applications
Torque can be used on the production line to identify defects in the following applications:
Read more about the basics of torque testing from our experts in the pages of Assembly Magazine.
Torque testing in manufacturing: Application stories
Torque testing electric motors
Torque testing is a critical part of the functional test of an electric motor. Sciemetric’s solution identifies faulty motors based on ‘High Potential’, ‘Minimum Start Voltage’, ‘Pull-up Torque’ and ‘No-load’ tests. Key components of the testing and the related waveforms include:
- Rotary testing
- Encoder sampling
- Torque signature vs. angle
- Current testing
Short block torque-to-turn testing
A major engine manufacturer was experiencing customer complaints and costly warranty repairs and quickly required a solution that could detect defects early in the Short Block assembly process, specifically defects caused by crankshafts.
Sciemetric’s Short Block Crank Torque- to-Turn test measures the torque as the crank is rotated, applying advanced algorithms for consistent and reliable detection of defects such as contaminated bearings, debris, incorrect fit, bent or nicked cranks, etc.
Consolidate production fastening data with other station data for better visibility
Fastening and rundown stations often have monitoring solutions provided by the tool supplier. The valuable part data collected by these systems often reside in silos. Sciemetric’s QualityWorX enables manufacturers to store all part data from across the assembly line into a centralized database. Unique manufacturing analytics software allows the analysis of the waveforms, comparison and correlation of stations and more.