In industrial assembly processes, monitoring what actually happens at the level of each individual tightening operation is essential to ensuring quality, repeatability, and safety. The eTensil range of electric torque screwdrivers with built-in transducers meets this need by offering high-precision tools capable of analyzing, measuring, and controlling all stages of the tightening process.
We have already explored the importance of direct measurement of torque and angle parameters in our previous article: Precision as a measure of quality: why choose screwdrivers with built-in transducers | Fiamgroup and in this new analysis, we focus on three particularly noteworthy features of these eTensil torque screwdrivers with transducers that further enhance process control: Smart Torque Programming, Prevailing Torque, and Average Torque Monitoring (Rolling).
Let’s take a closer look at each one:
SMART TORQUE PROGRAMMING
The Smart Torque Programming feature allows you to set a maximum torque limit beyond which the system automatically stops the tightening cycle.
This control is essential when abnormal situations occur, such as:
- damaged threads,
- non-conforming components,
- irregular friction, or abnormal resistance resulting from an incorrect manufacturing process
Under such conditions, the screwdriver could cause reactions that are hazardous to the operator, such as kickback affecting the hand-arm system.
Smart Torque Programming thus ensures operator safety, prevents mechanical stress and damage to the tool, and immediately identifies defective components.
PREVAILING TORQUE
The concept of Prevailing Torque is one of the most underestimated aspects of industrial tightening.
It refers to the rotational resistance generated before the surfaces come into contact during tightening: a real, often significant value that indicates the absorption of part of the torque applied by the tool during thread formation.
Here are some examples of critical applications:
• Self-locking nuts (Nyloc)
The nylon insert they contain provides constant resistance.
If, for example, 2 Nm is required to overcome this resistance and the target is 10 Nm, the control unit would measure 10 Nm, but the actual tightening torque would be only 8 Nm.
• Off-center metal panels
Their holes may be misaligned, and different levels of deformation may be required between them to allow the screw to pass through.
The risk here is even greater: the screwdriver may detect a torque value before the parts are in full contact, resulting in a false tightening.
The problem is therefore clear: if the prevailing torque is not taken into account, the tightening result can be completely distorted.
Thanks to built-in transducer, the eTensil electric screwdriver measures the actual torque values, allowing for the display of:
- only the final tightening torque (actual tightening torque or “peak torque”)
- or the total torque, i.e., the final tightening torque plus the average torque measured during the thread-forming phase (prevailing torque)
AVERAGE TORQUE MONITORING
Average Torque Monitoring, also known as rolling, is a function that allows you to verify the average torque on the component.
By setting the minimum and maximum values for the prevailing torque according to your specifications, the system verifies whether the component’s integrity falls within the accepted range.
One typical application is checking the integrity of bearings.
By measuring the average torque trend during rotation:
- you can identify defects in the bearing’s inner ring
- you can detect manufacturing irregularities
This function therefore allows for a preliminary, non-invasive validation of the bearing’s proper rotation.
The Smart Torque Programming, Prevailing Torque, and Average Torque Monitoring (Rolling) functions are therefore three advanced tools that take the eTensil range with transducers beyond the traditional concept of precision.
In fact, they allow you to:
- detect anomalies during the tightening process,
- control component quality,
- verify the integrity and compliance of parts,
- increase repeatability—and thus tightening precision—and reduce discard rates.
The result is a truly controlled tightening process that is more stable, safe, and reliable, even in the most critical and variable applications.