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A battery torque wrench is a battery-operated torque wrench that can apply a specified torque without effort from the operator. It contains a planetary torque multiplier or a gearbox. A reaction device that absorbs the torque rather than the tool operator. The torque output is adjusted by varying the voltage on the motor. The battery torque wrench is used to remove stubborn nuts, or to apply accurate torque. The gearboxes can have multiplication ratios up to 125:1.
The battery torque wrench is sometimes confused with a standard impact wrench, due to their similar appearance. A battery torque wrench is driven by continuous gearing, and not by the hammers of an impacting wrench. A battery torque wrench has very little vibration, and excellent repeatability and accuracy.
The benefit of a battery torque wrench is its capability to operate independently of an outside power source, making them useful for applications that require work in tight spaces such as oil or gas pipelines. They also come with electronic features not found on pneumatic wrenches.
In addition, newer wrench models weigh much less than older battery-powered tools and feature an automatic release function which activates once torque is applied to the bolt.
Meanwhile, advancements in battery technology have doubled the life of the batteries used in these wrenches. Newer battery-powered wrenches also allow for brushless motors, leading to a longer motor life.
Torque capabilities of battery torque wrenches range from 30Nm, up to a maximum of 15.000Nm (20 Ft. Lbs - 11.000 Ft. Lbs). The first large-capacity battery torque wrench was invented in 2004 by New World Technologies Inc. (NWT), located in Abbotsford, BC, Canada. These are sold worldwide under the brand name RAD Torque Systems. NWT held a North American patent on the battery torque wrench from 2008 to 2018. The first battery torque wrench with brushless motor was made in Germany in 2013. Because of the power limitations of the accurate motors, tools are available with 2 speeds: one for speed, and one for power.
Battery requirements
A brushless battery motor using lithium-ion battery is the most common source of power for battery torque wrenches. The voltage required is designated by the amp hours of a battery. A complete battery with lower ampere hour must have higher voltage, and a physically larger size, to make up for loss of capacity, and vice versa. Manufacturing a battery motor that can handle higher-Ampere hour batteries are more costly, and the internal electronics are more complicated. The more complex the electronics, the more accurate the motor is when shutting off at a desired torque value. A very common battery combination would be compact 18 volt with a 5.0-ampere hour capacity. This combination varies by manufacturer.
Torque verification
Torque can be verified by a transducer mounted on the outside of the gearbox, connecting to the output shaft of the tool. This transducer can wireless talk via Bluetooth to a mobile smartphone app. This allows the creation of reports, to export incredibly accurate bolting data. In addition, these battery torque wrenches come with a certificate of calibration. The output of these tools can be adjusted by a potentiometer at the calibration facility.
An electric motor is an electrical machine that converts electrical energy into mechanical energy. Most electric motors operate through the interaction between the motor's magnetic field and electric current in a wire winding to generate force in the form of torque applied on the motor's shaft. An electric generator is mechanically identical to an electric motor, but operates in reverse, converting mechanical energy into electrical energy.
A power tool is a tool that is actuated by an additional power source and mechanism other than the solely manual labor used with hand tools. The most common types of power tools use electric motors. Internal combustion engines and compressed air are also commonly used. Tools directly driven by animal power are not generally considered power tools.
A power inverter, inverter or invertor is a power electronic device or circuitry that changes direct current (DC) to alternating current (AC). The resulting AC frequency obtained depends on the particular device employed. Inverters do the opposite of rectifiers which were originally large electromechanical devices converting AC to DC.
A torque wrench is a tool used to apply a specific torque to a fastener such as a nut, bolt, or lag screw. It is usually in the form of a socket wrench with an indicating scale, or an internal mechanism which will indicate when a specified (adjustable) torque value has been reached during application.
A brushless DC electric motor (BLDC), also known as an electronically commutated motor, is a synchronous motor using a direct current (DC) electric power supply. It uses an electronic controller to switch DC currents to the motor windings producing magnetic fields that effectively rotate in space and which the permanent magnet rotor follows. The controller adjusts the phase and amplitude of the DC current pulses to control the speed and torque of the motor. This control system is an alternative to the mechanical commutator (brushes) used in many conventional electric motors.
A DC motor is an electrical motor that uses direct current (DC) to produce mechanical force. The most common types rely on magnetic forces produced by currents in the coils. Nearly all types of DC motors have some internal mechanism, either electromechanical or electronic, to periodically change the direction of current in part of the motor.
A dynamometer or "dyno" for short, is a device for simultaneously measuring the torque and rotational speed (RPM) of an engine, motor or other rotating prime mover so that its instantaneous power may be calculated, and usually displayed by the dynamometer itself as kW or bhp.
A motor–generator is a device for converting electrical power to another form. Motor–generator sets are used to convert frequency, voltage, or phase of power. They may also be used to isolate electrical loads from the electrical power supply line. Large motor–generators were widely used to convert industrial amounts of power while smaller motor–generators were used to convert battery power to higher DC voltages.
A load cell converts a force such as tension, compression, pressure, or torque into a signal that can be measured and standardized. It is a force transducer. As the force applied to the load cell increases, the signal changes proportionally. The most common types of load cells are pneumatic, hydraulic, and strain gauge types for industrial applications. Typical non-electronic bathroom scales are a widespread example of a mechanical displacement indicator where the applied weight (force) is indicated by measuring the deflection of springs supporting the load platform, technically a "load cell".
A cheater bar, snipe, or cheater pipe is an improvised breaker bar made from a length of pipe and a wrench (spanner).
An electronic speed control (ESC) is an electronic circuit that controls and regulates the speed of an electric motor. It may also provide reversing of the motor and dynamic braking. Miniature electronic speed controls are used in electrically powered radio controlled models. Full-size electric vehicles also have systems to control the speed of their drive motors.
An ampere-hour or amp-hour is a unit of electric charge, having dimensions of electric current multiplied by time, equal to the charge transferred by a steady current of one ampere flowing for one hour, or 3,600 coulombs.
An impact wrench is a socket wrench power tool designed to deliver high torque output with minimal exertion by the user, by storing energy in a rotating mass, then delivering it suddenly to the output shaft. It was invented by Robert H. Pott of Evansville, Indiana.
A hydraulic torque wrench is a power tool designed to exert torque on a fastener to achieve proper tightening or loosening of a connection through the use of hydraulics. A torque wrench is applied to the nut either directly or in conjunction with an impact socket. Hydraulic torque wrenches apply a predetermined, controlled amount of torque to a properly lubricated fastener.
A torque multiplier is a tool used to provide a mechanical advantage in applying torque to turn bolts, nuts or other items designed to be actuated by application of torque, particularly where there are relatively high torque requirements.
A torque tester is used as a quality control device to test or calibrate torque controlled tools. This includes electronic torque wrenches, click torque wrenches, dial torque wrenches, electric screwdrivers, air screwdrivers, pulse tools, cordless screwdrivers, nutrunners, and torque screwdrivers. Today's advanced torque testers include the ability to measure in clockwise and counter-clockwise directions, and potentially convert to engineering units. They can also have different modes of operation, or include a certificate from a local regulator.
A torque screwdriver is a screwdriver with components that ensure tightening to a specified torque, ensuring tightening which is sufficient, but not excessive. An insufficiently tightened screw connection may loosen in operation, and excessive tightening can damage parts; for example, if the nuts holding the wheel of a car in place are too loose, or damaged by overtightening, a wheel may come off at speed. Torque screwdrivers are used in mechanical production, manufacturing, and maintenance; their use is part of quality assurance.
Norbar Torque Tools Ltd specialises in the manufacture and worldwide distribution of torque tools for torque tightening, measurement and calibration. The primary office and factory location is in Banbury, United Kingdom and there are also Norbar sales, service and calibration facilities in Australia, United States, New Zealand, Singapore, China and India.
The motor size constant and motor velocity constant are values used to describe characteristics of electrical motors.
An electric motor (E-motor) test stand is a test stand for reproducible testing of electric motors. In addition to the mechanical design, an electric motor test stand consists of accompanying measurement devices, sensors and application software. The bus systems used to control and monitor the test objects are also included in the test stand. There are a variety of different types of test stands, such as developmental test stands, endurance test stands, end-of-line (EoL) test stands, and hardware-in-the-loop (HiL) test stands.
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