How does the torque sensor affect the accuracy and performance of mechanical torque screwdrivers?- Hangzhou Hao Gong Tools Co., Ltd.

As a key component in a mechanical torque screwdriver, the core responsibility of the torque sensor is to accurately measure and feedback the torque acting on the screwdriver head. It uses advanced sensing technologies such as strain gauges and magnetoelastic effects to convert the physical quantity of torque into an electrical signal, which is then amplified and processed by the internal circuit, and finally outputs the torque value in the form of a digital or analog signal for user reference or further control.

The accuracy and stability of the torque sensor are key indicators for its performance evaluation. Accuracy refers to the degree of deviation between the sensor's measured value and the true value, while stability refers to the sensor's ability to maintain its measurement performance unchanged under long-term use or environmental changes. The accuracy and stability of the torque sensor directly determine the torque control accuracy of the mechanical torque screwdriver, and are the basis for ensuring that the tool can accurately and reliably complete various torque operations.

In the manufacturing process of the torque sensor, it needs to undergo a series of rigorous screening and testing to ensure that it has high sensitivity, low drift rate and long-term stability.

Material selection and processing: The manufacturing materials of the torque sensor need to have high sensitivity, high stability, good fatigue resistance and corrosion resistance. Commonly used materials include precision alloys, stainless steel, etc. After the material is selected, a series of processes such as heat treatment and surface treatment are required to improve the performance of the material.
Precision machining and assembly: The manufacture of torque sensors involves precision machining and assembly processes. It is necessary to ensure the dimensional accuracy, shape accuracy and position accuracy of each component, as well as the matching accuracy between the components. During the assembly process, strict calibration and debugging are also required to ensure the measurement accuracy and stability of the sensor.
Performance testing and screening: After manufacturing, the torque sensor needs to undergo a series of performance tests, including sensitivity test, stability test, repeatability test, anti-interference ability test, etc. Through these tests, torque sensors with excellent performance and meeting the requirements can be screened out to ensure the high performance of mechanical torque screwdrivers.
Long-term stability test: In order to verify the long-term stability of the torque sensor, a long-term stability test is also required. During the test, the torque sensor is placed under specific environmental conditions, such as high temperature, low temperature, high humidity, etc., to simulate the working conditions under long-term use or environmental changes, and observe and record the changes in its measurement performance. Through long-term stability testing, it can be further ensured that the torque sensor can maintain its measurement accuracy and stability during long-term use.

The installation position, direction and matching degree of the torque sensor with other components will have an important impact on its performance.
Selection of installation position: The installation position of the torque sensor needs to be selected near the point of action of the measured torque to ensure the accuracy of the measurement results. It is also necessary to consider the impact of the installation position on the working environment of the sensor, such as temperature, humidity, vibration, etc. During the installation process, it is necessary to ensure that the connection between the sensor and the measured component is tight and reliable to avoid measurement errors caused by looseness or misalignment.
Selection of installation direction: The installation direction of the torque sensor needs to be selected according to the direction of the measured torque. Generally speaking, the measuring axis of the torque sensor needs to be consistent with the direction of the measured torque to ensure the accuracy of the measurement results. During the installation process, it is necessary to ensure that the angular deviation between the measuring axis of the sensor and the measured component is within the allowable range to avoid measurement errors caused by angular deviation.
Matching degree with other components: The matching degree of the torque sensor with other components will also affect its performance. For example, the connection between the sensor and the circuit board needs to ensure good conductivity and signal transmission quality; the connection between the sensor and the screwdriver head needs to ensure tightness and reliability to avoid measurement errors caused by looseness or misalignment. In addition, the interference between the sensor and other components, such as electromagnetic interference and mechanical interference, needs to be considered to ensure the normal operation of the sensor.

In practical applications, torque sensors face many challenges, such as complex and changeable working environments, diverse measurement objects, and high measurement accuracy requirements. In order to meet these challenges, a series of solutions need to be adopted.
Environmental adaptability optimization: In view of the complex and changeable working environment, the material, structure, surface treatment and other processes of the sensor can be optimized to improve its fatigue resistance, corrosion resistance and vibration resistance to meet the needs of different working environments.
Optimization of measurement object adaptability: In view of the diverse measurement objects, the measurement range, sensitivity and other parameters of the sensor can be optimized, and a combination of multiple measurement principles can be used to achieve accurate measurement of different measurement objects.
Improved measurement accuracy: In view of the high measurement accuracy requirements, the measurement accuracy and stability of the sensor can be improved by adopting high-precision sensors, high-precision circuits, high-precision calibration methods and other means.
Intelligence and networking: With the development of intelligence and networking technologies, torque sensors can be combined with intelligent control systems, remote monitoring systems, etc. to realize remote monitoring, intelligent diagnosis, early warning alarm and other functions, and improve the intelligence level and maintenance efficiency of tools.