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Transforming Traditional Torque Tools Into Smart, Transducerized Tools

Posted on by ZIPP GROUP

How ZIPPTORK’s Wireless Rotary Torque Transducer Enables Real-Time Verification and Complete Data Collection

 

 

In modern manufacturing, torque accuracy is now essential rather than optional—it’s vital for ensuring product reliability, safety, and adherence to global quality standards. However, most factories still depend on traditional torque tools—impact wrenches, pulse tools, pneumatic tools, and many electric tools—that lack torque feedback and data traceability.

 

 

ZIPPTORK’s Wireless Rotary Torque Transducer (TTES / TTEB / TTAS / TTEH Series) completely transforms this. By connecting directly between the tool and the fastener, it turns any legacy torque tool into a smart, transducer-equipped, data-driven device, allowing for torque verification, real-time measurement, process monitoring, and automatic data collection on every fastening cycle.

 

 

1. Real-Time Torque Verification—Directly on the Production Line

 

 

Traditional calibration checks require removing the tool from the assembly line and testing it on a bench tester, which only verifies performance at that moment. But ZIPPTORK’s wireless rotary torque transducer performs in-line verification during actual tightening operations.

 

 

How it works

 

 

  • Installed between the tool and the socket/bit.
  • Measures torque during real fastening (including dynamic torque profiles of impact and pulse tools).
  • Sends real-time data wirelessly (BLE/RF) to a controller, gateway, or PC.

 

 

This provides:

 

 

  • Instant verification that the tool is delivering the correct torque.
  • Immediate detection of calibration drift or mechanical issues.
  • Data to validate every single fastener, not just sample checks.

 

 

With ZIPPTORK, torque verification becomes continuous—not periodic.

 

 

 

 

2. Complete Data Collection for Every Task and Every Fastening

 

 

Many industries (automotive, aerospace, heavy equipment, energy) now require 100% traceability for critical joints. ZIPPTORK’s transducers make this possible without replacing existing tools.

 

 

What data can be collected from every tightening?

 

 

  • Peak torque
  • Angle (optional with integrated angle encoder)
  • Torque curve profile
  • OK/NOK judgment
  • Time Stamp
  • Operator ID and station ID
  • Cycle count and tool performance trend

 

 

Where the data goes

 

 

ZIPPTORK’s wireless transducer can connect to:

 

 

  • ZIPPTORK Torque Controller (TCA / TCB / TCC)
  • ZIPPTORK TMS Software (Torque Management System)
  • MES/ERP/QMS systems through APIs
  • Cloud dashboards or factory IIoT analytics platforms

 

 

This turns every fastening point into a source of actionable manufacturing data—critical for Industry 4.0.

 

 

 

 

3. Upgrade Any Existing Torque Tool into a Transducerized Smart Tool

 

 

Most torque tools on the market—air impact wrenches, hydraulic torque wrenches, pulse tools, and many DC tools—are not transducerized, meaning they provide no torque feedback.

 

 

ZIPPTORK changes that.

 

 

Compatible tool types

 

 

  • Pneumatic impact wrenches
  • Pneumatic pulse tools
  • Air ratchets
  • Cordless impact wrenches
  • Cordless assembly tools
  • Manual torque wrenches
  • Torque multipliers / Nutrunners
  • Hydraulic torque wrenches

 

 

Immediate upgrade benefits

 

 

With one installation:

 

 

  • The tool becomes a torque device with built-in feedback.
  • The factory can perform accurate torque verification during production.
  • Every fastening is automatically recorded.
  • No need to buy expensive transducerized DC tools.

 

 

This approach dramatically reduces investment costs while maintaining (or improving) data traceability.

 

 

 

 

4. Improving Production Quality and Reducing Rework

 

 

Using ZIPPTORK’s wireless rotary transducer directly improves production efficiency and quality control.

 

 

Key benefits

 

 

  • Eliminates quality escapes by catching torque deviation immediately
  • Reduces rework and warranty claims through full traceability
  • Identifies worn tools early through torque signature analysis
  • Accelerates root-cause analysis with detailed torque curves
  • Supports certification & compliance (ISO 5393, VDI/VDE, automotive standards)

 

 

For global OEMs and Tier 1 suppliers, these benefits directly translate to lower costs and more stable production.

 

 

 

 

5. Plug-and-Play Integration with Industry 4.0 Systems

 

 

ZIPPTORK’s wireless transducer is engineered for modern connected factories:

 

 

  • Supports BLE 5.0, RF proprietary, and optional Wi-Fi gateways
  • Low power consumption for over 8 hours of operation
  • Highly impact-resistant design for use with pulse and impact tools
  • Compact modular mechanical design fits various tool sizes

 

 

The transducer becomes a smart sensing node within the customer’s IIoT network—turning raw torque processes into valuable, analyzable data streams.

 

 

 

 

6. A Practical Upgrade Path for Manufacturers Worldwide

 

 

Instead of replacing their entire fleet of pneumatic or cordless tools with expensive DC transducerized tools, manufacturers can:

 

 

Option A: Keep existing tools

 

 

Option B: Add ZIPPTORK Wireless Rotary Transducers

 

 

Result: Achieve complete digitalization and torque traceability at a fraction of the cost.

 

 

This makes ZIPPTORK a powerful solution for:

 

 

  • Automotive final assembly
  • Heavy machinery
  • Truck and bus manufacturing
  • Aerospace MRO
  • Wind turbine construction
  • Industrial equipment assembly
  • Any critical bolting process

 

 

 

 

ZIPPTORK’s Wireless Rotary Torque Transducer is more than a measurement device—it is a complete, innovative tool upgrade platform. By providing real-time torque verification and comprehensive fastening data, it converts traditional torque tools into intelligent, connected, transducerized tools suitable for modern Industry 4.0 environments.

 

 

Factories gain a practical, cost-effective path to achieving:

 

 

  • Full traceability
  • Better quality control
  • Reduced downtime
  • Data-driven process optimization

 

 

And most importantly: every fastening becomes verifiable, recordable, and trusted.

news

The 2018 SEMA Show

Posted on by ZIPP GROUP
The 2018 SEMA Show
31
Jan

The SEMA Show takes place October 30 – November 2, 2018 at the Las Vegas Convention Center located at 3150 Paradise Road, Las Vegas, NV 89109.

The SEMA Show is the premier automotive specialty products trade event in the world. It draws the industry’s brightest minds and hottest products to one place, the Las Vegas Convention Center. In addition, the SEMA Show provides attendees with educational seminars, product demonstrations, special events, networking opportunities and more.

The 2017 SEMA Show drew more than 70,000 domestic and international buyers. The displays are segmented into 12 sections, and a New Products Showcase featured nearly 3,000 newly introduced parts, tools and components. In addition, the SEMA Show provides attendees with educational seminars, product demonstrations, special events, networking opportunities and more…

Note: The SEMA Show is a trade-only event and not open to the general public.

 

The 2018 SEMA Show. Oct 30th – Nov 2nd. Las Vegas Nevada. Booth Number not yet available. For more information visit HERE

news

2018 Performance Racing Industry Show

Posted on by ZIPP GROUP
2018 Performance Racing Industry Show
31
Jan

The PRI Trade Show Is The Epicenter Of New Racing Technology

  • Buyers From All 50 States And 70+ Countries
  • 1,100 Exhibiting Companies Totaling Over 3,300 Booths
  • More New Racing Products Than Anywhere On Earth

Attention Racing Industry Suppliers:

  • Capture Your Share Of This Powerful Market
  • Conduct Business Face To Face With Racing Key Decision Makers
  • Get Your Products Into The All-Important Racing Distribution Pipeline
  • Exhibit Space Is Still Available!

Attention Racing Industry Buyers:

  • Preview The Latest Advances In Racing Technology And Products
  • Shop The Latest Machining And Fabricating Equipment
  • Get Ready For 2017! You Can’t Afford To Miss A Single Day
  • Preregister Online, And Receive Your Credentials In The Mail

Don’t miss the three biggest business days in motorsports when the worldwide racing industry gathers in Indianapolis, December 7 – 9, 2017, for the 30th Annual Performance Racing Industry Trade Show.

1,100 companies will display the latest advances in racing products and race engineering. Engine parts, suspension components, data acquisition, safety gear, new metal alloys and coatings, machining equipment, race electronics—it’s all part of the world’s largest racing trade show.

Arriving from 70+ countries and all 50 states, buyers will scour the displays to source the new technology that will be winning races next year. It’s all hardcore racing. No fuzzy dice. No neon windshield wipers. The PRI Trade Show is so big, they can’t afford to miss a single day.

Attendees are pre-qualified. Admission is complimentary, but they must all prove they own, manage or are employed by a racing business. Buyers for tens of thousands of racing retail stores, warehouse distribution centers, professional race engine builders, race car production companies, are making 2018 inventory decisions in each exhibit. They represent the all-important distribution pipeline for racing products. In the US alone, there are more than 400,000 racers, the vast majority of whom are at the grassroots level, purchasing products from their local race store or race engine builder.

Thousands of professional race teams, from NASCAR Cup teams to NHRA Top Fuel, Japan to the UK, send buyers to ensure they are current with today’s race technology.

If you are a supplier of components, equipment or engineering services active in the growing racing industry, capture your share of this powerful market by exhibiting. Conduct business face to face, and get your products into the all-important racing distribution pipeline!

If you are a racing industry buyer, we guarantee you’ll see more new racing products and technology than anywhere on Earth!

Please note that children under 16 will not be permitted to enter the Show.

Register Online Today!

 

ZIPP TOOL is attending the 2018 Performance Racing Industry Show. Dec 6th – 8th. Indianapolis, Indiana. Booth Number not yet available. (Will update once confirmed) For more information visit HERE

news

New Bolt Tightening Technology @ 2017 Stuttgart Fastener Fair

Posted on by ZIPP GROUP
New Bolt Tightening Technology @ 2017 Stuttgart Fastener Fair
29
May

New Bolt Tightening Technology
For
Achieving the Most Accurate Bolted Joints Excellence

 

ZIPP will launch the most advanced bolt tightening technology at the upcoming Stuttgart Fastener Fair 2017 in Stuttgart this March from 28th – 30th. The new technology includes the Sensing Bolt, the Tagged Bolt, and the Torque Transducer with RFID Reader, the Transmitting Socket, and the Transmitting Cap, all capable of communicating with a Controller.

The Sensing Bolt is the bolt embedded with a strain gauge, an MCU, a battery and a wireless unit driven by a patented Transmitting Socket to keep transmitting the sensed strain signal to the Controller or Monitor wirelessly during bolting process. It provides the trace-ability of the bolt production, bolt assembly record, even the control ability of the bolting sequence. The clamping force of the Sensing Bolt can be monitored remotely through the Transmitting Cap after the bolt fastened. The effective transmitting distance of the Transmitting Cap is 15m～20m. It is to be placed every 15m～20m or even a custom-made more powerful one for longer distance transmission such as 1000M or longer to act as a Repeater for transmitting the sensed strain signal endlessly even in hard to reach areas.

The patented Transmitting Cap was developed to keep supplying battery power to the Sensing Bolt after fastened. It keeps transmitting the strain signal from the bolt to the peripheral receiver for monitoring the bolt tightening status remotely and periodically.

Another economic alternative solution is the patented Tagged Bolt along with the patented Torque Transducer with RFID Reader. It utilizes the special features of the RFID Tag, readable and writable for enabling to do bolting sequence control as well as outstanding trace ability of bolt production and bolt assembly record.

Our new technology has been proven to be the ultimate solution for achieving the most accurate bolted joint tightness and monitoring its condition after assembly. It’s great for production control with the traceable record of bolt production, assembly and bolting sequence for the best of joint quality assurance and reliability.

Please visit our booth Hall: 5 Booth# 2436 at the show for a demonstration of our latest innovations and further discussion about how to apply or implement this new technology in your bolting works.

news

The Fundamentals of Torque Control in Modern Assembly Lines

Posted on by ZIPP GROUP

The Fundamentals of Torque Control in Modern Assembly Lines

Empowering Precision, Safety, and Efficiency with ZIPPTORK Smart Torque Solutions

 

 

In every manufacturing sector—from automotive and aerospace to medical devices and electronics—the importance of torque control cannot be overstated. A single improperly tightened bolt can lead to vehicle wheel detachment, life-critical instrument failures, or malfunctioning electronic products.

Without torque control, engineers risk product failure, safety incidents, and rising costs from scrap and rework. Yet, in many factories, torque management remains overlooked or misunderstood, especially in traditional pneumatic tool environments.

 

 

Why Torque Control Matters

 

 

Torque represents the rotational force applied to a fastener. Controlling it ensures the proper clamp load—the real force holding components together. When the torque is too low, joints loosen under vibration; when it is too high, threads strip or parts deform.

Whether assembling a pacemaker, repairing an aircraft engine, or mounting heavy equipment, achieving the correct torque for every bolt is essential for safety, reliability, and traceability.

 

 

Variables That Affect Torque Accuracy

 

 

Several factors influence torque:

 

 

  • Friction coefficients (thread, under-head, surface)

  • Tool type and condition (impact, clutch, pulse)

  • Joint characteristics (soft vs. hard joints)

  • Operator technique

  • Environmental factors such as temperature or vibration

 

 

These variables make it critical to measure and monitor torque, rather than relying solely on theoretical values or tool calibration.

 

 

ZIPPTORK: Bridging OT and IT for Smart Torque Control

 

 

Traditional pneumatic tools excel in durability and power, but historically lacked data feedback. ZIPPTORK bridges this gap by integrating Operational Technology (OT) with Information Technology (IT)—enabling smart, traceable fastening under Industry 4.0.

 

 

1. Smart Torque Controllers (TCA/TCB/TCC Series)

 

 

ZIPPTORK torque controllers transform conventional pneumatic or hydraulic tools into precision-controlled systems.

 

 

  • Regulate output torque in real time

  • Interface with torque and bolt-load sensors

  • Record torque-angle curves and time-series data

  • Transmit results to IIoT/MES systems via Wi-Fi or Bluetooth

 

 

This enables production lines to automatically log tightening data, ensuring every fastener meets its specification.

 

 

2. Wireless Rotary Torque Transducers (TTES / TTEB / TTAS / STA Series)

 

 

ZIPPTORK’s patented anti-vibration wireless transducers can be integrated directly into impact, pulse, or clutch-type wrenches.

 

 

  • Measure torque dynamically under shock and vibration

  • Transmit signals wirelessly to controllers or gateways

  • Eliminate wiring constraints on moving tools

  • Maintain ±5–10 % accuracy in demanding environments

 

 

These transducers bring real-time torque visibility to pneumatic tools—once considered impossible.

 

 

3. Bolt Load Monitoring Systems (BLT & SWC Series)

 

 

For critical joints where clamp force matters more than torque, ZIPPTORK offers bolt-load transducers and sensing washers.

They measure actual bolt tension, not just torque, providing a direct measure of joint integrity.

This ensures optimal preload and prevents fatigue or loosening in heavy-duty applications such as wind turbines, rail bogies, and structural assemblies.

 

 

Smart Assembly Line Integration

 

 

In a modern assembly line, ZIPPTORK systems form a closed-loop fastening ecosystem:

  1. The operator uses a pneumatic impact or pulse tool equipped with a wireless torque transducer.

  2. The torque controller receives live data and applies real-time correction or cutoff logic.

  3. Each fastening record (torque, angle, time, status) is transmitted to the plant’s MES/QMS/SPC systems.

  4. Supervisors gain traceability reports, SPC charts, and quality analytics dashboards for complete transparency.

 

 

This seamless integration turns legacy pneumatic lines into data-driven smart assembly stations, ready for Industry 4.0 compliance.

 

 

From Precision to Prediction

 

 

Torque control is not merely a quality requirement—it’s a foundation of safety, reliability, and digital manufacturing. With ZIPPTORK’s advanced controllers, sensors, and bolt-load monitoring systems, manufacturers can ensure every joint is tightened correctly, verified instantly, and traceable globally.

By transforming traditional pneumatic tools into intelligent systems, ZIPPTORK empowers industries to achieve:

 

 

  • Higher accuracy

  • Fewer fastening errors

  • Complete traceability

  • Predictive maintenance and quality insights

 

 

ZIPPTORK – Smart, Affordable, Traceable.

The future of torque control and bolt-load monitoring for Industry 4.0.

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