The electric torque wrench is a powerful tool widely used in industrial and mechanical applications. However, after prolonged use, it's common for the output power to gradually decrease. As time goes on, the performance of the wrench diminishes until it eventually stops working altogether. This decline in efficiency is primarily due to the internal mechanics of the tool. The motor drives the planetary gear system, which reduces the speed and increases the torque before transferring it to the impact head. The impact head then rotates the wrench shaft through its claws, allowing the tool to deliver the required force.
Through careful disassembly and inspection of used electric torque wrenches, technicians have consistently observed severe wear on the working surface of the wrench shaft. This worn area forms an inclined plane at approximately 45 degrees relative to the original surface. This slope causes the impact forces during operation to be distributed unevenly, leading to changes in the stress conditions of internal components. Over time, this uneven distribution contributes to increased wear and mechanical failure.
Based on these findings, it's clear that the primary cause of electric wrench failure is the excessive wear on the wrench shaft. To extend the lifespan of the tool, it's crucial to address this issue. Since the wrench shaft experiences more wear than the impact head, solving the problem of the shaft's wear is key. If we can replace just the worn part instead of the entire component, the overall durability of the tool can be significantly improved.
One effective solution is to design the wrench as a split-type rather than an integral one. This allows the working surface to be removed and replaced individually based on wear. By selecting appropriate materials for the active working surface—such as high-carbon steel—and applying a heat treatment process involving quenching followed by tempering, the surface can achieve high hardness and sufficient toughness. This ensures the component can withstand repeated impacts without breaking.
Additionally, this design enables mass production and long-term replacement, making maintenance more convenient and cost-effective. With this approach, the issue of electric wrench failure can be effectively resolved, ensuring longer service life and better performance in real-world applications.
Jiangsu Zhongyi Tools and Riggings Co., Ltd. , https://www.zy-rigging.com