The torque setting and selection of the right speed are the two most important factors for achieving a perfect screwdriving result, since they precisely adjust the screwdriving process to the screw properties, its diameter and, most importantly, the material.

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Fastening screws is one of the common jobs in manufacturing plants, but using manual screwdrivers would cause fatigue in many operators.  This would eventually lead to costly mistakes that would have to be corrected.  This is where the electric screwdriver shines.  Electric screwdrivers provide plenty of advantages including increased power, precision and compact size with improved handling.

There are two different types of screwdrivers: brushless and brushed.  We covered the differences brushed and brushless screwdrivers in a previous article. The main difference between the tools is that brushed screwdrivers utilize a carbon brush that helps to create the electricity within the screwdriver.

Brushless Screwdrivers, as it says in the name, do not use brushes.  This gives an advantage to brushless screwdrivers, as they produce less friction and heat creates less wear and tear on the machine giving it a longer lifespan.  This makes it a great choice for high volume production lines.

Here are the steps for using a plug-in brushless electric screwdriver:

How to use an Electric Screwdriver

1. Prepare Your Setup

Securely connect the power tool cable to both screwdriver and transformer.  Establish a firm connection to avoid interruptions during use.

2. Power Up The Transformer

Turn on the transformer, plug the transformer power cord into the appropriate socket on the back of the screwdriver. Plug the other end of the power cord into a reliable power outlet.

3. Check the Power Indicator

Ensure that the power indicator is turned on. If the indicator light is off, be sure that the transformer’s power switch is set to “on”.

4. Choose and Attach your Bit

Choose the correct screwdriver bit for your application, and ensure that

5. Adjust Torque Settings

To increase the torque, locate the adjustment nut and turn it clockwise. For the reverse, turn it counterclockwise. Accurate results, test the adjusted torque using a reliable torque-testing system.

6. Test Rotation and Operation

Turn the driver on to ensure proper rotation.  Lever start tools, gently squeeze the lever to engage the tool. Push-to-start models, apply light downward pressure on the tool’s nose

7. Reverse Operation for removal

To remove screws, flip the switch to reverse mode and apply gentle pressure to unscrew.

Benefits of Brushless Screwdrivers

-Energy Efficiency

As mentioned earlier, choosing to use Brushless Screwdrivers on your assembly lines helps to provide more power without the wasted energy. Brushless motors operate through electronic commutation, unlike brushed motor screwdrivers which transfer electricity through physical contact of carbon brushes. This difference in design reduces energy loss and makes them more power-efficient.

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Why it matters in manufacturing:

• Brushless motors consume a lot less power – brushless motors convert more electrical energy into me
• Less wasted energy means longer battery life – for cordless screwdrivers with torque control, this mean longer usage without swapping batteries and a lot less downtime
• Consistent power at all rpm – compared to its brushed counterpart, which experience power fluctuations, brushless motors maintain a steady torque output across different RPMs.

-Consistency & repeatability

Brushless motors offer advanced electronic control, which allows better torque accuracy and repeatable fastening. This is critical for preventing product failures.

Why it matters in Manufacturing:

• minimized torque drift – brushed motors experience torque loss over time due to the deteriorating brushes per use, but brushless motors maintain consistent torque output
• Better fastener integrity – inaccurate torque can strip screws or leave the loose, leading to inevitable defects. Brushless screwdriver provide more accurate and repeatable fastening.
• integration with smart systems – many brushless models can be integrated with torque tracking and data logging, ensuring full traceability in applications

-Low maintenance

Because of the elimination of carbon brushes, brushless screwdrivers experience less wear and tear, which means they experience fewer breakdowns and lower maintenance costs.

Why it matters in manufacturing:

• No Carbon Brush replacements – brushless motors do away with frequent brush replacements, reducing downtime needed to maintain the tools.
• less heat buildup – brushless motors generate less internal friction, reducing the risk of overheating which can degrade components over time.
• High duty cycles – because there is less heat buildup, the brushless tools run cooler and can operate without needing cool-down periods, increasing productivity

Common Mistakes and Best Solutions for Electric Screwdrivers

1. Using Too Much Torque (Over-Tightening Fasteners)

The mistake: In the world of fastening, many operators assume that “tighter is better”, but there are many serious issues that this can cause:

• stripped screw heads – too much torque to the screw heads can cause the screw heads to wear down or round out the screw head making it impossible to remove
• thread damage – over tightening can strip the threads inside a hole or deform them, reducing the strength of the fastener
• material deformation – over torquing on workpieces like electronics, plastics, or aluminum can cause the pieces to deform
• weakened assemblies – if torque is not controlled properly, parts may become structurally weaker over time.

Solution: Proper torque adjustment & Control

The solution to combating over-tightening issues can be a combination of a few different things:

1. Use a Torque Tester for Verification – when precision becomes a critical part of the application, use a torque tester to validate your settings.

• torque analyzers allow you to calibrate your electric screwdrivers to confirm that they are consistently delivering the correct force
• testing on sample materials before production to ensure that the current torque setting does not cause damage.
• schedule regular maintenance checks to ensure accuracy of the screwdriver, this is an important step, especially in high-volume manufacturing

2. Use a screwdriver with a precision shut-off clutch – using a precision shut-off clutch is highly recommended to prevent over-tightening.

• automatic shut-off feature – stops the screwdriver once the pre-set torque is reach, ensuring uniform fastening
• reduces operator error – operators don’t manually control the force, which helps to reduce wrist strain and increasing efficiency.

2. Not Calibrating the Screwdriver before Precision Work

The Mistake: forgoing torque calibrations can cause a number of different issues with products, including: inconsistent fastening results, loose screws, or critical product failures.

Torque settings on screwdrivers are designed to ensure consistent torque through every tightening process. Electric screwdrivers will go through a process of normal wear and tear and cause the driver’s torque accuracy to drift over time. This could lead to issues such as under-tightening and over-tightening as mentioned previously.

Solution:

1. Use a Torque Tester – torque testers are essential to measuring the actual output of the screwdriver.

• attach the screwdriver to the torque tester and run it for several cycles
• compare the results to the intended torque setting
• at the first sign of any deviation, then adjust the torque setting appropriately

2. Set Up a Regular Calibration Schedule

Electric screwdrivers used in high production assembly require frequent testing and calibration to maintain its accuracy and precision. The best practice is to follow a weekly or monthly verification.

• for high-volume production, weekly calibration should suffice
• moderate usage, monthly or even bi-weekly calibration
• for occasional use every 3-6 months

3. Verify Torque before Critical Work

For high-precision applications, it is always a good idea to test your screwdriver on a torque verification tool before assembly begins

4. Consider Digital Torque-Controlled Screwdrivers

For manufacturers that need high repeatability, transducerized torque Screwdrivers provide real-time torque monitoring. These tools can store multiple torque settings and ensure consistency.

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