Integrated thread inspection with the TorqBee EC screw system
Increase process reliability – reduce testing effort
In car and commercial vehicle body construction, threaded nuts and bolts are joined to sheet metal components using thermal or mechanical processes such as press-fitting, projection welding, or stroke ignition. However, where high forces and temperatures are involved, damage to the threads can occur—with a direct impact on downstream screw-fastening processes.
In order to make quality assurance more efficient and reduce manual testing efforts, Wagon Automotive in Nagold has successfully integrated thread threadability testing into its existing assembly process.
Sensor-based testing in fast forward
The thread is checked directly using the battery-powered TorqBee EC screwdriving system from HST, which has been an integral part of the assembly process for many years. Thanks to a measuring accuracy of 0.5%, the integrated torque and rotation angle sensors detect even the smallest deviations in stage 1 of the screwdriving process (rapid feed).
A specific torque monitoring window was defined depending on the thread size and joining method. If this is exceeded during screwing, the system stops immediately. Errors are thus detected before costly consequential damage occurs.
Reliable detection of typical fault patterns
The integrated process monitoring detects, among other things:
Jamming when attaching the torque adapter
Damaged or deformed threads as a result of the joining process
Weld beads or material displacement in the thread area
Greater efficiency – fewer test devices
Integration into the screwdriving process completely eliminates the need for additional testing using a thread limit gauge or gauge ring. This not only reduces cycle time, but also increases process reliability:
Automated, reproducible testing
Immediate feedback during the ongoing process
Documentable quality assurance
Reduced rework and lower follow-up costs
result
The intelligent expansion of the existing screwdriving system infrastructure has created additional added value in terms of quality—without the need for additional hardware or separate testing stations.
The result is a streamlined, economical, and technically reliable manufacturing process with integrated 100% thread inspection.
