ME LABORATORY 2 BSME 4-2

PRELIM PROJECT
TORQUE TESTING RIG
OPERATIONAL MANUAL

Introduction:

A torque testing machine is a specialized device utilized to

measure the torque or rotational force applied to an object. Its primary
function is to assess the strength and performance of components,
fasteners, and assemblies that involve rotational force. Torque testing
machines are invaluable tools in product development, manufacturing, and
quality control across various industries.
Torque testing machines have several essential functions, the
1. Torque Measurement
• It accurately measures the rotational force applied to
objects, crucial for assessing product performance.
2. Quality Control
• Torque testing ensures products meet specified torque
standards, maintaining consistent quality.
3. Calibration
• Used to calibrate torque tools for precise assembly and
manufacturing processes.
4. Product Development
• Aid in optimizing torque-related features during product
design.
5. Failure Analysis
• Identify weaknesses or defects in components to prevent
product failures.
6. Fastener Testing
• Assess the performance of screws, bolts, and nuts.
7. Material Testing
• Evaluate material strength and suitability for
applications.
8. Safety Testing
• to ensure secure fastening in critical safety components.
9. Production Line Integration
• Perform real-time quality checks in mass production.
10. Data Analysis
• We collect and analyze torque data for insights and
improvements.
11. Documentation
 • To maintain records for compliance with standards and
regulations.

Safety Precaution:

● Make sure you are trained ,unauthorized person is not allowed to

operate this machine.

● Wear personal protective equipment before you operate this machine.

● Inspect the machine for any signs of wear ,damage or malfunction

.Address any issues promptly.

● Make sure that workspace is clean and organized to avoid trip

hazard.
● Ensure the torque test rig has emergency stop button which is
accessible during unexpected situations.

● Do not operate the machine outdoor or in wet areas to avoid

electrical hazard.

● Follow manufactures guidelines, set up the machine on a flat surface

not on a slope surface.

● Use the machine in a well-ventilated area to avoid exposure from

gases or fumes.

● Handle the samples and materials with care to avoid dropping which
could lead to damage.
● Used specified tools for testing, never put your hands beside the
machine moving parts during operation.

● Always disconnect the power supply to the rig when doing adjustment
and maintenance to prevent accidental activation.

● Maintain a safe distance from the rig during testing to prevent

accidental contact with moving parts.

● Follow specified load limits and torque for the machine. Do not
exceed the machine’s capacity.

● Always turn off and unplug the machine when not in use, especially
at the end of the test.

● Maintain records of inspection and maintenance for Safety protocols

compliance.
Equipment/System Overview:

Torque test machines measure the torsional strength, stiffness

and stress-strain properties of materials and products which are
the ideal solution for biomedical, automotive, and aerospace
applications. Torsional testing machines are used to simulate real
life service conditions and to check product quality for products
such as drill tool bit tips and medical devices, screws and other
fasteners, wire, and much more.

Most electricians don’t realize that a bolt and nut is not a

means for AC Current to flow through. The actual resistance of the
bolt is a much higher resistance that the resistance of two
sandwiched pieces of copper.

When a bolt is torqued to spec, it firmly applies pressure to

the copper, making the resistance lower. Low resistance is good
when pertaining to electric. Current flows in the path of least
resistance. So, if the copper connection is lower than the bolt,
all current will go through the copper and not the bolt. That is
the purpose. If its over torqued bolt caused the bolt to melt in
half while testing. The National Electrical Code requires that
equipment be installed according to its listing and labeling. This
requirement includes verifying the given torque setting.

Components

● Torque Transducers

Torque transducers convert torsion (Surface shearing stress)

corresponding to a torque of the shaft to an electric quantity
(Voltage), and then output signals through slip ring, brush, rotary
transformer and photo transmittance. They ensure accurate and easy
measurement of the torque transmitted from the target object under
conditions of standstill to high-speed rotation. Since all these
transducers use strain gages for the sensing element, precise and
stable measurement is assured even for long-term operation under
severe conditions. Thus, they are widely used not only for
experiments and research but also for industrial measurement.
● Joint Simulators or Run-down-fixtures

Joint Simulators or Run-down-fixtures are required for accurate

torque measurement of power torque controlled tools (electric,
hydraulic or pneumatic). They simulate real-world application
conditions, allowing the power tool motor to ramp-up to freely
rotate several times before building resistance to rotation. The
resistance will increase until the torque that the tool’s clutch
is set at is achieved and the tool stalls or shuts off.

● Digital display

A key component of modern torque testers is the digital display. A

digital display is used to measure the output signal from the
transducer and calculates that reading into a torque value that is
displayed on screen. In most cases the display and transducer are
contained together inside a housing. This is known as a “Desktop
Torque Tester”. External rotary and stationary transducers can be
used with portable displays (handheld torque analyzers).

● Single Phase AC Torque Motor

Torque motors are designed to provide high starting torque and

sloping characteristics (torque is highest at zero speed and
decreases steadily with increasing speed), along with operating
over a wide speed range. They also provide stable operation,
especially in the low speed range or under a locked rotor condition.
Available output power of 3 W (1/250 HP) up to 20 W (1/38 HP) with
a maximum low speed / stalled rotor torque of 4.97 N-m (88 lb-in.).

● SEW Eurodrive Geared Motor

Torque motors are AC squirrel -cage motors designed to operate with
rated torque at a stand starting torque). They are equivalent to
springs with an unlimited spring travel Geared to motors move
flaps, gates, or switches. They move press dies into die change
position in all these cases, they serve as a drive in which a stop
position must be reached and held following a short movement. While
under voltage ,they can also have their speed matched temporarily
by another drive and the continue running under their own force.

Schematic Diagram

Fig. 1 Schemas of (a) the torsion testing machine without a torque

cell and photograph of the grippers, (b) equivalent electric circuit
model of the electrical structures of the torsion testing machine
in (a), and (c) the torsion testing machine with a torque cell

Working Principle
 Fig 2.Metal Foil strain gage
Torque sensor working principle, which is the strain gauge (aka
Strain gage). Metal foil strain gauge is a force transducer whose
electrical resistance varies with applied force. In other words,
it converts strain derived from force, pressure (aka industrial
pressure sensors for pressure measurement), tension, compression,
torque, weight (aka weight sensors), etc… into a change in
electrical resistance, which can then be standardized for measuring
torque.Structurally, a reaction torsion sensor is made of a metal
body (also called flexure) to which foil strain gauges are bonded.
The sensor body is usually made of aluminum or stainless steel,
which gives the transducer two important characteristics: (1)
provides the sturdiness to withstand high torques; and, (2) has the
elasticity to minimally deform and return to its original shape
when the torque is removed.

When torque is applied (clockwise or counterclockwise), the metal

body acts as a “spring” and is slightly deformed, and unless it is
overloaded, it returns to its original shape. As the flexure
deforms, the strain gage also changes its shape and consequently
its electrical resistance, which creates a differential voltage
variation through a Wheatstone Bridge circuit. Thus, the change in
voltage is proportional to the torque applied to the transducer,
which can be calculated via the torque sensor circuit voltage
output.

Start up and Shutdown Procedures:

Start up procedures:

1. Safety Preparations: Safety Preparations are crucial when

working with a torque test machine to prevent accidents and
ensure the well-being of operator/s.
• Always wear appropriate PPE, including safety glasses,
hearing protection , gloves, and any other required
protective gear.
• Before use, inspect the machine for any visible damage or
wear. Ensure that all components are in good working order.
• Keep the work area around the machine clean and free of
clutter, obstructions, and trip hazards.
2. Machine Evaluation: Inspecting a torque test machine before
use is critical to ensure its safe and proper functioning.
• Perform a thorough visual inspection of the entire machine.
Look for any visible signs of damage, wear, or corrosion.
• Clear the workspace around the machine of any obstacles,
debris, or materials that could interfere with the
inspection.
• If the machine uses fixtures to hold the test samples,
examine them for damage or wear. Confirm that they are
securely fastened and aligned.

3. Activate the machine: Powering on a torque test machine should

be done carefully and in accordance with the manufacturer's
instructions.
• Confirm that the machine is properly connected to a
suitable power source.
• Locate the main power switch for the torque test machine.

4. Sample Setup :Setting up a sample on a torque test machine

involves securing the object or sample you want to test for
torque to the machine's testing fixture.
• Choose the sample or object you want to test for torque.
Ensure that it is representative of the materials or
components you intend to assess.
• Prepare the sample by ensuring it is clean and free of any
contaminants that could affect the test results. Remove any
surface oil, dirt, or debris.

5. Emergency guidelines: Emergency guidelines for a torque test

machine are critical to ensuring the safety of operator/s and
preventing damage to the equipment in the event of unexpected
incidents or malfunctions.
• Familiarize yourself with the location of the emergency
stop button on the torque test machine.
• If there is any sign of electrical malfunction, such as
sparks, smoke, or unusual odors, immediately turn off the
main power switch of the machine.
• In the event of a sample or fixture failure, immediately
press the emergency stop button to halt the test.

6. Preliminary Test: Conducting a test run on a torque test

machine is essential to ensure that the equipment is
functioning correctly and that it is properly set up for
accurate torque measurements.
• Initiate the test run from the control panel. This may
involve pressing specific buttons, entering test
parameters, and confirming the start of the test.
 • Continuously monitor the test run to ensure that the sample
remains securely attached to the fixture and that the
torque is applied as per your testing parameters.

7. Adjustment: Adjustment is a critical process in torque test

machines to ensure that the measurements are accurate and
consistent.
• Before conducting any torque tests, it's crucial to ensure
that the machine is properly calibrated to read zero torque
when no force is applied.
• Ensure that the machine is set to measure torque in the
appropriate units (e.g., Newton-meters, inch-pounds,
footpounds). Make adjustments as needed to match the
required units for your testing.

8. Testing Phase: Conducting a full torque test on a torque test

machine involves subjecting a sample or object to controlled
torque forces to measure its torque characteristics. The
specific steps and parameters for a full test will depend on
the testing requirements, standards, and the machine's
capabilities.
• Continuously monitor the test to ensure that the sample
remains securely attached to the fixture and that the
torque is applied as per your testing parameters.
• Once the full torque test is completed, carefully release
the torque applied to the sample through the control panel.

Shutdown Procedure for Torque Test Rig Machine:

1. End Testing: Stopping a torque test on a torque testing

machine should be done carefully to ensure the safety of
personnel and the integrity of the test results.
• Before stopping the test, ensure that all personnel
involved are wearing the necessary personal protective
equipment (PPE) such as safety glasses and gloves.
• After initiating the stop or pause sequence, wait for the
machine to respond and complete the action. The machine may
need a brief moment to safely stop all operations.

2. Release Sample: Releasing the sample from a torque test

machine should be done with care to avoid damaging the sample
or the machine.
• Visually inspect the sample and the fixture to ensure that
there are no obstructions or issues that could hinder the
safe removal of the sample.
• Identify the release mechanism or method used to secure the
sample to the fixture. This may involve clamps, grips,
screws, or other fasteners.
• Carefully and slowly release the sample from the fixture
by undoing the fasteners or following the specific release
 procedure. Avoid using excessive force that could damage
the sample or the fixture.

3. Machine Power down: Turning off a torque test machine should

be done carefully to ensure safety and proper machine
shutdown.
• Locate the main power switch or control panel on/off
button.
• Switch the main power switch to the "Off" position or press
the control panel's power button to turn off the machine.
• After turning off the machine, wait for it to respond and
complete the shutdown sequence.
4. Emergency guidelines: Emergency guidelines for a torque test
machine are critical to ensuring the safety of personnel and
preventing damage to the equipment in the event of unexpected
incidents or malfunctions.
• Familiarize yourself with the location of the emergency
stop button on the torque test machine.
• If there is any sign of electrical malfunction, such as
sparks, smoke, or unusual odors, immediately turn off the
main power switch of the machine.
• In the event of a sample or fixture failure, immediately
press the emergency stop button to halt the test.

5. After-test cleanup: Proper after-test cleanup in a torque

testing machine is essential to maintain equipment integrity,
ensure safety, and prepare for future testing.
• Clean the testing area and remove any debris or materials
used during the testing process.

6. Documentation: Documentation is a critical aspect of torque

testing. Properly documenting the testing process and results
is essential for research, experiment etc.
• Record information about the sample being tested, including
its part number, lot number, dimensions, and any relevant
specifications. This helps in traceability.
• Record the test results, including the maximum torque
achieved, any torque peaks or fluctuations, and any
testspecific measurements or parameters. Ensure that
results are labeled clearly and are traceable to the sample
and test setup.

Operating Procedures:

1. Pre-Setup Preparations: The pre-setup preparations include wearing

of appropriate protective equipment, inspection of machine and
workspace as well as other safety precautions.
• Ensure the torque test machine is properly installed, calibrated,
and in good working condition.
 • Confirm that the machine's power source is connected and turned
on.
• Inspect the test area to ensure it is clean and free of obstacles.

2. Preparation of Samples: Sample preparation for a torque test

machine is a critical step to ensure accurate and reliable torque
measurements.
• Choose the appropriate samples or components that you want to
test for torque. Ensure they represent the materials or products
you are interested in assessing.
• Select a sufficient number of samples to conduct statistically
significant tests if needed.

3. Test Parameter Setup: Test parameter setup includes the setting of

the desired testing parameters, such as torque range, speed, and
any other relevant settings on the machine's control panel or
software interface.

• Input any necessary data, such as sample information or testing

conditions, into the machine's software if applicable.

4. Safety Precautions: Safety precautions are crucial when working

with a torque test machine to prevent accidents, injuries, and
equipment damage.
• Ensure all safety interlocks, emergency stop buttons, and safety
shields are functioning properly.
• Maintain a clean and organized workspace to prevent tripping
hazards or accidental contact with moving parts. Keep the area
well-lit and free from clutter.

5. Test Operation: The actual process of performing a torque test on

a sample or component using the machine. It involves applying
controlled torque to the sample and measuring the resulting torque
values, often to assess factors like torque yield, torque at
failure, or other torque-related characteristics.
• Start the torque test machine, either manually or using an
automated control system. Depending on the test requirements,
you may initiate a static test (holding torque at a fixed value)
or a dynamic test (applying torque while monitoring changes).

6. Data Collection: As the test is executed, the machine measures and

records torque values continuously or at specified intervals. This
data is typically displayed on the machine's interface in realtime.
• Collect torque data at predefined intervals or continuously,
depending on the nature of the test.
• Monitor the torque test machine for any anomalies during data
collection.
 7. Post-Test Maintenance: Proper maintenance helps prevent issues,
extends the machine's lifespan, and ensures that it remains in
optimal working condition.
• Clean the machine thoroughly to remove any dirt, debris, or
lubricants that may have accumulated during testing.
• Conduct a visual inspection of the machine's components,
including the torque sensor, fixtures, and any moving parts.
Look for signs of wear, damage, or loose bolts.
•
8. Shutdown: Performing a shutdown operation for a torque test
machine requires a systematic process to ensure safety, maintain
equipment integrity, and prevent damage.
• Turn off the torque test machine by using the power switch or
control panel. Ensure that all power sources, including
electrical connections, are properly disconnected if the machine
uses an external power source.
• Secure the machine and clean the work area.

Calibration and Testing:

Torque testing is a critical component of quality control and assurance

in various industries, especially those where the correct application
of torque is essential for product functionality, safety, and
reliability.

Calibrating and testing a torque test machine is essential to ensure

accurate measurements. Here's a general procedure for calibration and
testing:

• Calibration:

1. Check Requirements

Make sure to have the necessary calibration standards and

equipment required for the specific torque range of your
machine.

2. Prepare the Environment

Perform the calibration in a controlled environment with stable

temperature and humidity.

3. Zero Calibration

Start by performing a zero calibration means to sets the

baseline with no torque applied.
 4. Calibration Standard

Apply a known torque value to the machine using a calibrated

torque wrench or load cell. Ensure it covers the full range
of your machine's capabilities.

5. Record Readings

Record the torque readings displayed by the machine during

calibration. Compare them to the known values applied. Adjust
the machine's calibration settings as needed to match the
known values.

6. Repeat if Necessary

If the readings are not within an acceptable tolerance,

repeat the calibration process until accurate readings are
achieved. 7. Documentation

Document the calibration process, including the date,

equipment used, and results. Maintain these records for
future reference.

• Testing:

1. Select the Test Sample

Choose the sample or component that you want to test for torque.

2. Prepare the Test Setup

Securely mount the sample in the machine's fixture or chuck,

ensuring proper alignment and fixation.
3. Set Test Parameters

Configure the machine's settings, including torque range,

speed, and any specific test parameters. Example, angle of
rotation.

4. Perform the Test

Initiate the torque test. The machine will apply torque to the
sample, and the readings will be displayed.

5. Monitor and Record

Monitor the test in real-time. Record torque values, any break

points, or other relevant data.

6. Data Analysis

Analyze the test results to determine if the sample meets the

required torque specifications. Look for any anomalies or
deviations.
 7. Documentation

Document the testing process, including the date, sample

details, test parameters, and results. This documentation is
crucial for quality control and traceability.

8. Aftercare

After testing, clean the machine and inspect it for any wear
or damage. Address any issues before the next use.

Always follow the manufacturer's guidelines and recommendations for

calibration and testing specific to your torque test machine model.
Calibration should be performed regularly to maintain measurement
accuracy and reliability.

Emergency Procedures:

Emergency Procedures for Torque Test Machine:

1. Fire Emergency:

- In the event of a fire, immediately stop the operation of the

torque test machine.

- Activate the nearest fire alarm and alert others in the area.

- Safely power down and disconnect the torque test machine from
its power source.

- Use the appropriate fire extinguisher based on the type of

fire (e.g., Class C for electrical fires) if it's safe to do so.

- Evacuate the area and call the emergency services (911 or your
local emergency number).

- Do not use water on electrical fires, as it can worsen the

situation.

2. Equipment Failure:
- If the torque test machine experiences a malfunction or
equipment failure that poses a safety risk, immediately turn off
the power.

- Isolate the machine by disconnecting it from the power source

and lock it out to prevent accidental restart.

- Report the issue to a qualified technician or supervisor for

repair.

- Do not attempt to repair the equipment yourself unless

authorized and trained to do so.

3. Spill Response:

- In case of a spill involving hazardous substances, stop the

operation of the torque test machine.
 - Assess the spill to determine its nature and potential
hazards.

- If it's a hazardous chemical spill, put on appropriate

personal protective equipment (PPE), such as gloves, goggles, and
a lab coat.

- Contain the spill using absorbent materials, preventing it

from spreading further.

- Notify your supervisor and the designated personnel

responsible for hazardous material cleanup.

- Follow established spill response protocols and, if necessary,

evacuate the area according to safety guidelines.

- Decontaminate affected areas and equipment as directed by

safety procedures.

Maintaining safety in the workplace is paramount when using torque test

machines. Ensure that all personnel are familiar with these emergency
procedures, have access to necessary safety equipment, and receive proper
training. Regular safety drills and inspections can help maintain a
secure working environment.

Appendices

Appendix I:Emergency Hotline Numbers

Cebu City Hotline Emergency Fire

Numbers Department

161- ERUF 160 – Cebu City Fire

Department
ERUF Banilad: 233-930
Fil-Chinese Volunteer
ERUF Abellana Sports Fire Brigade: 254-
Complex: 255-7287 0200, 254-0300, 0918-
909-9785

Mandaue City, Cebu

Fire Department: 344-
4747, 344-3364

Appendix II:Documentation

Torque Testing Machine Checklist

Components Remarks Check by:

Motor

Oil

Power

Transducer

Digital Display
 Calibration

Glossary:

• Biomedical - research examines the effects of drugs and medical

techniques on the biological systems of living creatures.
• Chuck- is a specialized type of clamp used to hold an object with
radial symmetry, especially a cylinder.
• Elasticity- a physical property of materials which return to their
original shape after the stress that had caused the deformation is
no longer applied.
• Fume- gas, smoke, or vapor that smells strongly or is dangerous to
inhale.
• Gas- is one of the four fundamental states of matter. The others
are solid, liquid, and plasma
• Humidity- is the concentration of water vapor present in the air.
Water vapor, the gaseous state of water, is generally invisible to
the human eye.
• Hydraulics - is a mechanical function that operates through the
force of liquid pressure. In hydraulics-based systems, mechanical
movement is produced by contained, pumped liquid, typically through
hydraulic cylinders moving pistons.
• Microprocessor - is a computer processor where the data processing
logic and control is included on a single integrated circuit, or a
small number of ICs. The microprocessor contains the arithmetic,
logic, and control circuitry required to perform the functions of
a computer's central processing unit.
• Personal Protective Equipment- equipment worn to minimize exposure
to hazards that cause serious workplace injuries and illnesses
• Pneumatics - is an aspect of physics and engineering that is
concerned with using the energy in compressed gas to make something
move or work.
• Slope- a surface of which one end or side is at a higher level than
another; a rising or falling surface.
• Stiffness- the quality of being severe or strong
• Strain- In mechanics, strain is defined as relative deformation,
compared to a reference position configuration.
• Strain Gauges - are devices that are commonly used by engineers to
measure the effect of external forces on an object.
• Stress- the measure of an external force acting over the
crosssectional area of an object
• Sturdiness- the quality of being physically strong and solid or
thick, and therefore unlikely to break or be hurt
• Torque- a twisting force that tends to cause rotation.
• Torque Test Rig- a way of determining how an object will react when
it is being turned.
• Torsional stress-shear stress which acts on a transverse
crosssection that is caused by the action of a twist.
• Transducer- is an electronic device that converts energy from one
form to another.
• Wheatstone bridge- is used for the precise measurement of low
resistance.