Taiwanese Hand Tool Makers Go Digital

The development of digital tools is one means that Taiwan's hand tool makers are using to deal with price-slashing rivals in emerging countries. Digital models, including torque wrenches and screwdrivers, require advanced electromechanical integration and feature higher torque precision than mechanical models, and they generate better profit margins. Their relatively high technological threshold also keeps manufacturers ahead of the lower-end competition in the DIY-tool landscape.

This is why a number of Taiwanese hand-tool manufacturers have upgraded to the development of digital tools in recent years. The general consensus is that the digital trend was inaugurated by the government-funded Industrial Technology Research Institute (ITRI) in 2007, when it was commissioned by the Industrial Development Bureau under the Ministry of Economic Affairs to carry out a three-year project aimed at upgrading traditional metal-product industries.

Even before that, ITRI had already succeeded in applying strain gauges and improving production methods, with the help of the Metal Industries Research & Development Centre (MIRDC), resulting in the production of the first Taiwan-made digital tools. ITRI has continued its efforts since then, and has shared the results of its research with local hand-tool makers.

The institute unveiled its latest products, including a complementary pneumatic digital module, digital torque calibration device, and self-stopping sensor circuit, at the Taiwan Hardware Show (THS), which was held at the Taipei World Trade Center on Oct. 20-22, 2011.

Complementary Pneumatic Digital Module
Pointing to the pneumatic digital module displayed at the ITRI booth during the show, Cho Chih-hua, a senior researcher in ITRI's Mechanical and Systems Research Laboratories, stated that the aim of his R&D team in developing the product, with cooperation from local hand-tool manufacturers, was to meet the need of end users for torque tools that could be used quickly and easily.

Digital tools now on the market are expensive, and are used primarily by professionals. It is a lucrative market, but upgrading to digital is beyond the financial capabilities of Taiwan's hand-tool makers because of the complicated electromechanical integration engineering and sophisticated ICs and microelectronic components required. The manufacturers, Cho explained, “would take considerable operating risk if they engaged in the development of digital tools by themselves, because they do not have enough electromechanical engineering know-how and have weak financial resources. ITRI serves as an R&D platform to help them access the digital-tool market. That's why we developed the pneumatic digital module.”

ITRI's small, easy-to-carry digital module can be installed on most interchangeable torque handles, allowing users to transform manual tools into digital ones. “The way the module works,” Cho explained, “is by giving tools pneumatic power as a complementary means of driving screws to some extent, and then the users tighten the screws manually to the desired torsion using digital readings shown on the module's LCD screen.”

The modules can work in “peak” or “track” mode, and measurement can be switched between n-m, kg-m, and lbf-ft. Data can be stored for transmission. The modules come with a torque alarm beeper and indicator, and automatically go into “sleep” mode after lying idle for a time. “The module is designed to serve as a practical, economical solution for digital power tools,” Cho commented, “and we believe it will ease the entry of Taiwanese manufacturers into the digital-tool sector.”

First Home-grown Digital Torque Calibrator
Another indication of the growing trend toward digital is the island's first home-grown digital torque calibrator, which was developed jointly by ITRI and the William Tools Co., a globally known original design manufacturer (ODM) of torque wrenches and digital tool parts.

To facilitate its entry into the digital-tool market, William Tools has worked closely with ITRI on joint development for some time. This is now paying off, said the company's president, William Chiang, who noted that the digital torque calibrator on exhibit at THS is the second product of the partnership, the first being a semi-powered digital torque wrench that was unveiled in late 2010.

Chiang said that his new torque calibrator, which incorporates a beefed-up processor, features high-speed computing capacity to assure precision and accuracy. Calibration data are stored in the device and can be conveniently transmitted, via USB interface, to a computer for further analysis.

“Unlike traditional mechanical calibrators,” Chiang added, “this device provides digital readings of data through the whole calibration process. We aim to provide customers with all-around digital-tool solutions; that's the reason why we've developed this calibrator, despite all the time and effort its complex electronic and IT engineering cost us.”

Chiang's company also introduced a new series of digital torque wrenches at the show, all of them incorporating miniature DC motors to provide a complementary source of torsion. They also feature an automatic loosening mechanism, which automatically separates leverage parts inside the tools when the applied torque reaches a desired level to prevent excessive torsion. “These products were also developed jointly with ITRI,” Chiang reported, adding that his cooperation with the research institute, which has been going on for two years, will benefit not only William Tools but the overall industry.

World-class Accredited Precision and Quality
While some other companies are working to develop digital tool modules and related solutions, the Stand Tools Enterprise Co. is striving to become a top-end player in the industry by upgrading torque precision and quality. The calibration lab established by the company, which is the first in the industry to be accredited by the Taiwan Accreditation Foundation (TAF) and ILAC-MRA, serves as a benchmark for others to emulate.

As he watched interested buyers crowding into the Stand Tools booth at THS for a close look at the digital tools with integrated microelectronics mechanical system (MEMS) chipsets on display there, the firm's young manager, Brand Hsiao, commented proudly, “Our painstaking efforts in the pursuit of unbeatable, world-caliber precision and quality assurance in the development of digital tools has been recognized.”

Stand Tools' effort to become an accredited digital tool supplier began, Hsiao noted, with launch of the industry-first digital torque wrench with integrated MEMS chipset in 2008. Some other companies, Hsiao recalled, were skeptical about his chances of succeeding.

“Despite the doubts,” he reported, “we spent a lot of time and money learning about the contextual framework for the necessary standards, and installing advanced instruments in our lab. We succeeded in obtaining certification in 2010, and since then Stand Tools has enhanced its profile as a company that is better able to compete on the basis of precision and quality reliability. This started a trend in the industry.”

New Hit Products
Stand Tools also introduced other new products at the show. One of its new hits is a 9x12mm female interchangeable digital torque wrench with a more-sensitive sensor and higher-grade CPU to provide a higher degree of torque precision. It accepts all insert accessories, including ratchet heads, open-ended heads, ring heads, open-ring heads, and adjustable spanner heads.

Hsiao went on to introduce the firm's 16MM Spigot Digital Torque Wrench, which, he said, was developed to meet the demand of professional users for a reliable tool specifically designed for fastening and loosening lathe blades and CNC machinery accessories. The wrench provides better torsion sensitivity and torque precision, and has been tested (in the company's own lab) and found to be in compliance with stringent global standards.

The new Angle Measuring Digital Torque Wrench is an even stronger testament to the company's professionalism and commitment to precision. Angle measuring is widely used by engineers and architects to determine the optimal torque force to apply to screws installed in objects that are subject to persistent or intermittent vibration, with the aim of preventing vibration-caused loosening of screws in bridges, buildings, cars, or machinery, and thus avoiding the disasters that could result.

The Angle Measuring Torque Wrench features a patented angle gauge on its head, allowing users to fasten screws to the desired tension conveniently and accurately. “We developed this tool to meet the needs of angle measuring,” Hsiao commented, “and all of the related parameters were analyzed during development to make sure that the proper torque figures can be achieved by setting the gauge and turning the tool.”