RAD blog

Advancing Beyond Hydraulic Torque Tools

The landscape of industrial tools used for high-torque applications has evolved significantly over the years. Historically, the hydraulic torque tool has been the standard across various industries, such as wind energy, oil and gas, and mining. However, over the past 15 years, electric, pneumatic, and battery-operated tools have begun to lead the way, favoured for their superior ergonomics, speed, and safety.

Given that hydraulic torque wrenches remain prevalent, it is crucial to compare them with modern electric torque wrenches to highlight the advancements and improvements available today. One such tool that exemplifies these advancements is the E-RAD BLU (and E-RAD BLU-S) smart torque wrench. The E-RAD BLU offers enhanced precision, safety, and efficiency, setting a higher standard in high-torque applications and showcasing the benefits of modern electric tools over traditional hydraulic tools. This comparison is important because, while hydraulics were the standard, there is now a noticeable improvement with electric torque wrenches, making them a better choice in many applications.

Limitations of Hydraulic Torque Wrenches

A Hydraulic torque tool comes with significant challenges and limitations. Ergonomics and usability can be problematic, especially in an industry like wind and power where a hydraulic pump can weigh between 50 and 75 pounds and needs to be hauled up to the worksite. Additionally, hydraulic torque wrenches are incredibly slow and inconvenient, with one piston actuation being a long, slow process, and they require handling two separate items. Safety can also be an issue due to the high-pressure hoses, which can fail and be dangerous. The two-piece design creates more opportunities for accidents.

What is the E-RAD BLU Smart Torque Wrench?

The E-RAD BLU, one of the first smart torque wrenches available is known for its advanced feature set. It is a standout tool due to its ease-of-use functions, torque presets, torque and angle function, data logging, advanced safety features, and auto back off. This tool is used predominantly in the wind industry for applications such as tower bolts, yaw bearings, generator maintenance, and blade maintenance. It is also widely used in mining for turnaround and maintenance applications, such as mill liners. However, the E-RAD BLU can be used in almost every industry due to its smart features and ergonomic design.

E-RAD BLU Product Highlights:

• Torque Range: 100 – 11,000 ft. lbs (135 – 15,000 Nm)
• Accuracy to target: 2.8%
• Servo motor technology to reduces bolting time up to 300%
• Highly advanced data logging and tool management features
• Lightweight and ergonomic pistol grip
• Multiple models of wrenches can be used in combination with one controller

The E-RAD BLU Advantage: Outperforming Hydraulic Torque Wrenches

The E-RAD BLU addresses common challenges faced by users of hydraulic torque tools, offering superior speed, safety, and convenience. Here’s how it compares:

Safety: The E-RAD BLU features a pistol grip, making it easier and safer to use by keeping hands away from the application. Its design removes the need for hoses or couplers, thereby eliminating the risk of hose or coupling failure—a significant danger associated with hydraulic tools. Additionally, it allows users to use a harness for less accessible work sites and operates as a single piece of equipment versus the two-piece design of hydraulic tools.

Cost Savings & Efficiency: The operational costs of a hydraulic torque tool is higher due to the maintenance of hydraulic pumps, fluids, and hoses. In contrast, the E-RAD BLU is more cost-effective and efficient due to its faster operation and reduced maintenance requirements. The E-RAD BLU’s design reduces setup and operation time, allowing workers to complete tasks more quickly and efficiently. This increased speed means that projects can be completed in less time, reducing labor costs and downtime. Additionally, the reduced need for maintenance minimizes interruptions and ensures that the tool remains in operation longer without costly repairs or replacements. This efficiency translates into significant cost savings over time, making the E-RAD BLU a more economical choice in the long run.

Precision & Accuracy: Most hydraulic torque tools advertise an accuracy of 3% to the target, whereas the E-RAD BLU is certified to 2.8%. Some industry professionals believe that this greater accuracy may partly be due to the continuous motion of the E-RAD BLU (Dynamic Friction), as opposed to the stop-and-start nature of hydraulic tools, which may lead to under-torquing (Static Friction).

E-RAD BLU-S Supercharged Precision & Performance

The E-RAD BLU-S builds on the superior accuracy and advantages of the E-RAD BLU, taking performance and precision to the next level. Here’s how:

Integrated Torque Transducer

Precision Control: Unlike standard electric tools that rely on a calibration chart to compare motor current to torque output, the E-RAD BLU-S features an integrated torque transducer in the gearbox. This transducer directly measures torque output during a torque cycle, ensuring increased accuracy and repeatability.

Advanced Features: This direct measurement enables additional functionalities like the torque check – which allows users to verify that already tightened bolts have maintained their tension without needing to back them off and retighten, streamlining the maintenance process.

Improved Maintenance Routines

Due to Torque Check, the E-RAD BLU-S excels in scenarios requiring regular maintenance checks, such as ensuring the tension of bolts on a flange. The torque check function lets users reapply torque and measure any movement without removing the bolts, significantly simplifying and speeding up the process.

Ideal Alternative to Hydraulic Torque Tools

The E-RAD BLU-S not only incorporates all the benefits of the E-RAD BLU but also enhances them with a particular focus on accuracy, making it an ideal alternative to hydraulic torque tools.

The Next-Gen Solution

Overall, the E-RAD BLU series, including the enhanced E-RAD BLU-S, offers significant improvements over the traditional hydraulic torque tool. With features designed to enhance speed, safety, and accuracy, these tools represent the next generation of high-torque solutions across various industrial applications.