In the assembly processes of automotive components, new energy vehicle power systems (battery, motor, and electric control), and 3C electronics, the quality of bolt tightening directly affects product safety and reliability. However, traditional tightening operations rely heavily on operators' hand feel and memory, making it prone to issues such as duplicate tightening, missed tightening, and incorrect sequence tightening. These problems not only reduce production efficiency but also introduce potential quality risks to products.

I. Why Does Traditional Manual Tightening Easily Lead to "Duplicate Tightening" Issues?

In traditional assembly modes:

• Operators find it difficult to accurately remember every tightening position

• Fast-paced multi-station operations easily lead to repetitive actions

• Without real-time position detection, it is impossible to identify whether tightening has been completed

• Lack of process data recording makes problem tracing difficult

In automated production lines with multiple bolts and high takt times, duplicate tightening may cause:

• Abnormal preload force fluctuations

• Thread damage or stripping

• Decreased product consistency

• Increased after-sales risks

Therefore, relying solely on personnel training can no longer meet high-quality assembly requirements.

II. How to Achieve Duplicate Tightening Prevention Control?

To effectively avoid the risks brought by duplicate tightening, Danikor's intelligent electric screwdrivers are equipped with duplicate tightening error-proofing functions. Through the intelligent electric screwdriver, operators can activate the duplicate tightening detection function with one click, setting corresponding detection torque and angle window values. These parameter settings can be adjusted according to specific production conditions to ensure detection accuracy and reliability.

1. Detection Torque and Angle Window Values

Intelligent electric screwdrivers monitor torque and angle in real-time during the tightening process through high-precision sensors. When a screw has already been tightened in place, the angle change during subsequent tightening attempts will be significantly smaller. By setting angle window values, the system can detect this abnormal change and immediately report an error, alerting the operator to stop the operation to avoid continued torque application that could damage the screw from over-tightening.

2. Combined with Positioning Torque Arm

By pre-setting XYZ coordinates for tightening positions, position identification and sequence control during the tightening process are achieved. Through encoders, position detection in XYZ directions is performed, converting angles and displacements into digital signals for transmission to achieve precise positioning.

Only when confirming arrival at the programmed position can tightening be executed; only after tightening completion can movement to the next position proceed. This effectively prevents erroneous operations such as duplicate tightening and missed tightening, ensuring the assembly process is standardized and controllable.

Duplicate tightening is not simply an operational error but rather a result of insufficient control dimensions in traditional assembly modes. Automatic tightening systems achieve full-process constraint of tightening behavior through spatial position identification, sequence logic management, and status locking, fundamentally solving the duplicate tightening problem and building a controllable, traceable, and highly consistent assembly quality system.