Hydraulic torque wrench
Hydraulic torque wrenches are torque multipliers that can generate torques of up to 72,000 Nm with the help of oil and a corresponding pump. The hydraulic torque wrenches can be designed as cassette torque wrenches (i.e. the torque wrench wraps around the screw without a socket) or as square drive tools. Depending on the model size, the hydraulic square drive tools are equipped with a drive from 3/4" to 2 1/2". The screw connection can be successfully completed with the appropriate socket.
Structure and content
1. Design of a hydraulic torque wrench
How is a hydraulic torque multiplier constructed?
A hydraulic torque wrench is a powerful assembly tool specially designed for the precise tightening and loosening of bolted connections. This tool is often used in industry and construction where high torques and accuracy are required.
A hydraulic torque wrench consists of several essential components that work together to provide the desired torque transmission. The main components are: Hydraulic pump, hydraulic hose, hydraulic cylinder, ratchet body, torque arm, drive unit and the reaction arm.
The hydraulic square drive tool is equipped with a square drive. Depending on how high the maximum torque is, the square drive is 3/4" or up to 2 1/2" in size. To be able to carry out the assembly, you need the matching socket with the same size as the screw.
The cassette screwdrivers, on the other hand, consist of a drive unit and a cassette that fits directly around the screw without a socket.
In this way, 72,000 Nm are possible with the hydraulic torque spanners with square drive and up to 44,800 Nm with the hydraulic wrenches with cassette.
2. Funktionsweise
How does a hydraulic torque multiplier (cassette torque wrench or square drive tool) with adjustable torque work?
1. Hydraulic pump and hydraulic hose
The hydraulic pump is the heart of the system consisting of the hydraulic torque multiplier (square drive tool or cassette torque wrench) and pump and supplies the hydraulic energy required to operate the torque wrench. This pump can be operated electrically, pneumatically or manually. It generates the required pressure, which is channelled through the hydraulic hose to the torque wrench. The hydraulic hose connects the hydraulic pump to the hydraulic cylinder of the torque wrench. It is specially designed to withstand high pressures and transport the hydraulic fluid safely and efficiently.
2. Hydraulic cylinder and ratchet body
The hydraulic cylinder converts the hydraulic pressure into mechanical force. This force is then used to move the ratchet body of the torque wrench (square drive or cartridge wrench). The cylinder is robust and precisely manufactured to ensure accurate and controlled torque application. The ratchet body is the central element of the torque wrench that generates the rotary motion. It contains a ratchet mechanism that enables the torque to be transferred to the screw in controlled steps. The ratchet body ensures that the tool rotates in one direction and runs freely in the other.
3. Torque arm
The torque arm acts as a lever and amplifies the force generated by the hydraulic cylinder. It is designed to efficiently transmit the rotary motion to the drive unit. The torque arm is a crucial component for generating the required torque.
4. Drive unit and reaction arm
The drive unit consists of a socket that is placed on the bolt or nut. It transmits the torque from the ratchet body to the fastener. The drive unit is available in various sizes and shapes to suit different types and sizes of screw. The reaction arm is used to absorb and neutralise the torque generated when tightening or loosening the screw. It is supported against a fixed point to prevent the tool from twisting and thus ensure precise torque application.
3. Characteristics
What are the features of hydraulic torque wrenches?
1. high precision
Hydraulic torque wrenches offer exceptional accuracy in torque application. This ensures that bolted joints are always tightened or loosened to the exact desired torque, which is crucial for the safety and reliability of structures and machinery.
2. high torques and repeatability
These tools are capable of producing extremely high torques, far beyond what can be achieved manually or with other types of torque multipliers. This makes them ideal for heavy industrial applications such as wind energy or regular flange connections regardless of industry. Thanks to precise hydraulic control, hydraulic torque wrenches offer high repeatability. This is particularly important in production processes where consistency and reliability are crucial.
3. robustness, durability and ergonomic design
Hydraulic torque wrenches are made from high-quality materials that are known for their robustness and durability. They are able to withstand the harsh conditions of industrial environments while operating reliably for long periods of time. These tools are designed to be light and ergonomic in the hand. This reduces the physical strain on the operator and increases efficiency and safety at work. With the same power compared to a torque wrench with a planetary gearbox, hydraulic torque wrenches are lighter and more compact.
4. versatility and safety features
Hydraulic torque wrenches are extremely versatile and can be used in a wide range of applications, from machine maintenance and repair to construction assembly. They are available in various sizes and configurations to meet the specific requirements of different tasks. With torque wrenches from Juwel, you can achieve torques between 110 and 72,000 Nm. Many models have integrated safety functions such as overload protection and pressure relief valves, which protect both the operator and the tool itself. These functions help to prevent accidents and extend the service life of the tool.
5. easy operation and maintenance
Hydraulic torque wrenches are designed to be user-friendly and require minimal maintenance. Their ease of use and low maintenance costs make them an economical choice for many companies. It is not uncommon for torque wrenches to be used for more than 15 years.
6. modularity and adaptability
Many hydraulic torque wrenches have modular designs that allow different accessories and attachments to be used. This increases their adaptability and makes them a versatile tool for different applications. Thanks to Juwel's in-house CNC production, the reaction arms can be customised precisely to our customers' applications.
4. Applications
Hydraulic torque wrenches (hydraulic wrenches), whether square drive or cassette, are used in various sectors and industries. A closer look can help to find out which tool is the most suitable.
1. construction industry
In the construction industry, hydraulic torque wrenches are often used for tightening and loosening large bolted connections. They are indispensable in the construction of bridges, high-rise buildings and other large building projects where strong and precise bolted joints are crucial.
2. offshore and onshore wind energy
The installation and maintenance of wind turbines, both onshore and offshore, requires the use of hydraulic torque wrenches. These tools ensure that the large screws and bolts holding the turbines together are tightened to the correct torque to ensure the safety and efficiency of the turbines.
3. oil and gas industry
In the oil and gas industry, hydraulic torque wrenches are essential for assembling and maintaining drilling rigs, pipelines and refineries. They enable the safe tightening of high-pressure flange connections and other critical components.
4. heavy industry and mechanical engineering
Heavy industries such as mechanical engineering and steel construction utilise hydraulic torque wrenches for the assembly and maintenance of large machinery and equipment. These tools are ideal for applications that require high torques and precise settings, such as the installation of presses and forging machines.
5. power plants and power generation
In power plants, including nuclear, coal and gas-fired power plants, hydraulic torque wrenches are essential for the maintenance and installation of turbines, generators and other large plant components. The accuracy and reliability of these tools are critical to the safe operation of the equipment.
5. Models
Hydraulic torque wrenches are generally available in two versions: Either with a square drive (see left), which requires an additional socket to transfer the torque to the screw, or a hydraulic torque wrench with a cassette (see right), which wraps around the screw without a socket.
Hydraulic torque wrenches with square drive: There are several advantages of square drive hydraulic torque wrenches: The square drive is extremely robust and can withstand high loads. It is available in different sizes to suit the maximum torque. It is also versatile, as different sockets can be used to handle a wide range of screw and bolt sizes. In contrast to the cassette screwdriver, there is no need to buy interchangeable cassettes here; regular, cheaper sockets are sufficient. The following performance classes are available:
- BT-11 with max. 1,100 Nm
- BT-18 with max. 1,800 Nm
- BT-45 with max. 4,500 Nm
- BT-107 with max. 10,700 Nm
- BT-155 with max. 15,500 Nm
- BT-266 with max. 26,600 Nm
- BT-347 with max. 34,700 Nm
- BT-487 with max. 48,700 Nm
- BT-720 with max. 72,000 Nm
Hydraulic torque wrenches with cassette: The cassette technology enables a compact and flat design of the tool. This is particularly advantageous in confined working areas where space is limited and conventional torque wrenches may not be able to be used. The flat design facilitates access to hard-to-reach screws and bolts.
The following power classes are available:
- KS-23/24 with max. 2,400 Nm
- KS-58 with max. 5,850 Nm
- KS-64 with max. 6,400 Nm
- KS-109 with max. 10,900 Nm
- KS-117 with max. 11,700 Nm
- KS-185 with max. 18,500 Nm
- KS-418 with max. 41,800 Nm
- KS-445 with max. 44,500 Nm
6. Technical Data
You can quickly find out which hydraulic torque wrench is right for you, whether with a cassette or square drive, during a consultation or an on-site visit. You are also welcome to test our hydraulic torque wrenches. Below you will find the general technical data of our hydraulic torque spanners.
7. FAQ
You can quickly find out which hydraulic torque wrench is right for you, whether with a cassette or square drive, during a consultation or an on-site visit. You are also welcome to test our hydraulic torque wrenches. Below you will find the general technical data of our hydraulic torque spanners.
What are hydraulic torque wrenches used for?
Hydraulic torque wrenches such as cassette torque wrenches or hydraulic square drive tools are used for the assembly of flanges in industry or wind energy, among other things. They are also particularly suitable for tight installation spaces in pockets or for particularly high torques.
What torques are possible with hydraulic torque spanners?
Torques of over 40,000 Nm are possible with the hydraulic cassette torque wrenches from JUWEL. The hydraulic square drive tools can be used up to 72,000 Nm.
What is the difference between a hydraulic torque spanner with a square drive and one with a cassette?
With a hydraulic torque wrench with square drive, you need a suitable socket to mount your components. Every hydraulic square drive tool has a drive square of different sizes, depending on the maximum torque. You can carry out your screw connection with the appropriate socket.
Does a hydraulic torque wrench need to be calibrated and checked?
Yes, we recommend checking a hydraulic torque wrench every 1-2 years.
How is a hydraulic torque wrench driven?
To drive a hydraulic torque wrench, you need a pump - this can be driven electrically or pneumatically.
How expensive is a hydraulic torque multiplier?
Depending on the maximum torque, hydraulic torque wrenches can cost different amounts. Please contact us for a non-binding enquiry and we will be happy to advise you.
How long can I get service for my hydraulic torque wrench?
Thanks to our own CNC production, we do not stipulate an end date for maintenance. We still service hydraulic torque wrenches that are more than 20 years old.
When do I use a hydraulic torque wrench?
If screws need to be tightened to a specific torque, then calibrated tools such as torque wrenches are used. Hydraulic torque spanners are a possible drive type. They are particularly recommended for tight spaces or high torques. A hydraulic torque wrench is generally lighter than a torque multiplier with planetary gears for the same maximum torque.
What is the difference between a hydraulic torque wrench and a torque wrench with a planetary gearbox?
A distinction is made between continuously rotating torque wrenches and stroke-controlled torque wrenches. The hydraulically driven torque wrenches work stroke by stroke.