Torque Wrench with Digital Counter

Abstract

This project shows the construction and design of a torque wrench featuring an inbuilt digital tracker for improving accuracy and efficiency in aircraft maintenance operations. The device solves a common issue with manual application of torque i.e., human errors in tracking the number of rotations and double-checking proper torque values by the use of a real-time digital feedback system. The greatest innovation of this project is the combination of torque sensing and a digital counter system, that records and indicates the torque applied and the fastener's rotations during fastening. Autodesk Inventor was utilized to model the design and casing parts were printed 3D using Hyper PLA material, chosen for its durability as well as simplicity in prototyping. The device integrates sensors, microcontroller, and LCD display to provide users precise real-time information. Various sensors and switch types were tested throughout the project to provide precise reading and longer working life in workshop conditions. Debugging through software, physical positioning, and hardware modifications were performed to optimize performance. The final prototype was successfully operational and tested with a training kit setup, demonstrating its potential as a feasible tool for technicians in real-world maintenance environments. The results indicate that this innovation can reduce tightening errors, improve workflow consistency, and increase safety in aviation maintenance processes.