In modern manufacturing, precision is everything — especially when it comes to torque. Whether you’re assembling delicate components or testing powerful machinery, applying the correct torque ensures both product quality and equipment longevity. That’s why torque sensors have become an essential part of automated production systems.
At Applied Modular Automation, we provide integrated torque sensor solutions in Singapore, designed to give manufacturers precise, real-time control over their torque-related operations — improving performance, traceability, and safety.
What Is a Torque Sensor — and Why Pair It with a Controller?
A torque sensor (also known as a torque transducer) is a device that measures the rotational force applied to a shaft, bolt, or rotating element. It captures torque in real time — whether during assembly, testing, or calibration — and converts it into an electrical signal.
When combined with a controller, the system becomes far more powerful. Controllers allow you to:
- Monitor torque dynamically
- Set torque limits or ranges
- Trigger alarms or automated responses when torque values exceed thresholds
- Record and store torque data for traceability and quality assurance
This pairing transforms basic torque measurement into a complete closed-loop system, ideal for modern production environments that demand accuracy, repeatability, and documentation.
Key Benefits of Using Torque Sensor & Controller Systems
1. Precision Torque Control
Ensure every fastener is tightened to the correct specification. This prevents common issues like over-tightening, which can damage components, or under-tightening, which may cause performance failures later.
2. Real-Time Quality Assurance
Catch torque deviations instantly. The system can reject faulty assemblies or stop the process before a mistake becomes a costly defect.
3. Process Automation
Torque controllers can be fully integrated into your PLC or SCADA systems, automating decision-making, process flow, and data handling — streamlining your production line.
4. Tool and Equipment Protection
Avoid premature wear or failure of tools by ensuring torque is applied within safe working ranges. If the system detects a potential overload, it can shut down the operation before damage occurs.
5. Data Logging and Traceability
Automatically record torque values for every operation. This helps with product traceability, audit trails, and continuous improvement initiatives, especially in regulated industries like automotive and aerospace.
Common Applications of Torque Sensors in Industry
Torque sensors and controllers are widely used across a range of industries and processes:
- Automated fastening systems – Ensure precise torque during screw, nut, or bolt tightening
- Motor and gearbox testing – Validate performance under different load conditions
- Aerospace and automotive assembly – Maintain strict quality control over critical components
- Calibration of torque tools – Accurately verify the performance of torque wrenches and screwdrivers
- R&D and lab testing – Capture high-resolution torque data during product development
How Torque Sensor Systems Work
Here’s how a typical torque measurement system operates:
- Torque Detection
The torque sensor captures the applied rotational force in real-time, either in a rotating (rotary sensor) or fixed (reaction sensor) configuration. - Signal Processing
The sensor’s output is sent to a controller, which compares the measured torque against preset thresholds or target ranges. - Automated Actions
If the torque is too high or too low, the controller can take immediate action — stopping a motor, alerting an operator, or flagging the part for rework. - Data Handling
The controller logs the torque values and displays them via an HMI, touchscreen panel, or integrated PLC interface for operator review and record-keeping.
How to Choose the Right Torque Sensor and Controller
To select the best system for your needs, consider the following:
- Torque Range & Resolution
Choose a sensor with a range that suits your application, plus sufficient resolution for the precision you require. - Sensor Type
- Rotary torque sensors are ideal for rotating shafts and tools.
- Reaction torque sensors are better for stationary measurements.
- Strain gauge-based sensors are common for high accuracy.
- Communication Protocols
Ensure compatibility with your control system — Ethernet/IP, Modbus, RS485, or other industrial protocols. - User Interface & Programming
Consider whether you need local controls, touchscreen interfaces, or remote programming capabilities. - Environmental Conditions
Think about operating temperature, humidity, vibration, and any special conditions like cleanroom requirements or outdoor use.
Why Partner with Applied Modular Automation?
At Applied Modular Automation, we don’t just sell sensors — we help you build smarter systems. Here’s why customers across Singapore trust us for torque sensor solutions:
- Expert Guidance
We help you select and integrate the right torque sensor-controller combination for your application. - Tailored Solutions
From basic setups to fully customised systems, we adapt to your process and automation needs. - Technical Support & Training
Our team offers local training, commissioning assistance, and after-sales support. - Complete Systems & Accessories
We supply not only torque sensors, but also controllers, displays, calibration tools, and mounting kits — everything you need for a fully functional system.
Looking to improve torque control in your automation setup? Contact Applied Modular today for expert support and tailored torque sensor solutions in Singapore.