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DC Torque Tools: Understanding the Differences and How to Choose the Right One

DC Torque Tools: Understanding the Differences and How to Choose the Right One

In various industrial applications, precise torque control is crucial for ensuring the safety and reliability of mechanical assemblies. DC torque tools (DC stands for direct current) have emerged as an invaluable solution for achieving accurate torque for any application. However, with many different tool options available in the market, it’s important to understand the differences between these tools and how to choose the one that best suits your needs. In this blog post, we will explore the key differences in DC torque tools and provide practical guidance on selecting the right tool for your specific requirements.


What is a DC Torque Tool?

DC torque tools are electrically powered devices used to apply torque to fasteners, ensuring they are tightened to the desired specifications. They offer several advantages over manual or pneumatic tools, such as improved accuracy, repeatability, and ease of use. When it comes to DC torque tools, there are primarily two types to consider: brush-type and brushless.


Brushed DC Torque Tools:

Brushed DC torque tools employ a brushed motor design, where carbon brushes are used to transmit electrical current to the rotating part of the motor. These tools are often more affordable than their brushless counterparts and are suitable for general torque applications. However, they tend to have a shorter lifespan due to the wear and tear associated with brush maintenance.

Brushed DC Torque Tools

Brushless DC Torque Tools:

Brushless DC torque tools, on the other hand, utilize a brushless motor design. They offer improved durability, longer lifespan, and higher torque accuracy compared to brushed tools. The absence of brushes eliminates the need for maintenance, reducing downtime and costs in the long run. Brushless tools are typically more expensive upfront but provide better value over time. This lever-start torque limiting screwdriver, EA-BN4 series, has a range of 1.3 - 16.49 in-lbs with an ESD (Electrostatic Discharge) housing designed to ensure the operator's comfort. It has a brushless motor that generates less heat, requires less maintenance, and is ideal for clean-rooms. A selection of power supply controllers are available that provide Hi/Lo speed, Slow Start, Output Signals, fastener counter and run down verification functionality. Common usages for this screwdriver are demanding assembly fastening applications that require one or all the following: torque control, ESD protection, or screw counting functionality. Does not include power supply.Factors to Consider When Choosing a DC Torque Tool:

It’s extremely important to select the right tool that is best for your application. Some factors to consider when deciding on the best tool include the type and volume of work, the torque range, work space constraints, power options and your budget.


  1. Torque Range and Accuracy:

Consider the torque range required for your specific application. Ensure that the tool you choose can deliver the necessary torque output while maintaining the desired accuracy. Different models may have varying torque ranges, so it’s important to match the tool’s capabilities with your specific needs. Express Assembly’s DC Brushless Torque Screwdrivers cover the largest torque range available in the assembly industry: from 0.07 –  442 in-lbs.


  1. Speed and Control Options:

Evaluate the speed at which the torque tool operates. Some applications may require high-speed tightening, while others may necessitate a slower, more controlled approach. Additionally, check if the tool offers adjustable torque settings and control options, such as digital displays or programmable presets, to accommodate different torque requirements.


  1. Ergonomics and Ease of Use:

Since torque applications can be repetitive and time-consuming, consider the ergonomics and user-friendliness of the tool. Look for features like a comfortable grip, lightweight design, and intuitive controls that minimize operator fatigue and enhance productivity. Our torque drivers are produced in in-line, pistol grip and angle head form factors and each has characteristics that make it right for specific jobs.


  1. Durability and Reliability:

Assess the build quality and overall durability of the torque tool. It should be robust enough to withstand the demands of your working environment. Look for features like rugged casings, sealed electronics, and reliable internal components to ensure long-term reliability.


  1. Calibration and Maintenance:

Regular calibration is essential to maintain the accuracy of torque tools. Consider tools that offer easy calibration procedures or those that can be sent to certified calibration labs. Additionally, inquire about the recommended maintenance schedule and spare parts availability to ensure uninterrupted usage. Express Assembly also offers a certification of calibration for all screwdrivers that we sell.


Choosing the right DC torque tool is a critical decision for any industrial application that requires precise torque control. Understanding the differences between brushed and brushless tools and evaluating factors such as torque range, accuracy, speed, ergonomics, durability, and maintenance requirements will help you make an informed decision. By selecting the appropriate DC torque tool, you can enhance productivity, ensure the integrity of your assemblies, and improve overall operational efficiency.


Express Assembly tool experts are ready to help you select the torque tool for your application. Contact us today!