Fastening screws is one of the common jobs in manufacturing plants, but using manual screwdrivers would cause fatigue in many operators.  This would eventually lead to costly mistakes that would have to be corrected.  This is where the electric screwdriver shines.  Electric screwdrivers provide plenty of advantages including increased power, precision and compact size with improved handling.

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There are two different types of screwdrivers: brushless and brushed.  We covered the differences brushed and brushless screwdrivers in a previous article. The main difference between the tools is that brushed screwdrivers utilize a carbon brush that helps to create the electricity within the screwdriver.

Brushless Screwdrivers, as it says in the name, do not use brushes.  This gives an advantage to brushless screwdrivers, as they produce less friction and heat creates less wear and tear on the machine giving it a longer lifespan.  This makes it a great choice for high volume production lines.

Here are the steps for using a plug-in brushless electric screwdriver:

How to use an Electric Screwdriver

1. Prepare Your Setup

Securely connect the power tool cable to both screwdriver and transformer.  Establish a firm connection to avoid interruptions during use.

2. Power Up The Transformer

Turn on the transformer, plug the transformer power cord into the appropriate socket on the back of the screwdriver. Plug the other end of the power cord into a reliable power outlet.

3. Check the Power Indicator

Ensure that the power indicator is turned on. If the indicator light is off, be sure that the transformer’s power switch is set to “on”.

4. Choose and Attach your Bit

Choose the correct screwdriver bit for your application, and ensure that

5. Adjust Torque Settings

To increase the torque, locate the adjustment nut and turn it clockwise. For the reverse, turn it counterclockwise. Accurate results, test the adjusted torque using a reliable torque-testing system.

6. Test Rotation and Operation

Turn the driver on to ensure proper rotation.  Lever start tools, gently squeeze the lever to engage the tool. Push-to-start models, apply light downward pressure on the tool’s nose

7. Reverse Operation for removal

To remove screws, flip the switch to reverse mode and apply gentle pressure to unscrew.

Benefits of Brushless Screwdrivers

-Energy Efficiency

As mentioned earlier, choosing to use Brushless Screwdrivers on your assembly lines helps to provide more power without the wasted energy. Brushless motors operate through electronic commutation, unlike brushed motor screwdrivers which transfer electricity through physical contact of carbon brushes. This difference in design reduces energy loss and makes them more power-efficient.

Why it matters in manufacturing:

• Brushless motors consume a lot less power – brushless motors convert more electrical energy into me
• Less wasted energy means longer battery life – for cordless screwdrivers with torque control, this mean longer usage without swapping batteries and a lot less downtime
• Consistent power at all rpm – compared to its brushed counterpart, which experience power fluctuations, brushless motors maintain a steady torque output across different RPMs.

-Consistency & repeatability

Brushless motors offer advanced electronic control, which allows better torque accuracy and repeatable fastening. This is critical for preventing product failures.

Why it matters in Manufacturing:

• minimized torque drift – brushed motors experience torque loss over time due to the deteriorating brushes per use, but brushless motors maintain consistent torque output
• Better fastener integrity – inaccurate torque can strip screws or leave the loose, leading to inevitable defects. Brushless screwdriver provide more accurate and repeatable fastening.
• integration with smart systems – many brushless models can be integrated with torque tracking and data logging, ensuring full traceability in applications

-Low maintenance

Because of the elimination of carbon brushes, brushless screwdrivers experience less wear and tear, which means they experience fewer breakdowns and lower maintenance costs.

Why it matters in manufacturing:

• No Carbon Brush replacements – brushless motors do away with frequent brush replacements, reducing downtime needed to maintain the tools.
• less heat buildup – brushless motors generate less internal friction, reducing the risk of overheating which can degrade components over time.
• High duty cycles – because there is less heat buildup, the brushless tools run cooler and can operate without needing cool-down periods, increasing productivity

Common Mistakes and Best Solutions for Electric Screwdrivers

1. Using Too Much Torque (Over-Tightening Fasteners)

The mistake: In the world of fastening, many operators assume that “tighter is better”, but there are many serious issues that this can cause:

• stripped screw heads – too much torque to the screw heads can cause the screw heads to wear down or round out the screw head making it impossible to remove
• thread damage – over tightening can strip the threads inside a hole or deform them, reducing the strength of the fastener
• material deformation – over torquing on workpieces like electronics, plastics, or aluminum can cause the pieces to deform
• weakened assemblies – if torque is not controlled properly, parts may become structurally weaker over time.

Solution: Proper torque adjustment & Control

The solution to combating over-tightening issues can be a combination of a few different things:

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1. Use a Torque Tester for Verification – when precision becomes a critical part of the application, use a torque tester to validate your settings.

• torque analyzers allow you to calibrate your electric screwdrivers to confirm that they are consistently delivering the correct force
• testing on sample materials before production to ensure that the current torque setting does not cause damage.
• schedule regular maintenance checks to ensure accuracy of the screwdriver, this is an important step, especially in high-volume manufacturing

2. Use a screwdriver with a precision shut-off clutch – using a precision shut-off clutch is highly recommended to prevent over-tightening.

• automatic shut-off feature – stops the screwdriver once the pre-set torque is reach, ensuring uniform fastening
• reduces operator error – operators don’t manually control the force, which helps to reduce wrist strain and increasing efficiency.

2. Not Calibrating the Screwdriver before Precision Work

The Mistake: forgoing torque calibrations can cause a number of different issues with products, including: inconsistent fastening results, loose screws, or critical product failures.

Torque settings on screwdrivers are designed to ensure consistent torque through every tightening process. Electric screwdrivers will go through a process of normal wear and tear and cause the driver’s torque accuracy to drift over time. This could lead to issues such as under-tightening and over-tightening as mentioned previously.

Solution:

1. Use a Torque Tester – torque testers are essential to measuring the actual output of the screwdriver.

• attach the screwdriver to the torque tester and run it for several cycles
• compare the results to the intended torque setting
• at the first sign of any deviation, then adjust the torque setting appropriately

2. Set Up a Regular Calibration Schedule

Electric screwdrivers used in high production assembly require frequent testing and calibration to maintain its accuracy and precision. The best practice is to follow a weekly or monthly verification.

• for high-volume production, weekly calibration should suffice
• moderate usage, monthly or even bi-weekly calibration
• for occasional use every 3-6 months

3. Verify Torque before Critical Work

For high-precision applications, it is always a good idea to test your screwdriver on a torque verification tool before assembly begins

4. Consider Digital Torque-Controlled Screwdrivers

For manufacturers that need high repeatability, transducerized torque Screwdrivers provide real-time torque monitoring. These tools can store multiple torque settings and ensure consistency.

Checkout our article on the Top 5 Best Electric Screwdrivers from Delta Regis.

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I used to work at a manufacturing plant, and of all the different tasks I performed each day at that job, one of the most common was fastening screws into small electronic components. If I had to do these applications manually, I don’t think I would have lasted one whole shift. Fatigue would have set in, my work would have become sloppy, and I would have ended up making potentially costly mistakes.

Fortunately, I was provided with the right tool to make the job easier: an electric screwdriver. Electric screwdrivers provide major advantages for anyone working in electronics because they pack power, precision, and an On/Off switch into a convenient and efficient tool. Using this tool saved me time and energy on the job and, as an added bonus, was also easy to operate once I understood the basic steps for use.  

Types of Electric Screwdrivers

For light assembly applications such as electronics or manufacturing medical devices that require intricate work, an electric screwdriver is the ideal tool. It is a manageable size and delivers torque control and increased productivity. Plus, it will automatically stop when the preset torque has been reached, making it relatively simple to operate.

There are two basic types of electric screwdrivers: standard or brushless. For a standard electric screwdriver, there are small carbon brushes housed inside the tool that conduct electricity between the stationary wires and the rotating shaft. While this type of screwdriver is still very effective and precise, keep in mind that over time, heat can shorten the lifespan of the screwdriver. Standard electric screwdrivers typically require maintenance more frequently than brushless electric screwdrivers, depending on the number of screws tightened per day. Check the manufacturer’s maintenance interval guidelines to know when you will need maintenance for this type of tool.

As its name suggests, a brushless electric screwdriver does not contain brushes. Because this tool produces less heat, there is less wear and tear, giving it a longer lifespan. For the same reason, it can be a good choice for higher volumes of work.

How to Use an Electric Screwdriver for Electronics: Standard and Brushless

Standard and brushless electric screwdrivers are not difficult to operate. Still, it’s important to carefully review how to correctly use the tool before beginning work. After all, electronics work is delicate, and a small mistake could have big ramifications.

While both types of electric screwdrivers require many of the same steps to operate, it’s important to think about how they will be used day-to-day and to ensure you understand the joint application. When selecting the proper tool for the joint you are fastening together, it is wise to consider factors such as the type of screws and hardware involved, the type of materials you are working with, and whether the application involves sensitive assemblies like disk drives. If you find you are unsure about the fastening application, it is ideal to contact a torque specialist.

Here are the general steps to follow when using a brushless electric screwdriver that operates with a transformer (power supply):

1. Start by attaching a power tool cable to the screwdriver and the transformer.
2. Plug in the power cord to the back of the transformer and power outlet.
3. Check the power indicator on the transformer. If it is not on, check the “on” and “off” switch of the transformer.
4. Select the bit you want to use.
5. Retract the bit collar.
6. Insert the bit and release the retracted collar.
7. Make sure the bit fits the head of the fastener.
8. To set the torque limit, rotate the torque adjustment nut.
9. To increase the torque, turn the adjustment nut clockwise. To reduce the torque, turn the nut counterclockwise to reduce the torque.
10. Confirm the torque setting with a torque-testing system.
11. To check for proper rotation, turn the driver on.
12. Squeeze the lever to apply torque. For Push-to-Start models, place light downward pressure on the nose of the driver. The screwdriver will automatically stop when the preset torque has been reached.
13. To remove the screw, flip the switch to Reverse.

The methods of operation between the two types of tools are similar, with some slight variations to take note of. Here’s how to typically operate a standard (with brushes) electric screwdriver that operates with a transformer (power supply):

1. Attach the power cable to the screwdriver and the transformer.
2. Tighten the ground ring.
3. Plug the power cord to the back of the transformer and power outlet. Turn the power switch to “on.”
4. Choose the bit you want to use.
5. Retract the bit collar.
6. Insert the bit and release the retracted collar.
7. Turn the torque adjustment nut to set the amount of torque you need. Clockwise increases the torque, while counterclockwise decreases it.
8. Switch the driver on and make sure it rotates properly.
9. To apply torque, gently squeeze the lever. For Push-to-Start models, place light downward pressure on the nose of the driver.
10. The driver will stop when the preset torque is reached.
11. Remove the screw by turning the for/rev switch to the “reverse” position.

Whether you’re using an electric screwdriver for electronics on small, specialty projects or on a large-scale basis, the underlying principle remains the same. Connect your power, select and set your bit and torque, test your settings, and get to work.

The Benefits of Using an Electric Screwdriver for Electronics

Every job has unique demands, and many industrial assembly applications are required to meet strict engineering and governmental specifications to ensure fasteners such as screws are torqued correctly. As such, it’s critical that you use tools that give you the control you need for electronics applications, and a quality electric screwdriver provides just such precision.

The end result? Better productivity, less wasted time, increased comfort, and overall, a more efficient workday. That’s just what happens when you have the right tool for the job.

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