HYTORC Additional Equipment
- HYTORC- Expansion nut
- DISC hexagon washer
- Washer System
- Workshop trolley - the complete solution
- Standard fasteners
- Special supports and safety accessories
- Accessories for ring wrench torque wrenches
- Accessories for square torque wrenches
- Hydr. Counterholder
- Support extensions
- Reaction arms and supports
- Hydraulic hoses and accessories
- Thread cleaning system
The JustBOLT is the simplified version of the SmartStud. The JustBOLTs available from size M20 can be precisely axially preloaded. Due to the axial tightening, the coefficient of friction is much more constant and even than with conventionally assembled screw connections. This assembly concept has proven its worth especially for assemblies in tight spaces. Users can also replace Allen screw connections according to ISO 4762 with the JustBOLT and screw them securely, quickly and precisely without a reaction arm. And that without any design changes.
The world’s first torsion-free screw!
The SmartSTUD ensures axial and torsion-free pretensioning of screws in threaded holes, under the most restrictive operating conditions and at very high operating temperatures.
The SmartSTUD is a three-part screw that is tightened torsion-free. The screw itself is designed as an extended shank or a full shank. This simple construction of the overall system makes it possible for the first time to brace the screw connection axially and, above all, torsion-free. The dimensions of the SmartSTUD have been optimized so that the outer diameter corresponds to that of an Allen screw or cap nut according to DIN 2510. This means that the SmartSTUD is resistant to creep up to 600 ° C.
The simple structure of the SmartSTUD
The SmartSTUD is a screw that can be tightened without torsion. The “screw” itself is designed as an extended shank or full shank and has two additional teeth on one side. The outer round sleeve forms the “mother” in the overall SmartSTUD system. A separate “washer” is also integrated for this purpose. This simple construction of the overall system makes it possible for the first time that the “screw” can expand axially and, above all, torsion-free. And that under control of all coefficients of friction.
Reduced to the essentials
The dimensions of the SmartSTUD have been reduced so that the outer diameter corresponds to that of an Allen screw. This means that the outer diameter is only 1.5 nominal thread diameter. Capsule nuts, which were previously used for reasons of space, can now also be replaced by the SmartSTUD. In this way, higher preload forces can be achieved faster and more precisely.
Purely axial tightening of screws
The drive of the assembly tool on the SmartSTUD is held in place in the axial direction of the screw via the external toothing of the screw. By turning the outer sleeve (nut) on its own washer, the screw is stretched axially and torsion-free. All relative movements take place within the SmartSTUD, so that this system can be precisely calibrated to the assembly preload regardless of the application. For even greater accuracy.
Application range up to 600 ° C
Due to the simple construction and the adaptation to the dimensions of the cap nuts according to DIN 2510, the SmartSTUD is creep-resistant up to 600 °. This gives this system new uses, e.g. in the field of turbine couplings and hot machines such as gas turbines. The SmartSTUD is assembled with all assembly tools of the XXI and AVANTI series, as well as the jGUN AirTensioner. The existing tool equipment can thus be used in a multifunctional manner.
In use worldwide
Numerous companies, especially in the field of energy generation, rely on the SmartSTUD for hot systems. The result is a significant reduction in dismantling and assembly times. In mechanical engineering, the SmartSTUD is primarily used where high preload forces are reliably generated in tight spaces.
The torsion-free torque preload system
The HYTORC expansion nut is a calibratable, mechanical pre-tensioning system that can be used for practically all screw applications up to 450 ° C. With the HYTORC expansion nut, pre-tensioning screw connections is much easier and safer. For the first time, the torque can be converted directly into a reproducible preload force. The screw connection is pre-tensioned torsion-free, with a pre-tensioning force accuracy of ± 5%.
The construction of the HYTORC expansion nut
The specialty lies in the construction. The HYTORC expansion nut has its own clamping thread and its own washer. As a result, all relative movements are combined in the HYTORC expansion nut and the preload forces can be calibrated independently of the application. This means: No turning on the component surface and no turning in the bolt thread.
little need for space
With an outer diameter of only 1.6 x the nominal thread diameter, the HYTORC expansion nut is smaller than a hexagon nut. This offers new possibilities in construction. Because the HYTORC expansion nut can be placed directly on a housing wall. And because the drive of the Torc tensioner has the same radius, no larger installation space is required.
The clamping thread of the HYTORC expansion nut is slightly larger than the bolt thread, but has a much smaller pitch. This reduces the tightening torques and ensures the use of smaller and more manageable TorcTensioners. As a result, the bolt to be tensioned is pre-tensioned torsion-free and for the first time up to the yield point. The low preload force spreads of less than ± 5% can only be managed through this closed force system.
The HYTORC expansion nut is designed for temperature ranges up to 320 ° C or 450 ° C as standard. Here the system shows its clear advantages in terms of reusability, quick dismantling and assembly and thus ensures a significant reduction of the radiation dose in the nuclear power plant area. For higher temperatures we recommend the torsion-free screwSmartSTUD.
Technical features of the HYTORC expansion nut
- Applicable to practically all screw applications
- No external reaction point necessary i.e. Screwing without reaction arm
- Hand-free screwing even when working overhead
- Side load-free pre-tensioning
- Torsion-free pre-tensioning
- All bolts are pretensioned equally
- High working speed
- Less equipment required for assembly
- High pretension force accuracy ± 5%
- Low tool weight
- Transmission of exact torques up to 190,000 Nm
- Easy to handle
- The risk of accidents is significantly reduced
- Parallel clamping with several tools is possible with just one fitter
- Doubling the working speed
- Protection of the bolts
- Protection of the machine support surfaces
- No counter holding key required
- Reduced stress on the tool
Twist-proof and friction-optimized screwing
With the DISC hexagon washer, the pre-tensioning of screw connections with hexagon nuts is considerably simplified. The calibrated torque of the assembly tool is converted into a reproducible preload force due to the constant coefficients of friction. The DISC ensures that the screw connection and the counter nut cannot turn during assembly. The counterhold keys previously used are no longer required and the assembly tools can be “attached” to the DISC.
A simple and ingenious solution
The DISC is a hexagon washer with an axially movable thread segment. Integrated in the screw connection below the hexagon nut, the DISC serves as a twist-proof washer, the thread segment of which adapts to the respective screw expansion. The precise surface of the DISC in combination with ourGleitlackspray GL 220 guarantee optimal thread friction and constant contact surface friction. And that regardless of the nature of the component surface.
THE solution for all flange connections
When opening flanges, there are always exposed surfaces and damage to the threads of the screw connections. The DISC eliminates this damage immediately and eliminates it for the future. Maintenance intervals can thus be planned and carried out significantly shorter and, above all, more cost-effectively. However, there are even more advantages when screwing flanges.
It simply works.
The assembly tool generates a low clamping force on the threaded segment in the DISC via the hexagon nut, so that the screw connection and the counter nut cannot turn and the preload force can be applied axially. The counter-holding wrenches previously used are no longer necessary and the hexagon nut turns on the DISC and not on the component.
More security on site without support arms
The external hexagon of the DISC provides the assembly tool with the necessary support and the ability to absorb a radial torque. External support arms on the assembly tool are no longer required, which ensures greater work safety. For vertical or overhead applications, the assembly tool is simply “attached” to the screw connection via the DISC and does not have to be held in place during the assembly process. Thereby we create a new safety standard in screwing technology.
Use assembly tools universally
All assembly tools of the series AVANTI, CTS-STEALTH, XLCT und VERSA as well as jGUN are suitable for clamping with the DISC. All of these assembly tools are the only ones of their kind to be supplied with a torque preload force table. And if you wish, with a documentation system too.
Certified preload force
BASF SE Ludwigshafen as well as WOOD GROUP / UK and Germanischer Lloyd Wind Energie have independently confirmed that the DISC can easily be used to achieve pre-tensioning force accuracies of less than ± 10%.
With new screws and new nuts even better than ± 5%. LIEBHERR has even achieved ± 5.6% for M64x4 screw connections in strength class 10.9, and that at 90% plugging limit utilization!
Technical features of the DISC washer:
zWasher and Backup Washer
Free of reaction arms, counter key free thanks to non-rotating washers.
The zWasher is a non-rotating washer that serves as an axial support element and at the same time ensures a defined coefficient of friction. The design is chosen so that all standard screws can be clamped axially. The BackUp Washer ensures that the lock nuts no longer turn.
zWasher – Non-rotating washer
The zWasher is a non-rotating washer that serves as an axial support element and at the same time ensures a defined coefficient of friction under the screw head. The design is chosen so that all standard screws according to ISO 4014, ISO 4017 and ISO 4762 can be axially tightened. With the zWasher, the pre-tensioning of screws in threaded holes is significantly simplified and, for the first time, is carried out axially. The calibrated torque of the assembly tool is converted into a significantly more reproducible preload force, since these washers cannot rotate on the component. To optimize friction, the use of washers is already prescribed in relevant regulations such as ASME-PCC 1 or VDI 2200-2007-07.
In conjunction with the zWasher, the Backup Washer ensures that the lock nuts no longer rotate.
The usual counter holding keys are not required. To optimize friction, the use of washers is already prescribed in relevant regulations such as ASME-PCC 1 or VDI-2200-2007-07.
Either impact wrenches, pneumatic torque wrenches, cordless and electric torque wrenches or hydraulic torque wrenches are used for the known, conventional screwing to torque.
With the exception of the impact wrench, all other assembly tools can only be used with one support arm. And that has major disadvantages. The high bending moment of the external, non-axial support changes the coefficient of friction in the screw connection. As a result, the torque is no longer optimally converted into preload force. Due to the system’s external support arm.
Since the development of hydraulic assembly tools in 1968, new ways have been explored to eliminate the support arm. This damages components, scratches painted surfaces, bends screws and harbors a considerable risk of injury, especially for untrained assembly staff.
The simple, safe and inexpensive solution is called zWasher.
Function of the zWasher washer
The zWasher is a twist-proof washer that reliably guarantees constant under-head friction. For all screw connections with connecting elements according to ISO 4014, ISO 4017, ISO 4762, DIN 934, DIN 2510 NF and ASME B 18.2.2.
The patented design of the zWasher prevents it from turning on the component. The assembly tool is centered over the outer profile of the zWasher without an external support arm. This axial centering ensures a torque-controlled, axial and friction-optimized tightening process with the highest preload accuracy of ± 10%.
The zWasher is installed on the side on which the assembly tool is used. All hydraulic, electrical and pneumatic torque tools require a torque support to rest on a fixed support point. The zWasher washer now becomes the reaction point under the hex nut or under the screw head and eliminates all assembly risks. The system is simple and easy to use and prevents damage to the support surfaces. As a result, the coefficient of friction now becomes a known, calculable quantity.
With all through connections, e.g. on the flange, a BackUp Washer is used under the hexagon nut. This prevents the lock nut from turning and jammed counterhold keys are a thing of the past. The BackUp Washer are inexpensive and deliver a return on investment from the very first use, as the assembly time is reduced by at least 50%.
The complete solution for serial screw connections
The workshop trolley offers space for pumps, scanners, label printers and screwing tools, thus enabling complete documentation of risky screwing.
The sturdy trolley brings all components safely to the respective location. The scanner reads e.g. Barcodes and QR codes as well as RFID tags and can thus read out the information on the respective screw connection. This data is then used to send the documentation pump (e.g. theEco2TOUCH) with the correct parameters. The pump then not only forwards this data to the screwing tool (e.g. hydraulic screwdriver from HYTORC) again and again without errors.
It also records all values recorded during the screwing process, thus ensuring the required documentation. At the end of the screw connection, the label printer, which is also mounted on the car, outputs all data relevant to the vehicle accompanying folder.
At HYTORC, C-parts are 1A components
HYTORC delivers everything from a single source with the corresponding acceptance certificates EN 10204.
Screws, nuts, washers and other connecting elements are among the components of a system that are often underestimated. But there is no doubt that these so-called C-parts are indispensable for proper function.
At HYTORC, these C-parts are always 1A components. Because the quality of the connecting elements is decisive for a perfect screw connection and thus for the safe and smooth operation of the system. That is why we take over the procurement of all connecting elements for our customers, from the detailed construction and individually coordinated production to quality testing and certificate allocation. At HYTORC, the term “everything from a single source” includes the specified corrosion protection as well as the use of suitable lubricants and test methods.
Our manufacturing options
- External and internal threads up to M200 up to 18 m in length, all threads also in inch dimensions
- Screws etc. ISO 4014, ISO 4017, ISO 4762, EN 14399
- Stud and expansion screws according to DIN, ASTM, AISI and UNS
- Hex nuts according to DIN 934, DIN 2510 and ASTM A193
- Certificate assignment EN 10204
- Hot and cold forming
- Surface coating, etc. Zinc flake, galvanically ecologically galvanized and hot-dip galvanized
- In-house laboratory for all test methods
Our testing options
- chemical analysis (up to 20 elements)
- Notched impact moment determination down to -150 ° C
- Surface crack testing (two methods)
- Spectral analysis
- Tensile tests (testing machine up to 600 kN)
- Hardness test HRC and HRB
- Determination of the surface roughness (measuring machine)
- Determination of coating thickness
- Pre-tension force measurement up to M90 and 3000 kN
Special supports and safety accessories
- customer-specific special supports
- individually adapted to your applications
- Customer requirement, CAD design, production
- also available as a 3D STEP file for collision checking
- also available as a complete set in a hard case
Accessories for ring spanner torque wrenches
- InOut sockets according to customer requirements
- Allen adapter
- Square adapter
- Hexagonal sockets
- Double hexagon inserts
Accessories for square torque wrenches
- Sockets in mm or inches up to SW200
- Square drive ¾ “to 2½”
- Direct drive sockets in all wrench sizes
- Direct Allen drives in all wrench sizes
- Allen nuts in mm up to SW100
Hydraulic counter holder
- hydraulic counterhold up to 5,000 Nm
- changeable double hexagon inserts
- mechanical counterholders for all torque ranges
- Versions with double hexagon
- also available as special solutions
- made of aluminum or steel
- one-piece, welded, screwed
- for all STEALTH, XLCT and VERSA tools
- also for ICE, AVANTI, MXT and EDGE
- available in individual lengths
Narrow, high-torque, robust.
The new offset link replaces angle wrenches and is much more versatile.
Offset Link – Product benefits
- Available in two sizes from SW 30 to SW 80 and from 1-1 / 4 “to 3-1 / 8”
- Can be used with all HYTORC square screwdrivers
- Easily switchable clockwise / counterclockwise rotation without having to implement the offset link
- Easily exchangeable double hexagon inserts for quick attachment
- Ready for low-reaction screwing with the zWasher
- Ideal for plate heat exchangers, clamp screws and threaded spindles
HYTORC Offset Link offers absolute flexibility and versatile use in almost all screwing applications. The drive unit can be equipped with easily interchangeable double hexagon inserts, which guarantee quick assembly and relocation. All wrench sizes from 30 mm to 80 mm and from 1-1 / 4 “to 3-1 / 8” can be covered. Offset Link can also be used for hydraulic torque wrenches ICE and AVANTI.
Offset Link – Equipment Features
- Robust continuously rotating drive system
- Right / left rotation for all continuously rotating tools
- Universally applicable for many torque wrenches
- Easy to put on thanks to the double hexagon
- Also available as a complete case set
Simple. Fast. Screwed.
Practical and ingeniously simple: A patent-pending tape that can be placed around flange connections and that indicates the correct order of the parts to be screwed together with the specified numbering. The flangeFIX marking system developed by HYTORC is put around the flange by the user in a matter of seconds. The numbering to identify the tightening sequence ensures that the strap guarantees fast and secure screwing and documentation in accordance with national and international regulations.
NEW: flangeFIX made of stainless steel – Safe. Robust. Screwed.
- Made of robust stainless steel
- For use under extreme conditions such as heat, corrosive liquids or harsh climates
- Engraving of customer-specific bar and QR codes possible
- 70% time saving with flange numbering
- For ANSI B16.5 – ANSI B16.47B and EN 1092 Typ11
- For standardized and error-free assemblies
- Can be used in any installation situation
- For all 1-TOOL, 2-TOOL and 4-TOOL assemblies
- Also suitable for equipment and special flanges
- Suitable for single or multiple use
- Freely customizable with company logo, QR code, RFID chip
Advantages of flangeFIX
- Fast and error-free labeling
- Cost and time savings
- Can be used in any installation situation
flangeFIX in three variants:
The labeling system is available in three versions: for the use of an assembly tool or for the parallel operation of two or four tools:
- 1TOOL – Assembly sequence when using a tightening tool
- 2TOOL – Assembly sequence when using two Tightening tools crosswise
- 4TOOL – Assembly sequence when usingfour tightening tools crosswise
A flange connection ideally consists of the components flange, screws, nuts, seal and anti-twist washers. However, certain quality assurance measures must be taken to ensure the tightness of a flange connection.
In order to achieve the desired tightness class, essential boundary conditions are necessary. In addition to the specification of the tightening torques, this also includes the exact marking of the flanges with regard to the assembly sequence of the screw connections to the assembly personnel. And this depends on the number of assembly tools used.
flangeFIX: The numbers on the tape indicate the sequence and the stages in which the individual screw connections are to be tightened in accordance with national and international regulations.
Reaction arms and supports
- Custom-made products for all torque wrenches
- Axial reaction arm extensions
- Inline reaction arms
- Reaction arms with adjustment option 360 ° / 360 °
- TWINTORC- Reaction arms
Hydraulic hoses and accessories
- available with couplings from all manufacturers
- Pressure gauges in class 1.0 and 1.0
- Hoses in 5 m or 10 m lengths
- tested according to BGR237
- Burst pressure 2,800 bar (4-fold safety)
- Special lengths available on request
For external and internal threads
For a precise screw connection, clean external and internal threads are an absolute basic requirement, without which a precise assembly preload cannot be achieved. This applies both to the internal thread of the nut and its contact surfaces as well as to the external thread of the bolt and its shaft.
Automatically adjustable thread cleaner for external and internal threads
- simple, easy and quick to use
- compact and ergonomic shape
- safe and spring-mounted round brushes
- almost wear-free
- low service and maintenance costs
- fixed and adjustable internal thread cleaners
- optionally with suction
- available complete in case
External thread cleaner
The external thread cleaners are used for the optimal cleaning of threaded bolts in sizes M8 to M230. The patented brush system allows automatic and stepless adjustment to the thread diameter in the respective adjustment range. Both the thread turns and the threaded shaft can be machined in one operation. The flank top and bottom sides of the thread are optimally cleaned of adhering rust and dirt and smoothed. This results in an even coefficient of friction in the thread. The spring-mounted stainless steel brushes sit in a solid aluminum housing. By turning the feed ring, the contact pressure on the brushes is continuously adjusted over the entire adjustment range. This means that the devices can be optimized for the respective cleaning task.
Internal thread cleaner
The internal thread cleaners are used for optimal cleaning of threaded holes in sizes M60 to M210. The protected technology allows an automatic and stepless adjustment to the thread diameter in the respective adjustment range. A set with special individual brushes is available for the range from M8 to M70. The flank upper and lower sides of the thread are optimally cleaned of adhering rust and dirt with the internal thread cleaner and smoothed. This achieves an even coefficient of friction in the thread. The stainless steel brushes sit in an aluminum brush holder. After loosening the screws and then turning the feed ring, the brushes are continuously adjusted to the desired thread diameter (in the respective adjustment range).