4 ways to Stop Injuries From torque reaction in manufacturing

Torque reaction is one of the biggest health and safety risks to operators. Constant exposure to torque reaction over time can cause many health issues or injuries that affect operators’ quality of life. There are several ways to overcome torque reaction and reduce its impact on skilled workers.

So let’s start with what torque reaction actually is and why it’s an industry-wide problem.

What is torque reaction and why does it matter?

Torque reaction is Newton’s third law of motion at work — for every action, there’s an equal and opposite reaction.

When an assembly process is completed and the target torque is reached, the operator can experience a twist or kickback in the wrist or arm. The higher the torque, the greater the reaction. However, torque reaction can become problematic even at torques as low as 10Nm.

Uncontrolled torque reaction is a safety hazard for operators. No matter the size or circumstance of the torque reaction, repeated consistently can lead to injuries such as stress fractures or carpal tunnel syndrome.

Aside from the health and safety risk, torque reaction can lead to inaccurate and inconsistent tightenings that affect the quality of your end product. An operator may under torque to avoid experiencing the reaction or over torque as a result of the stress of the reaction.

How do you Stop torque reaction?

Many production solutions allow you to control and manage torque reactions and prevent workplace accidents and hazards.

1) Tool programming

Specific tools can be optimised and programmed to reduce torque reaction. The tightening will be fast at the start and then slow down towards the end when torque is reached, helping to achieve precise control over torque delivery. Tool programming provides a safer and more controlled way to manage torque, but it only works in scenarios with low torques and can only be applied with certain tools.

2) Reactionless tooling

Reactionless tooling uses pulse technology to prevent torque reaction. It works by applying torque using an intermittent impact rather than a constant force — so no reaction occurs. Using reactionless tooling removes hazardous reaction forces, ensuring operators maintain ergonomics while improving the speed of production. Reactionless tools are effective up to torques of 50Nm.

3) Reaction arm

A reaction arm is an external mechanical device used when operating tools such as electric screwdrivers and nutrunners. Reaction arms can be installed on existing production lines or as stand-alone installations. The carbon fibre devices are designed to absorb the torque reaction produced by the industrial tool, so the reaction never reaches the operator’s hand. This way, the operator is protected from musculoskeletal stress, and can work more comfortably and productively.

4) Cobot

Cobots (collaborative robots) completely eliminate the risk of torque reaction by replacing the need for human interaction in the production process. Unlike other solutions, cobots are suitable for very high target torques and can work cohesively in any large or small-scale set up. By removing human risk from the production process, your business can improve employee well-being, reduce labour, and improve flexibility and efficiency.

Stop torque reaction with production solutions from Abbey Industrial Solutions

Torque reaction is a huge issue in the manufacturing industry, but one that can be overcome with efficient and cost-effective production solutions. Investing in high-quality, ergonomic tools like cobots, reaction arms and reactionless tooling can significantly reduce and even remove torque reaction altogether.

At Abbey Industrial Solutions, our trained experts understand your needs and pair you with the right tools for your business, resulting in a safer working environment for operators and improving the speed and efficiency of your production processes.

If you would like to know more about how we can help maximise your productivity. contact us today to arrange a free, no obligation consultation.