Full-Color Smart Digital Torque Tool Mainboard

The client planned to upgrade traditional torque tools into smart digital products. We delivered the complete hardware and software solution for the full-color smart torque tool mainboard — covering the measurement chain, display and interaction, firmware features, connectivity and power management — as a modular product base that can be freely combined to match market positioning.

Solution Contents

High-Precision Measurement Chain

• Strain-gauge full bridge + 24-bit delta-sigma ADC with software-switchable gain to match sensors of different ranges;
• Multi-stage digital filtering and spike suppression against vibration and EMI;
• Power-on zero self-calibration + multi-point linear calibration, with in-field recalibration support;
• IMU gyroscope for automatic tightening-direction detection, CW/CCW calibrated and displayed separately;
• Typical accuracy ±2% CW / ±2% CCW; range covers 1–1000 N·m by calibration model, with high-precision angle sensing.

Display and Interaction

• 1.69-inch color IPS (240×280) with dynamic torque-curve display;
• Visualized peak, target and tolerance band;
• Multi-unit display (N·m / kgf·cm / lbf·in / lbf·ft); multilingual UI extensible on demand.

Measurement Modes and Features

• Three measurement modes — PEAK / TRACK / preset + tolerance — with three-level audio-visual-haptic alerts as the target is approached, reached or exceeded;
• Large history storage (thousands of records) with curve playback and export;
• Preset groups for quick parameter switching in the field; configurable auto-sleep / auto-off.

Connectivity and Data

• USB Type-C: virtual serial port + open ASCII command protocol covering parameter read/write, live torque streaming, history export, calibration and firmware upgrade — easy for secondary integration;
• BLE 5.x: connects to mobile app / host tool with live curves and data upload; optional Wi-Fi and LoRa networking;
• Companion desktop tool (Windows): live torque curves, parameter configuration, history export (CSV), guided factory calibration and firmware upgrade.

Power and Reliability

• Two power options: Li-ion (Type-C charging with fuel gauge) and dry cell;
• Sub-μA sleep + DVFS low-power architecture keeps even the color-display model power-efficient;
• USB plug-in wake-up with seamless power switchover — works with or without a battery;
• Secure bootloader OTA, no bricking on power loss;
• Complete PCBA test specification (19 functional blocks, 100+ test cases) plus reliability verification: high/low temperature, drop, ESD and more.

On this modular base, display, power, connectivity and range dimensions can be freely combined to quickly spin off a full smart-tool product line from entry-level to networked models.

— Feel free to contact us to learn about our technical capabilities and cooperation models in this field.