During the installation of brackets and panels in large-scale solar projects, thousands of bolts must be tightened with appropriate torque to ensure a secure connection of the array. Tightening bolts too tightly can damage the long-term structural integrity of the system. Loosening the bolts can cause the components to loosen. Therefore, appropriate torque during installation is an important factor in ensuring successful operation and maintenance.

Mark Kelly, Product Marketing Manager at Milwaukee Tools, said he has seen audit results for solar projects showing a wide range of torque values, with up to 80% of bolts in incorrect positions at some sites despite passing quality inspections.

Incorrect torque is a common issue in solar projects, "Kelly said. The traditional two-step method involves first tightening the bolts with an impact wrench, and then manually tightening them with a click torque wrench, which heavily relies on the operator's skills. This can result in poor torque repeatability and severe overtightening

There are various tools and techniques to ensure torque consistency. The torque rod will absorb additional impact force when it reaches the preset torque level. Some installers avoid using battery powered tools to prevent insufficient torque due to low battery voltage. More technicians rely on markings to record the degree of bolt tightening, in order to see if it has changed over time.

However, not all of these suggestions are 100% reliable. Milwaukee's goal is to improve this field for solar installers. The company's M18 FUEL impact wrench is equipped with a TORQUE-SENSE sensor, which helps to obtain repeatable torque values.

Kelly said, "This tool provides repeatable torque results, ensuring consistent and reliable fastening, which is crucial for the quality and safety of solar installations

It does not require additional additions to existing impact wrenches like torque rods, as all core components are integrated inside the impact wrench. No need for two-step operation, only one tool is needed to provide the required torque value.

Milwaukee also offers "one click" technology, which can record each trigger pull and capture data such as target torque levels and error reports. The recorded data helps to detect potential issues early, enabling proactive maintenance and reducing downtime.

Kelly stated that access to ONE-KEY data can be customized according to project requirements, but typically individual installers, EPCs, and asset managers can see torque figures.

EPC can access data to help ensure that torque control settings are fully utilized and manage tool usage across multiple projects. Project managers can track tool performance, utilization, and maintenance plans to optimize project efficiency, "he said. The quality assurance team can use this data to verify whether the installation meets the required standards and generate reports for auditing. Each tool owner can customize settings, track tool locations, and monitor usage to prevent losses and ensure proper maintenance