BoltSense® Technology | Copper State

BOLTSENSE® TECHNOLOGY

BOLTSENSE® TECHNOLOGY OVERVIEW AND TRANSMISSION OPTIONS

BoltSense® revolutionizes milling operations by transmitting essential tension data via Load Indicating Fasteners (LIF) and Load Monitoring Fasteners (LMF+®), enhancing operational integrity.

Load Indicating Fasteners (LIF): LIF bolts facilitate precise spot checking of tension through a Magnetic Clip-On Reader that connects to the iOS Bolt Reader app via Bluetooth. Simply remove the protective dust cap, attach the reader to the LIF’s PCB board, and instantly log the bolt’s tension. This innovative method surpasses traditional UT and load-indicating techniques in both ease and efficiency. For optimal experience, we offer a Ruggedized Tablet with Mount, pre-equipped with the Bolt Reader app, designed for robust field use.

Load Monitoring Fasteners (LMF+®): LMF+® bolts are equipped with a Transmitting Cap that remains in place during operation, facilitating continuous monitoring. This feature transmits data directly to any iOS device through the Bolt Reader app, providing real-time feedback during installation and routine assessments, an invaluable tool for immediate operational adjustments. For critical flange hardware situated around the world, the Global Data Network (GDN) offers expansive coverage through transceiver gateway, which then relays the data to a cloud-based network.

BOLTSENSE® TECHNOLOGY SPECIFICATIONS

HARDWARE & DESIGN

Sensor Type: Strain gauge embedded in the bolt’s central axis
Bolt Sizes:
- Headed Products: 3/4" (M20) and above
- Threaded Studs: 1 1/8" (M30) and above
Bolt Grades: Compatible with all bolt grades

DURABILITY

Water/Dust Resistance: IP65 (optional IP67/IP68)
Vibration & Shock: IEC 61373 standard
Corrosion Protection: ASTM B117 standard
Fatigue Resistance: Engineered for high-cycle fatigue environments
Operating Temperature Ranges:
- Standard Battery: –25°C to 85°C (–13°F to 185°F)
- Non-Standard Battery: –40°C to 85°C (–40°F to 185°F)

ACCURACY & STANDARDS

Load Measurement Accuracy: ASTM F2482 ±5% (commonly ±2% in practice)
Testing & Quality Assurance: A2LA Accredited Laboratory and ISO 9001:2015-certified production

WIRELESS TRANSMISSION & RANGE

Technology: Bluetooth® Low Energy for standard configurations
Range:
- Standard: Up to 150 ft (45 m), subject to environment
- Extended: LoRa available (up to 5 km range); 1 km range caps under development
Global Data Network (GDN): Transmits bolt data to the cloud for remote access and predictive maintenance

FREQUENTLY ASKED QUESTIONS

TECHNICAL SUMMARY SHEET FOR THE DATA MONITORING FASTENER

I	Adheres to ASTM F2482: Classifies as “4.1.3 Strain Gauge Type (ST)—This type of fastener incorporates a bonded device wired in a Wheatstone bridge configuration which, through changes in relative resistance, reports tension in the fastener.” Calibration will be conducted with tension forces at 25 % increments up to the fastener proof load and must exhibit ±5 % accuracy. Performance. The load-indicating fastener shall be calibrated to ±5 % accuracy up to the proof load of the fastener unless otherwise specified at the time of order. Calibration Accuracy Test Reports may be requested and shall show the heat number (to ensure that the chemical composition is on record and could be furnished upon request), calibration loads, nominal size, calibration of accuracy lot identification number, ASTM designation, type or grade, issue date, and purchase order number.
II	Electronics Supplier conforms to BSI ISO-9001:2015 management and documentation standard.
III	Battery life will vary depending upon environment and programed intervals of data collection. For reference, long term testing has shown that with 5-minute intervals average battery life is 3.8 years and typical life with 1-hour data collection intervals can exceed 5 years.
IV	Operating Temperature Ranges: -25°C to 85°C with standard battery -40°C to 85°C with non-standard battery
V	Standard water resistance conforms to IP65 and can be sealed to IP68
VI	Application specific 3rd party testing for vibration, shock, temperature, cyclical loading, corrosion, and combined environment can be conducted at customer’s request.
VII	Electronic PCB pads are gold plated for corrosion resistance.
VIII	Shock and Vibrations IEC61373
IX	Corrosion ASTM B117
X	Standard O-ring material is Viton. Application specific sealing is available. Changing O-ring at same time as battery is recommended.