For production managers and maintenance supervisors, deciding between brushed vs. brushless electric screwdrivers directly impacts tool life, maintenance intervals, energy efficiency, and long-term cost of ownership.

What’s the Difference Between Brushed vs. Brushless Electric Screwdrivers?

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At a high level, the difference between brushed and brushless electric screwdrivers comes down to how the motor is powered and controlled. That difference affects durability, efficiency, and suitability in assembly operations. Understanding how each motor type works makes it easier to determine which is the better fit for your unique application.

Brushed Electric Screwdrivers: How They Work and Where They’re Best Used

Brushed electric screwdrivers use carbon brushes and a commutator to transfer electrical current to the motor. The copper windings are located in the rotor, while permanent magnets sit in the stator. This mechanically simple design has been used for decades and helped make brushed tools widely available and cost-effective.

Key characteristics of brushed electric screwdrivers:

• Mechanical commutation using carbon brushes
• Simple voltage-based speed control
• More heat generated due to friction and electrical loss
• Brush wear limits duty cycle and service life

Because of these factors, brushed tools are typically best suited for light-duty or intermittent applications.

Brushless Electric Screwdrivers: How Electronic Control Improves Performance

Brushless electric screwdrivers eliminate physical brushes entirely. Instead, electronic controllers manage commutation, with copper windings located in the stator and permanent magnets mounted on the rotor. This design significantly reduces friction, heat, and wear while allowing for precise electronic control of speed and torque.

Key characteristics of brushless electric screwdrivers for industrial assembly

• Electronic commutation (no brushes or commutator)
• Intelligent electronic speed and torque control
• Motor runs cooler and lasts longer
• Higher power utilization and efficiency

Because brushless motors adapt electronically to maintain performance under load, they are better suited for industrial and high-demand assembly environments.

When to Choose Brushed vs. Brushless Electric Screwdrivers for Assembly Applications

Choosing between brushed and brushless electric screwdrivers depends on production volume and performance expectations. Each technology still has a role, but those roles are increasingly different.

When Brushed Electric Screwdrivers Still Make Sense on the Assembly Line

Brushed tools remain a good choice in manufacturing environments where production demands are limited, and cost sensitivity is high. Typical brushed screwdriver use cases include:

• Low-volume or infrequent fastening tasks
• Simple applications without strict torque accuracy requirements
• Budget-driven tool replacement for legacy systems

However, brushed tools require periodic brush replacement and experience more heat buildup and sparking, which limits continuous use.

Brushless Electric Screwdrivers Are the Better Choice for High-Volume Assembly

Brushless electric screwdrivers are designed for manufacturing environments where uptime and consistency are critical. Common brushless screwdriver use cases include:

• High-volume or continuous production lines
• Longer duty cycles and heavier workloads
• Applications requiring consistent torque output
• Operations focused on reducing downtime and maintenance

Because brushless tools can maintain torque and speed under load and produce less heat, they are better suited for demanding assembly operations.

Matching Motor Technology to Assembly Stations

The choice between brushed and brushless electric screwdrivers often becomes clearer when evaluated at the station level, where torque requirements and duty cycles vary significantly.

For example, in electronics assembly, medical devices, and small component fastening, torque requirements typically fall in the 2–20 lbf-in (0.2–2.3 Nm) range. These stations prioritize precision, repeatability, and operator comfort, making brushless electric screwdrivers the obvious choice on the assembly line.

Why Brushless Electric Screwdrivers Are Becoming the Standard in Manufacturing

Brushless technology has become the preferred choice in many manufacturing facilities due to several measurable advantages:

Reduced Heat and Increased Durability

Brushed motors generate more heat due to brush friction, while brushless motors run cooler, allowing them to support longer duty cycles, handle heavier workloads, and deliver a longer tool life.

Lower Maintenance and Reduced Assembly Line Downtime

Brushed tools require carbon brush replacement as part of routine maintenance. Brushless tools eliminate this wear component entirely.

Although brushless electric screwdrivers have a higher upfront cost, they typically offer a lower total cost of ownership due to fewer tool failures and less unplanned downtime.

How to Choose the Right Electric Screwdriver for Your Operation

In addition to performance requirements, it’s important to consider how motor technology is evolving across the industry. For example, HIOS has officially discontinued its brushed electric screwdriver platforms, including long-running CL, VZ, and VB series, as part of a broader shift toward brushless platforms designed for higher efficiency, longer tool life, and next-generation technology.

According to HIOS, legacy brushed designs present inherent challenges in modern manufacturing environments, including carbon brush dust generation, periodic maintenance requirements, and increased safety management concerns associated with high-voltage operation. At the same time, growing emphasis on durability, energy efficiency, environmental impact reduction, and traceability has accelerated the transition toward brushless motor platforms.

For facilities currently using HIOS brushed tools, reviewing our substitution guide can help simplify future replacements and support evolving production demands.

Working with an experienced fastening partner like ASG can help ensure your electric screwdriving solution aligns with both current production needs and long-term scalability, while also accounting for industry trends and product lifecycle changes.

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The Role of Tape Dispensers in Lean Manufacturing

Tape dispensers can help manufacturers fully embrace lean principles. By automating certain procedures, tape dispensers contribute to increased productivity, improved accuracy, reduced waste, and minimized physical strain on workers.

Increased Productivity

One of the primary benefits of using tape dispensers is increased productivity. These devices make the assembly process easier for workers by dispensing and cutting the correct amount of tape with precision. Through the press of a button or the use of sensors, tape dispensers ensure that workers can focus on other aspects of the assembly line while having tape readily available when needed.

Improved Accuracy

Also, the importance of consistency cannot be overstated, and tape dispensers deliver consistent results by cutting the same amount of tape each time. This level of accuracy is especially beneficial for applications requiring multiple pieces of tape as fasteners or seals, where uniformity leads to higher quality finished products.

Reduced Waste

Waste reduction is another way to lower costs and operate a lean facility. Certain tape, such as Kapton tape, can be expensive, making any waste costly. Tape dispensers cut tapes at precise measurements, minimizing waste caused by cutting too long or too short of pieces for specific applications. This efficiency not only reduces costs but also promotes sustainability by limiting material waste.

Reduced Strain and Injury Risk

Manual tape cutting can be physically demanding, leading to strain on workers’ hands and wrists, and increasing the risk of repetitive motion injuries. Tape dispensers alleviate this strain by automating the cutting process and reducing the physical strain on workers. By minimizing injury risks, tape dispensers contribute to a safer work environment while improving overall productivity.

To conclude, embrace lean manufacturing with automatic tape machines like the EZ-9000GR. By enhancing productivity, accuracy, waste reduction, and worker safety, tape dispensers align with the core objectives of lean manufacturing, making them a valuable asset for any manufacturing operation requiring the use of tapes as fasteners.

References:

• Principles of Lean Manufacturing | ASCM. (n.d.). ascm.org

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Here is what you can expect:

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The new BLG-7000BC2-GT from HIOS is now available on ASG Express. This tool is available with either a handle or a stand. It is an electric screwdriver with an ergonomic design and smart features built in. Shop now: https://asg-jergens.com/product/blg-7000xbc2-gt-s-electr-driver-1-4-hex/

With this smart electric screwdriver, you get:

• Brushless motor: environmentally friendly with no emission of carbon particles, improving durability and stability. Additionally, it lowers maintenance costs and downtime since there are no brushes to replace.
• IoT System: data can be collected and centrally managed in the cloud
• Effective control: settings of the screwdriver can be changed via PC or PLC
• Direct teaching: when fastening several screws directly into a workpiece, it will automatically learn the number of rotation pulses from fastening start to seating
• Screw counter: you can set the number of screws from 1 to 99. The remaining number of screws is counted down

Combine all those features with an easy-to-grip ergonomic design, and you have a smart and capable tool.

To learn more about this tool or see it in action, check out this video from HIOS:

The post Error-Proofing in Assembly with the New HIOS BLG-BC2 Series Electric Screwdriver appeared first on ASG.

Balancers are frequently used not only in the automotive and electrical industries with screwdrivers and a host of other fastening applications, but they’re also used in other vocations such as welding. Furthermore, they go by other names such as retractors or compensators.

The features and benefits of tool balancers also include everything from the load they’ll carry (zero-gravity & weightless are amongst the options) and you’ll also see heavy-duty balancers out there on the market. How about explosion proof? There is an ATEX version of balancers for that. Spring loaded, stainless, you name it there is probably a balancer to meet your needs.

We have five main different factors to take into account when deciding upon which balancer will best fit your needs. We won’t dive into the deep end here, but these are the top five factors which should be on your radar as you begin your search for the perfect balancer to fit your application needs:

• Weight
• Cost
• Dimensions
• Specialized application needs
• Ergonomics

Addressing Health Concerns

To that last bullet point on ergonomics, this is a tool balancer’s largest benefit.

The frequent and repetitive movements of the assembly process have long been proven to have certain physical ramifications for the workers completing the assembly process.

If you would like to learn more about the direct impact of ergonomics in relation to assembly line workers specifically, please see the research below provided by the National Center for
Biotechnology Information:

• Musculoskeletal disorders (MSDs) continue to be a tremendous burden in industry with low back and shoulder disorders being among the most common and costly disorders (NRC, 2001; Dunning et al., 2010). Automotive manufacturing is one of several industries that has a high incidence of MSDs*.
• Electronics assembly workers are also reported to have a high prevalence of musculoskeletal disorders (MSDs)**.

Ready to Purchase a Tool Balancer?

Here at ASG we carry several different types of tool balancers and tool positioners.

View ASG Tool Balancer & Tool Positioner Options Here: https://asg-jergens.com/balancers-positioners/

If you have any questions about a balancer or positioner purchase, or need further assistance, please contact ASG Customer Service at 888-486-6163 or asginfo@asg-jergens.com.

SOURCES:

*The Ohio State University, Integrated Systems Engineering,
Biodynamics Laboratory, Center for Occupational Health in Automotive
Manufacturing, 210 Baker Systems, 1971 Neil Avenue, Columbus, OH 43210, USA

**Maimaiti N, Wang J, Jin X, Wang S, Qin D, He L, Wang F,
Zhang Z, Forsman M, Yang L, Yang Q, Wang H. Cervical musculoskeletal disorders
and their relationships with personal and work-related factors among electronic
assembly workers. J Safety Res. 2019 Dec;71:79-85. doi:
10.1016/j.jsr.2019.09.018. Epub 2019 Nov 13. PMID: 31862047

The post Identifying the Features You Want in a Tool Balancer appeared first on ASG.

This potential bottleneck will naturally lead the way towards the most important question at hand.

Do we need a label applicator, or a label dispenser, and what is the difference?

Label Applicators

A label applicator can be as small as a price gun or as large as an automated station on an assembly line. These units offer touchless removing of the backing and application of the label. Within an assembly environment these can take up valuable real estate on the manufacturing floor along with the high price tag barrier.

Label Dispensers

Label dispensers, on the other hand, offer a much more economical option and there are multiple options available. Most of the options will be of the mechanical and/or hand-held variety dating back to the first label dispensers of the 1920s. While these options improve productivity by providing the user with a process which doesn’t require peeling each label, there is an even better option which we’d like to focus on: Automatic label dispensers.

ASG’s Automatic Label Dispenser Solution

Auto label dispensers combine ease of use with dispensing. While the labels need to be manually applied to the surface, these dispensers remove the backing, and once a label is taken for application the dispenser serves up the next label automatically.

Here are a few of the features and benefits of an ASG LDX-130 label dispenser:

• Compact and versatile label dispenser fits any workbench or assembly station
• Increases productivity by automatically dispensing labels while removing and discarding backing material
• High performance, durability and affordable quality
• Designed for industrial and commercial use
• 10 Feeding speed settings
• LED Counter tracks the number of labels dispensed

View the LDX-130 Here: https://asg-jergens.com/ldx-130-label-dispenser/

Video: https://www.youtube.com/watch?v=FyVMShA6vZY&t=2s

Here at ASG we also carry several different types of tape dispensers. Like the label dispenser, they provide the user with a way to streamline the taping process.

View ASG Tape Dispenser Options: https://asg-jergens.com/tape-label-dispensers/tape-dispensers/

If you have any questions about a dispenser purchase, or need further assistance, please contact ASG Customer Service at 888-486-6163 or asginfo@asg-jergens.com.

The post All About Labels – A Guide to Efficient Labelling appeared first on ASG.

• Full Scale (FS)
• Indicated Value (IV)

The differences between these two metrics are significant.

Full Scale (FS) accuracy measures the allowable error over the full-scale range of the tool. When utilizing Full Scale, the tolerance against the scale varies from 5% to 50% (based on a tool that is accurate to + or – 5%) because we’re looking at the full range of the tool.

Indicated Value (IV) measures the allowable error at the set point on the wrench. When utilizing Indicated Value the scale varies at 5% at each value rather than the full scale.

What this means is that Indicated Value (IV) wrenches are more accurate to the specified torque level of your application. This is especially true at the lower end of the torque range.

The table below shows the allowable tolerance for Full Scale vs. Indicated Value accuracy:

Still researching? This blog post entitled Click, Break or Slip? Picking the Right Torque Wrench covers the types of torque wrenches and can assist you in selecting the perfect wrench for your application.

Ready to make a torque wrench purchase? See our full line of torque wrenches to find a tool which will provide the consistent threaded fastening results you’ve become accustomed to receiving from ASG.

If you have any questions about a torque wrench purchase, or need further assistance, please contact ASG Customer Service at 888-486-6163 or asginfo@asg-jergens.com.

The post The Basics of Torque Wrench Accuracy appeared first on ASG.

The cordless brushless pistol grip torque driver and cordless brushless industrial angle nutrunner series is a welcomed addition to our product lineup which we’re sure you’ll find to be efficient and
effective options in your precision fastening efforts.

With brushless motors and high-capacity lithium-ion batteries, these cordless screwdrivers are perfect for areas in which getting an air or electric power line to a tool is difficult or not possible.

We loved these two models mainly due to their versatility, maneuverability and accuracy.

The series offers:

• Torque ranges covering a wide range of applications
  • Pistol Grip: 9-105 in-lb
  • Right Angle: 35-531 in-lb
• Auto shut-off clutch which stops the bit from turning once target torque is reached
• Brushless motors which generate less heat and require less maintenance
• Usability on a shop floor or out in the field

There are also plenty of built-in protections against the following common failures:

• Over Heat Protection (OHP)
• Over Current Protection (OCP)
• Stalling
• Low Power

Each kit was created with ease of use in mind and contains all of the necessary accessories to hit the ground running. Included is the tool itself, charger, li-ion battery, suspension hook ring (right angle), adjusting wrench (right angle), torque ring assembly, socket extension (pistol grip) and waist hook.

Experience increased freedom of movement and ergonomic comfort without sacrificing the consistent threaded fastening results you’ve become accustomed to receiving from ASG.

See and compare each model kit below!

Cordless Brushless Pistol Grip Torque Driver: BLC-8010K | BLC-8020K | BLC-8030K

Watch the Unboxing Video Here

Cordless Brushless Industrial Angle Nutrunner: BLCA-9010K | BLCA-9020K | BLCA-9030K | BLCA-9040K

Watch the Unboxing Video Here

If you have any questions about these cordless screwdrivers, would like a demonstration, or need further assistance, please contact ASG Customer Service at 888-486-6163 or asginfo@asg-jergens.com.

The post ASG Launches New Cordless Screwdriver Solutions appeared first on ASG.

Picking the correct size and shape for your application is a rather straight forward process which we will not be diving into in this post, but if you have any additional questions, please reach out to us at asginfo@asg-jergens.com.

Today we’re going to focus exclusively on the three main primary indicators which alert the user of a digital or manual torque wrench that they’ve achieved their desired level of torque.

So, let’s jump right into some of the finer details of those three primary indicators: Click, Break & Slip.

Click

The most widely known, and used, form of torque wrench in use – the click torque wrench.

Upon reaching target torque these wrenches alert the operator in two very distinctive and unmistakable ways. The first is the audible click while the second is the feeling of the click which signals that fastener’s completed sequence. Having two ways of alerting the operators to stop pulling the moment the click is heard or felt is of particular importance.

As pressure is released the tool automatically resets and can immediately be used on the next fastener.

With multiple target torque indicators, combined with the efficiency of not having to manually reset the tool, it is very clear why click wrenches have carved out such an impressive market share.

Break

While click wrenches offer the benefit of multiple indicators, there are certainly special use cases in which limiting the amount of torque placed on a fastening application is necessary.

A breaking torque wrench could prove to be the go-to tool for those with highly specific torque targets. Most breaking torque wrenches break at the fulcrum, usually at the tool’s head, upon reaching the preset torque value for the application.

Having the tool break at that specific point gives more of a safeguard against overtightening, but that said, if the operator continues to apply force, torque will in turn be applied above the torque limit.

Slip

The slipping or “cam-over” style torque wrench essentially eliminates the ability of an operator to continue placing torque on a fastener after reaching target torque.

Like the breaking torque wrench, a slipping torque wrench will cam over once target torque is achieved, but if the operator continues to apply force it will not result in torque being applied above the set limit.

Completely eliminating the possibility of over-torque on the fastener makes slipping torque wrenches perfect for applications which require extremely stringent quality guidelines. These instances could include everything from military or medical applications to consumer goods where safety is paramount.

The easiest way to ensure those guidelines are being followed was to create a wrench which takes any possibility of operator error out of the equation to produce accurate and repeatable results.

Want to Learn More?

For more insight on these mechanisms, this video from our partners at Gedore can provide a more visual representation of the information we’ve just covered.

Ready to make a torque wrench purchase?

See our full line of torque wrenches or go ahead and look directly at our line of Gedore products.

The post Click, Break or Slip? Picking the Right Torque Wrench appeared first on ASG.

Adding torque arms to your assembly process provides numerous benefits in both efficiency and reducing operator fatigue/injuries. Therefore, in many cases the decision to purchase a torque arm is very easy.

Discovering the details which lead you down the path of selecting the correct torque arm is the topic we’d like to address today. ASG put together a guideline of questions to ask yourself when in the market for a shiny, new torque arm.

Once you have the answers to these questions, you’ll be on the fast track to buying your dream torque arm, and outfitting it with all of the accessories necessary to get the most out of your purchase.

1. What type of tool are you using?

• Is your tool In-line? Right angle? Pistol grip?

• Is your tool a stall tool, clutch tool, transducerized tool, or even a pulse tool?

2. What configuration will the tool be in? Horizontal / vertical?

• This is important to the model you’ll need – how will this tool be set up during production?

• Are all fasteners being run in the same plane- horizontally, vertically?

3. What is the diameter of the tool?

• ASG offers several different kinds of adjustable tool holders based on the diameter of the tool’s grip. It is important to know the diameter of the tool to ensure the torque arm is fitted properly. Multi position holders and swivel holders are also available based on your desired application.

4. How heavy is the tool?

• Knowing the weight of the tool will help choose a torque arm that eases operator usage. The arm will be able to balance the tool to ensure proper application and lessen risk of operator
  injury.

5. What is the torque range of the application?

• For a pulse tool, the weight of the tool is more important than the torque.

6. How much reach is needed to capture all the fasteners?

• Will assembly be happening close by or a distance away?

7. Will a positioning system be necessary?

• Applying encoders to a torque arm system ensures that all the fasteners are run, and that they are run in the
  correct sequence.

Now that you know exactly what you’re looking for in a torque arm an informed purchase decision is just steps away! Please feel free to visit our selection of premium torque arms to see our
options at your disposal.

We’re happy to help!

If you have any additional questions, have an application which requires a custom torque arm, or need help selecting the correct torque arm, please contact us at asginfo@asg-jergens.com.

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