Databolt: Real-Time Load Monitoring in a Smart Bolt
DATABOLT
The Databolt is built using Forcesure’s expertise in sensor technologies. Each bolt delivers accurate and reliable bolt tension measurement through a wired or wireless connection. This allows engineers to detect whether the connection is still clamped or measure tension changes in real-time.
Flexible for all kinds of industries
How It Works
Each Databolt contains an integrated sensor embedded within the bolt. As the bolt stretches or vibrates under load, the internal displacement changes. The sensor captures this change and converts it into a voltage output signal (0.5-4.5 V), providing real-time actionable data and accurate predictive capabilities.
Key features of the Databolt
- High Linearity: Within ±0.2% deviation
- Temperature-stable: Accurate across a wide range of conditions
- Compact: Adds only ~2.5 grams to the bolt
- Customizable: Works with various bolt materials and classes
Connectivity
Databolt is connected with
a small connector on top of
the bolt to measure the
bolt force in real-time.
Measurement
Databolt is integrated with
a force measuring sensor,
capable of delivering real-time
insights into bolt tension.
Welded Housing
The housing is micro-welded
and injected with UV resin
to prevent any dust or water
from entering the sensor.
Key Advantages
Why Choose Databolt?
- Real-Time Monitoring
Continuously track bolt tension, overload, and vibration, no need for manual checks
- Predictive Maintenance
Detect issues before they turn into failures. Plan maintenance based on data, not on assumptions.
- Plug-and-Play Design
Replace a standard bolt with a Databolt. It is as simple as that.
- No Batteries or Wireless Complexity
Wired connection ensures stable, interference-free data transmission, ideal for industrial environments.
- Scalable and Customizable
Available sizes from M10 to M30. Custom applications or sizes are available on request.
Remote Bolt Force Monitoring
Forcesure’s IoT-Module enables our Databolt to monitor bolt tension data remotely. This compact, LTE-connected device allows you to connect multiple Databolts and transmit real-time bolt force data from even the most remote or hard-to-reach places. With up to 4 years of battery life, IP67 protection, and support for multiple data protocols, it transforms your bolt monitoring setup into a fully connected, predictive maintenance system.
Why Measuring Force Matters More Than Ever
Want to know why force measurement is becoming the new standard in structural health monitoring? Discover how accurate force data is changing the way engineers approach safety, efficiency, and reliability.
Industrial Applications
Databolt is useful in industries where bolt integrity is critical. Whether you are working with small safety components or massive structural joints, Databolt delivers the insights you need. Discover how Databolt can benefit rail, wind, infrastructure, and energy sectors.
Wind Turbines
Foundation anchor bolts, nacelle frame bolts, blade root bolts, tower section flange bolts
Rail
Fishplate bolts, crossing bolts, rail clamps, tie plates, stretcher bar bolts
Infrastructure
Structural flange joints, and infrastructural connections
Energy
Pipeline supports, offshore platforms
Test it yourself with the M10 starter kit
For anyone interested in testing our technology before integration, Forcesure offers a test kit that includes an M10 Databolt and a compatible readout device. This kit is available on request and is ideal for internal testing, prototyping, or demos.
Ready to integrate Databolt into your systems? Whether you’re looking for a specific size, a custom material, or a full deployment strategy, our team is here to help.
Databolt delivers predictive maintenance capabilities without complexity. Plug-and-Play force monitoring for any bolt size.
FAQ
What is Databolt?
Databolt is a sensor integrated smart bolt that enables real time bolt load monitoring by measuring changes in bolt tension directly in the fastener. It supports engineers to verify preload during installation and monitor preload loss, overload and vibration driven tension changes during operations.
What is bolt load monitoring?
Bolt load monitoring enables measurement and tracking of the actual clamp force in a bolted connection over time. It could be used to verify whether a joint is correctly preloaded, detect loss of tension or relaxation, and prevent failures caused by insufficient clamp load or unexpected overload.
What is the difference between bolt tension, preload and clamp load?
Bolt tension is the tensile force in the bolt shank. Preload is the intended bolt tension applied during tightening. Clamp force is the compressive load clamping joint parts together. In most practical bolted joints these values are directly related, so monitoring bolt tension is a reliable way to verify whether a joint remains clamped.
Why is bolt preload monitoring important?
Correct bolt preload is crucial for maintaining joint integrity, extending fatigue life, enhancing vibration resistance, ensuring sealing performance, and ensuring structural safety. If preload drops below the required clamp load, joints can slip, leak, loosen, or crack. If preload is too high, it can damage threads, bolts, flanges, or joint members.
Why is torque not a reliable way to confirm bolt load?
Torque is an indirect input and does not directly measure bolt tension. Friction scatter at the threads and under the head, surface conditions, lubrication, and tool variation can cause large deviations between the intended preload and the actual preload. Databolt provides direct measurement of the force rather than assuming it from torque.
What problems does Databolt solve in critical bolted connections?
Databolt is used to reduce uncertainty in bolted connections by providing direct force measurement for:
- Preload verification during installation
- Detecting preload loss and relaxation in service
- Identifying overload evetns and vibration driven changes
- Reducing manual inspections and retightening cycles
- Enabling condition based maintenance on critical joints
How does Databolt measure force?
Each bolt contains an integrated sensor embedded within the bolt. As the bolt stretches or experiences load-related micro movement, the internal change is measured. The sensor captures this movement change and converts it to a stable voltage output signal for measurement and monitoring.
Is Databolt wired or wireless?
Databolt is initially a wired smart bolt. It utilises a small connector on top of the bolt to provide stable, interference-resistant data transmission. It provides an analog voltage output in the range 0.5 to 4.5 V. This makes integration straightforward with standard data acquisition systems, PLC analog inputs, and monitoring hardware.
Can Databolt be used for remote bolt load monitoring?
Yes, Databolt can be connected to a Forcesure IoT module to transmit bolt force data remotely. This enables monitoring for hard-to-reach or distributed assets by connecting multiple databolts to a compact LTE-connected device and sending data for analysis and alerts.
What sizes are available?
Databolt is available in different materials and sizes from M10 to M30, with custom sizes and application specific configurations on request.