Development of an Automated Wheel Spanner for Automobile Tyre

The process of tyre replacement is often tedious and challenging, particularly when dealing with stubborn or corroded wheel nuts. This study presents the design, fabrication, and performance evaluation of a sensor-based automated wheel spanner developed to address the limitations of conventional manual lug wrenches used in vehicle maintenance.
The system was designed through computer-aided modeling and simulation in Autodesk Inventor, followed by hardware implementation using a 20V DC planetary gear motor, Arduino microcontroller, current sensor, relay, buzzer, and lithium battery as the primary components. Mathematical analysis guided torque specification and gear design, while cost-effective materials such as stainless-steel shafts and PVC housings were employed to ensure durability and affordability. The developed device operates by delivering controlled torque through an integrated current-sensing mechanism that automatically terminates motor action once the preset torque threshold is achieved. An audible buzzer provides real-time feedback, while a digital display records operating parameters. Testing and comparative evaluation against a conventional manual spanner were performed on multiple Toyota car models, focusing on torque accuracy, operation time, and consistency.
Results revealed that manual tightening required an average of 247 seconds with torque values ranging between 108–115 Nm, while loosening averaged 213 seconds with similar variability. In contrast, the automated spanner achieved tightening in 3.76 seconds and loosening in 3.54 seconds, both with consistent torque application at approximately 111 Nm. This represents a time reduction of over 98% alongside improved torque precision and user convenience.
The study concludes that the automated wheel spanner significantly enhances efficiency, safety, and reliability in vehicle maintenance while reducing operator fatigue. It offers a low-cost, portable, and user-friendly alternative to commercial impact wrenches, with potential applications in automotive workshops, roadside services, and personal vehicle toolkits.