The customer came to Air Power wanting to upgrade their pump package that supplies material from their paint kitchen to two applicators on each end of their booth. The booth runs 60’ long, with a width of 20’ and would be used to touch up dump truck beds. After running a pressure drop calculation we determined that the material could fall out of solution if there were a day or 2 that no spraying was needed.
Air Power Solution
After reviewing the application with the customer, Air Power proposed using a 3:1 Graco Endura-Flo pump. This option allows for the 3x the pressure, which was more than enough to overcome any pressure loss during the materials travel, as well as, has a much larger fluid section requiring less wear and tear on the pump while in operation. Since this is strictly a touch up process and not guaranteed to be an everyday event, we also recirculated the fluid lines to prevent any material from falling out of solution.
This solution provided more than enough pressure to power the required spraying. Additionally, if there’s an occurrence where the system isn’t used for several days, the customer only has to run the pump a few minutes before spraying to move the stagnant material back within the agitated drum requiring no waste or quality concerns.
The Air Power solution solved the pressure problem, the potential solution issues, and provided a much larger fluid section to prevent wear and tear.
A local axle manufacturer has had ongoing issues with accurate torqueing of axle shaft bolts. The bolts are inaccurately torqued with pneumatic pulse tools or missed altogether by the operators as they are in 8 lug and 12 lug patterns and require many accurate rundowns to produce a quality part.
Air Power Solution
Apex Tool Group intelligent 4 spindle multi-spindles with torque management arms eliminate both inaccurate torques along with potential mishits of fasteners. The 4 spindles will be adjustable to hit both patterns, highly accurate within a few percent of the targeted torque, and have rotational transducers that will tell us which fasteners have been hit and eliminate missed fasteners and re-hits by the operators.
This solution will decrease the amount of manual operator input of fastener tightening thus speeding up the manufacturing process, as well as, eliminate re-hits and missed fasteners by the operators. This system will collect data and communicate with their existing MES system to confirm the accurate torque of each set of axle bolts, providing data points and a birth certificate of a successful assembly. This will have a profound effect on both the quality of the parts produced as well as the speed at which they are produced. One ergonomic bonus – the system will remove the operator from handling the existing large pneumatic pulse tools manually creating for a safer and more sustainable work environment.
This case study was presented by Baltimore Key Account Manager Lorne Rickert.
A counterweight was attached to a turntable before the Hydraulic Motor which “keys” the turntable to the frame, located underneath. The counterweight caused the turntable to rotate until it was so far off balance that the Turntable with Counterweight fell off the Frame, coming to a rest about 2’ from a Team Member! This posed a significant safety hazard, as well as, assembly frustration to the onsite engineering team.
Air Power Solution
Air Power utilized an Ingersoll Rand QX Power Tool and Sturtevant Richmont Digital Wrench to positively confirm that all of the tightening’s have been completed before the Counterweight can be installed.
Air Power’s Engineering Team, Michael John and Jesse Bryant, designed a “Lifting Sling Lock” device that will not release the lifting sling for the counterweight until the Tightening’s are complete – a Poke Yoke control to insure safety. This “Lifting Sling Lock” is utilized in conjunction with the I/O output of the Ingersoll Rand QX and the STR Digital Wrench, thus eliminating the safety hazard of a dropped counterweight. The Lifting Sling Lock will only unlock once all tightening have been positively confirmed, removing a safety hazard and improving overall production quality.
Taking total control of your fastening process doesn’t have to be complicated. Ingersoll Rand‘s new comprehensive QX Connect Series™ family of fastening systems delivers simple, flexible and capable solutions for all of your assembly requirements. No matter the industry or application, you can count on Ingersoll Rand as a trusted partner to help you get the job done right. We’re proud to be an authorized Ingersoll Rand distributor.
Here are a few pages of information….if you’d like to know more contact Air Power at 1-800-334-1001