Clamping with QX

Manufacturing defects are expensive and removing these errors prior to equipment leaving the production floor is an achievable result when utilizing the proper assembly equipment.  In the below case study, implementing proper tooling resulted in a significant reduction in warranty, service work, and recalls.

Customer

A global manufacturer of grain and sugar cane harvesters located within the Southeastern United States.

 

Challenge: Warranty, Service Work, and Recalls

During the manufacturing process; a sub assembly cell was responsible for proper tightening of fluid hose clamps.  The specified torque and angle of these hose clamps was not being achieved by current in plant tooling.  This failure was a direct result of joint conditioning and relaxation associated with the hose clamp tightening process.  In order to confirm clamps were properly tightened a manual QC measure was put into place in order to catch the issue prior to units leaving for in field use.   However, manual processes are reliant on operator execution and improperly tightened units continued to leave the production floor incorrect.  This issue was exaggerated once units reached final destinations for use within the field, as inadequate torqued hose clamps, were continuing to loosen causing costly warranty, recall, and infield technician repairs.

Air Power’s Solution

In partnership with the customer, Air Power implemented an Ingersoll Rand QX Precision fastening System. The hand held, battery operated, transducerized tooling solution provided an accurate final torque, while providing the operators with tightening status feedback, actual torque values, and 1,200 rundowns of tightening data for review.  A proper torque strategy was developed allowing the hose clamp to be properly torqued, relaxed (conditioned), then final torqued; all within a single trigger pull delivered by the operator.  The need for a manual QC measure was removed as the torque data was verified, tracked, and retained by the manufacturing facility for spot check and validation.

 

Ingersoll Rand QX Series Right Angle Wrench

Result

Currently, thirteen (13) right angle tools are being utilized within this facility allowing production to reach new heights of process control.  Proper tightening of the hose clamps, torque data retention, and date/time stamping have reduced warranty, service work, and those costly infield technician repairs.  The Air Power solution ensures that product leaving the production floor is assembled correctly, the first time.

 

 

Driving New Technology

 

As the manufacture sector continues to change we understand the tedious task of staying current on the most cutting edge tooling technology.  So, allow us to “Drive New Technology” to your facility for hands on application demonstrations, accurate torque programming, and ergonomic optimization.  Whether this is for a single application demo, in which an Air Power Account Manager loads up the appropriate equipment within their vehicle and brings onsite, or a much larger venture, where Air Power in partnership with a manufacture partner bring in dedicated personal for the day, our goal is to continually be a resource and “drive new technology”.  A few notable campaigns below in which Air Power, in partnership with our vendor partners, drove new technology to the customer for the most optimal customer experience.

 

Cleco CellTour

 

Completing over 35 stops within the Southeast, the Cell Tour proved to be a huge success for both Air Power and Cleco.  The CellTour showcased Cleco’s innovation in reinventing cordless through a unique, dynamic, and fun mobile experience.  When driving this new technology, customers were able to perform hands on testing through interactive demonstrations and joint simulations.  The new CellCore Cordless Assembly platform – Easy to Handle. Hard to Break. – consists of smart, durable, and ergonomically designed battery operated transducerized tools.  The lightweight ergonomic design reduces operator fatigue and the large user interface makes it very quick and easy to program.  The CellTour highlighted the CellCore product, as well as, provided an additional sampling of APEX’s assembly fabrication tool product solutions.

 

Cleco Cellcore CellTourCleco Cellcore Tour

 

 

Graco – Pumps and Process

 

Graco’s Pump and Process trailer has made numerous stops within the southeast; including our most recent location in Salem, Va. This valuable tool is packed with operational diaphragm, piston, peristaltic, and ram pumps ready for any and all to be trained.  Rob Woodward, of Graco, does an excellent job showcasing the products housed within the traveling trailer, highlighting New Graco offerings, including the Husky Electric Diaphragm Pump platform.  These pumps have the advantages of double diaphragm pumps (self-priming, running dry, and stalling under pressure) with the efficiency of an electric drive (up to five times more efficient than pneumatic diaphragm pumps).

 

Graco Pumps and Process Trailer

 

Dyna-Day

 

If you grind, sand, or polish, then experiencing the Dynabrade Difference during an onsite Dyna-Day is a must.  Dynabrade has earned a reputation for excellence and is a leader in innovation design and manufacturing of pneumatic abrasive power tools.  The fully outfitted Dyna-Van showcases Dynabrade’s commitment highlighting all the made in America tool manufacture has to offer.  Whether you would prefer a parking lot trade show style setup or in plant experience, Dynabrade is flexible in catering to the user experience.

Air Power and Dynabrade are currently on a Dyna-Day roadshow within North Carolina, South Carolina, and Virginia, so far completing twelve (12) events with plenty of excitement for additional locations.  A highlight of the event is being able to put the tools to use, including the new Dynorbital Extreme, known for its extreme power, extreme comfort, and extreme performance, this newly released model random orbital sander has been a show stopper.

 

Dynabrade's Dyna-Day with Air Power

Dynabrade's Dyna-Day with Air Power

 

Ingersoll Rand QX – The Future is Real

 

Ingersoll Rands “The Future is Here. The Future is Now. The Future is Real” roadshow allowed for the education and utilization of the QX Series platform of assembly tools.  This tour highlighted the benefits of the QX platform, showcasing next generation functionality; which was evident within the hands on demonstrations that could be performed on the active stations within the truck.  The complete line of QX tools feature: QXN, QXC, QXX, QXM, and the most recent QX+ETS models in both the pistol and right angle orientations.  This robust tooling platform can handle any torque with pistol and right angle orientations up to 2,000NM.  The New QX +ETS models feature an ergonomically enhanced motor algorithm for a significant reduction in the average force experienced by an operator during the tightening process.

 

Ingersoll Rand QX Roadshow Ingersoll Rand QX Roadshow

 

 

Within all of our assemble, move, and coat technologies; Air Power prides itself on our ability to drive these new technologies to your facility.  Not all technologies we drive to your facility, have to be as elaborate as the programs highlighted above.

Our Account Managers – Drive New Technology – every day.

Give Air Power a Call Today!

 

 

Ergonomics and Quality Control to New Heights

 
Manufacturers of passenger transportation systems make every effort to exceed in safety intelligence within the industry. This case study demonstrates safety improvements, as well as, operator ergonomic advantages, in an effort to decrease facility liability.

Customer

 
Manufacturer of vertical transportation systems.

Challenge

 
Operators manually load and unload valves utilizing an older pneumatic torque tool. The current tool utilized within production was non-shut off and provided no verification of installation. The operator was responsible for assuming the proper socket and torque combination capable for a successful installation. The inability to measure torque accurately resulted in an inconsistent quality of final product with no verification that it was done properly. In addition, this application proved labor intensive and was the cause of concern for operator safety and ergonomics.

Solution

 
Air Power implemented a custom Ingersoll Rand DC Electric Assemble tool, integrated into a GCI torque reaction arm, with a pneumatic clamping fixture omitting operator strain and removal before completion. Custom sockets were provided to insure precise fit.  The custom fixtured Ingersoll Rand DC Electric tool was coupled with a front end Norbar Multiplier producing actual real time torque verification and discreet I/O output, which was coupled with an Air Power provided PLC to monitor torque and track data usage.

 

 

Results

 

The solution realized by Air Power created a torque verified product that allowed for a safer work environment and smoother process for the operator. All build requirements can now be monitored, tracked and viewed through a transparent build as a result of system implementation.

 

 

 

Programming your Ingersoll Rand QX Tool – It’s that Easy

Taking total control of your fastening process doesn’t have to be complicated. Ingersoll Rand’s comprehensive QX Series family of fastening systems deliver 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!

 

The innovative QX Series of cordless precision fasteners is a revolutionary step for your entire facility – one that shows how a smarter tool can improve process control, operator comfort and data communication. In a single, affordable package, this tool puts you in control by helping to increase productivity, lower costs and ensuring a high-quality product at the end of your production line.

The QX Series family of tools consists of:

  • QXN
  • QXC
  • QXX
  • QXM
  • QX ETS

Currently, there are three (3) quick, easy, and effective methods in which to program a QX tool for deployment within your manufacturing process.

1.Programming with the Insight Connect App:

    1. The INSIGHT™ Connect app will help you stay productive, mobile and in control of your fastening process. It programs any Ingersoll Rand® QX Series™ tool without the need for additional technical training, special software, plant network permissions or a laptop computer. Working from a smartphone or tablet, operators can use the app to quickly program the torque and angle control configurations on these closed-loop, transducerized tools.
    2. Once installed, the INSIGHT™ Connect app can operate offline, so it functions in large facilities or other locations where Internet signal loss may be a problem, reducing downtime and maximizing ease of use. You can quickly perform key tasks with your mobile device, including:
      •  Strategy
        • Torque
        • Angle
        • Torque + angle
      • Back-up and restore tool settings
      • Retrieval of tool logs and the ability to send via email for post-processing
      • Review audit logs

 

 

2. Programming from the back of the tool

 

Or reference the below video (some of the menu options have changed since this video was posted by Ingersoll Rand in 2017 – but the overall flow and understanding remain unchanged)

 

 

3. Programming utilizing the Ingersoll Rand ICS Software

 

 

 

 

Water is Good. But Not in Your Airline.

Compressed air is readily available and simple-to-use, but it can be the most expensive form of energy in your application. Air leaving a compressor can also be dirty, and depending on the outside temperature, can contain moisture. The presence of moisture in the air line can damage and shorten the life of downstream equipment, such as pneumatic tools and Liquid/Powder spray equipment. Unregulated or improper air pressure can result in increased compressed air demand, which results in increased energy consumption. Excessive pressure can also increase equipment wear, resulting in higher maintenance costs and shorter tool life. Before compressed air can be used it should be Filtered, Regulated and in some applications, Lubricated.

Filters

 

Filters clean compressed air. Compressed air can carry condensed water, oil carryover from compressors, solid impurities (dirt and rust) generated within the pipelines, and other wear particles from the ambient air. These contaminants can cause problems at every point of use, and should be removed by installing suitable filters.

Regulators

 

Regulators reduce and control pressure in compressed air systems. They are used to control pressure to: air tools, such as impact wrenches and sanders, liquid and powder spraying devices and many other pneumatically powered manufacturing applications. Optimally, a pressure regulator maintains a constant output pressure regardless of variations in the input pressure and downstream flow requirements. Downstream equipment flow and pressure requirements must be determined to properly size the correct regulator for the application.

Lubricators

 

Lubricators add controlled quantities of oil into a compressed air system to reduce the friction of moving components. Most air tools and other air driven equipment require lubrication to extend their useful life. The use of an airline lubricator solves the problem of too much or too little lubrication that comes with other methods of lubrication such as a grease gun or oil, as well as supplying the right kind of lubricant for the tools being used. Once the lubricator is adjusted, a metered quantity of lubricant is supplied to the air operated equipment and the only maintenance required is a periodic refill of the lubricator reservoir. Adding lubrication to a system can also prevent synthetic compressor oil build-up on system components.

Clean air is a key ingredient that enables effective and efficient operation of tools, equipment, and machinery in almost every industry. As such, the use of air preparation devices, such as filters, regulators, and lubricators (FRLs) is an excellent way to keep your air supply in top condition, as well as enabling your tools and equipment to operate at their peak performance. Air Power can help you identify the cause of your airline issues and find a solution to keep your airlines clean and controlled.

 

ARO FLO Series

 

 

 

Graco Electric Fixed Ratio (EFR) Metering System

 

 

The Graco Electric Fixed Ratio (EFR) is an electrically driven proportioner for two component sealant and adhesives. The EFR provides advanced material control in applications requiring consistent shots and beads. Air Power Application Specialist Ronnie Lowe talks about the features of the EFR Metering System and the many ways it can improve your manufacturing process.

 

Graco EFR Metering System

  • Highly accurate, even with low flow rates
  • Capable of shots, beads and continuous flow dispense
  • Superior repeatability
  • Capable of handling a wide range of materials
  • Easy to configure, operate and maintain

 

 

 

Levitate Anti-Fatigue Exoskeleton

Introducing the AIRFRAME®, a practical new device that reduces muscle stress and fatigue – making the end of the day feel like the beginning.

 

The Levitate AIRFRAME is a wearable, lightweight technology engineered to improve upper extremity musculoskeletal health in professionals and skilled trade workers who engage in repetitive arm motion and/or static elevation of the arms. The AIRFRAME lowers exertion levels by up to 80% – keeping workers healthier and more productive, while mitigating healthcare and disability costs.

 

 

 

HOW IT WORKS

 

The AIRFRAME transfers the weight of the arms from the shoulders, neck and upper back to the outside of the hips, evenly distributing energy to reduce stress. It slips easily on and off, and moves seamlessly with the wearer without intruding into the workspace or limiting motion or dexterity. The AIRFRAME’s mechanical support system progressively activates as the arm is raised, and gradually releases as the arm is lowered, resulting in just the right level of support – at just the right time. It’s personalized to fit each wearer, so they can use their arms as normal while enjoying reduced fatigue and comfort they never thought possible.
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FEATURES

Light and Comfortable
Personalize Fit
Full Range of Motion
No Power Required
The AIRFRAME’s sleek, aerodynamic design and lightweight material construction make wearing the device feel nearly unnoticeable. Each AIRFRAME is custom-fitted to the individual user, allowing the device to fit comfortably on any body type or size. The AIRFRAME offers full range of motion, allowing the user to easily perform any task without limitation or stiffness. The AIRFRAME requires no electrical power – it is mechanically engineered to rely on a patented system of pulleys.

BENEFITS

 

Lowers Injury Risk
Boosts Productivity
Improves Quality and Precision
Lowers Healthcare and Disability Costs
On-Site Training
There are more than 650,000 cases of work-related musculoskeletal disorders (WSMD) annually. The AIRFRAME lowers exertion levels by up to 80%, significantly lowering injury risk. WMSDs are responsible for $50 billion in lost productivity annually. The AIRFRAME keeps workers healthy, and production humming. Muscle stress and fatigue are the enemy of productivity. The AIRFRAME allows workers to maintain quality and precision for longer periods of time. Musculoskeletal disorders represent $1 of every $3 spent on workers compensation. The AIRFRAME limits exposure to these injuries, reducing costs and boosting profits. We offer full, on-site training for both workers and safety engineers on how to custom fit and operate The AIRFRAME for all users.

Air Power Puts the Graco ProMix PD2K to the Test with HB Fuller

Air Power Manufacturing Solutions Put PD2K to the Test with Graco and HB Fuller

 

The customer is switching to Swifttak 4431 Heat Reactivated Water Based Adhesive, a two-component adhesive, for better product quality. They need a system to effectively mix and spray the 2K adhesive. The Graco PD2K is the only 2K system that can effectively handle the Swifttak adhesive due to the industrial pump based unit which allows for operation in either flow or pressure made.

More about Graco ProMix PD2K System

More about Graco ProMix PD2K System

The ProMix PD2K mixes the material close to the gun so the flush zone is significantly smaller. This allows customers to use less paint, spend less on disposal costs and allows for faster color changes. And because there is limited mixed material in the system, the ProMix PD2K is ideal for short pot life materials. It is also compatible with acid-based materials.

Graco has specific ProMix proportioners that are designed to manage tough acid catalyst applications like cabinetry and bar countertops. The corrosion resistance fluid section, plus the smart fluid plate with 316 and 17-4 SST catalyst sections, can easily handle strong acid catalysts.

 

Graco Electric Fixed Ratio (EFR) System

The Graco Electric Fixed Ratio (EFR) system is a meter, mix and dispense system for two component sealant and adhesive delivery. Ideal for applications requiring precision dispense, the EFR provides superior control over material and dispensing of gaskets, beads, shots and potting applications. Trust in the EFR, which is accurate, versatile and easy to use.

The Graco Electric Fixed Ratio (EFR) system

 

  1. Advance Precision Driver

    • Powerful driver reaches up to 20 cycles per minute
    • Precise encoder that assures low flows and small shots consistently
    • Direct pump control
    • Limited maintenance needs

 

  1. Industry Proven Z Pumps

    • Multiple Ratio options
    • Only the seals are wear parts
    • Abrasive resistant version
    • Mechanically linked pumps offer ratio assurance

 

  1.  MD2 Valve

    • Adjustable snuff back
    • Mixing at tip of the gun, limiting purge material waste
    • Multiple seal combination for material compatibility
    • Available in 1:1 to 10:1 for wide ratio applications
    • For manual or robotic applications

 

  1. Advanced Display Module

    • Easy to use interface
    • Possibility to have it completely integrated
    • Communication Gateway Modules: EtherNet/IP. DeviceNet, PRofibus, Profitnet

 

 

 

QX Series + ETS: Ergonomic Tightening System

Taking total control of your fastening process doesn’t have to be complicated. The Ingersoll Rand QX Series™ family of fastening systems deliver simple, flexible and capable solutions for all assembly requirements. No matter the industry or application, you can trust Ingersoll Rand  to help you get the job done right. Ingersoll Rand® has released the QX Series™ Ergonomic Tightening System (ETS). With ETS, reducing the torque reaction of the fastening process doesn’t have to be complicated. The ergonomically-enhanced motor control algorithm minimizes torque reaction to protect workers from injury. When tightening, ETS delivers short bursts of energy into the fastener, enabling the operator to safely stay in control of the tool.

What is ETS?

ETS stands for “Ergonomic Tightening System”

QX + ETS delivers all the performance & control features of the standard QX Series ™ precision fastening tools, with an improved ergonomic benefit. QX + ETS incorporates an ergonomically enhanced motor control algorithm that significantly reduces the average amount of force experienced by the operator during the tightening process.

Why choose ETS?

When ETS is Active, the operator’s arm movement is limited to a series of smaller movements instead of one large movement. This enables the operator to stay in control and in the ‘power zone’, reducing the chance for injury caused by quick, excessive movement.

QX + ETS reduces average reaction force experienced by the QX Series user by up to 63%!

 

ETS FEatures

Resources:

QX Series Ergonomic Tightening System – Agriculture Case Study

QX Series + ETS Catalog