Intelligent Multi Spindles Increase Production and Quality

Problem:

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.

Results

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.

Apex Tool Group intelligent 4 spindle multi-spindles with torque management arms eliminate both inaccurate torques along with potential mishits of fasteners.

 

 

Counterweight Confusion

This case study was presented by Baltimore Key Account Manager Lorne Rickert.

Challenge

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.

Results

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.

Counterweight Confusion

 

 

How to properly inspect the hydraulic oil on a Lobster Pneumatic tool – Lobster N1A2 Rivet Nut Setter

How to properly set up the N1A2 for the Rivet Nut Application – Lobster N1A2 Rivet Nut Setter

Ingersoll Rand – Makes it Easy

One of the main causes of injury in a manufacturing facility is due to lifting heavy objects. In this case study, Air Power helps a customer eliminate the risk of injury with an Ingersoll Rand custom monorail lifting system.

 

Challenge

 

A local machinery manufacturer has had issues finding a suitable solution to include as part of their OEM machinery builds. They had a history of using electrical hoists and I beam trolleys which have not been well received by their end-users. The previous offerings by others were hard to maneuver and difficult to position the load for final placement.

 

Air Power Solution

 

Air Power proposed an Ingersoll Rand Zimmerman rail system, which are easily adaptable, cost-effective and easy to use. We designed a system for them that included 4 individual monorails with rigid mount hanger kits to increase clearance and ZAW air balancers with pendant controls for load lifting and proper part positioning.  The solution allows each of the 4 sides of their machine to be covered from end to end.

 

Results

 

The proposed solution provided the necessary benefits including:

  1. The ZRA1 monorails utilized minimum push/pull forces, allowing ergonomics on the operator and ease of use.
  2. For future integrations, the individual monorails provide an easily adaptable solution, should the OEM design change over time.
  3. The aluminum profile ZRA1 provided a reduction in solution weight.
  4. The ZAW air balancers allow the end-user to position the load close to its final destination then use the “float” of the balancer for final (and exact) placement of the part; further enhancing the user experience.