In this case study, Air Power builds a custom integrated system that makes Ergonomics, Safety, and Quality simple with a team effort.
This customer is a supplier in the Truck and Bus industry.
The customer needed to outfit a new work cell assembling large metal components. First, the weight of the fully assembled sub-build components exceeded 1000 lbs. requiring a high weight capacity work table. Secondly, the height variation of the operators presented ergonomic issues from shift to shift to ensure each operator performed his necessary tasks at optimum work heights for ergonomics and safety. Thirdly, target torque for each component exceeded the safety threshold for handheld tooling, 69 ft/lbs, and 135 ft/lbs. requiring a torque management solution to be included in the overall work cell build. Lastly, the components needing to be torqued are deemed quality critical, requiring all data for the fasteners to be documented to ensure a proper build.
Air Power Solution
Air Power included the following in our solution; a 2000 lbs. capacity adjustable height pneumatic Presto lift table, a GCI torque reaction arm, and a Cleco MPro 300 controller with right angle NeoTek tool. We were able to meet the high weight by working closely with Presto directly to customize the adjustable height scissor lift table. GCI was able to build a custom torque arm to provide the needed reach and vertical travel while managing up to 240 NM of torque reaction. We were able to mount the torque arm directly to our adjustable height table, allowing the entire work station to adjust to ideal work height for any given operator. All of this wrapped around the brand new Cleco 300 controller with NeoTek right angle tool allowing for a precise fastening solution meeting and exceeding the quality critical parameters required. The Cleco 300 also allows our end-user to monitor, collect, and organize critical data to ensure they every unit out the door is a quality part.
Air Power’s solution addressed all of the problems the customer faced with this assembly process. The Presto Lift table allows the operator to adjust the height of the entire system to eliminate and bending and back strain. The GCI torque arm holds and handles the Cleco right angle NeoTek tool. This eliminates any lifting and hand or wrist injury from handling a torque tool. Lastly, the Cleco mPro 300 controller gave the customer the ability to ensure perfect quality with every assembly.
Air Power Technical Specialist James Stanley demonstrates the capabilities of an Ingersoll Rand InsightQC Controller paired with a FlexArm Smart Arm with DOGA DPC Touchscreen allowing the operator to enter sequence patterns quickly and efficiently. Visit us at airpower-usa.com or call us at 1(800) 334-1001 to hear more about this system!
Air Power Application Specialist Jerome Wood and Technical Specialist James Stanley show the remote access capabilities of our Ingersoll Rand QCX Controller in the lab. An Ingersoll Rand QX Pistol coupled with an ETA Inline Positioning Arm paired to the Ingersoll Rand QCX Controller with remote access will allow work from home opportunity. Engineer, operator, and Air Power technical assistance on Go To Meeting are able to troubleshoot, debug and live update the system. Technology 4.0.
If you have any questions regarding remote access or would like to learn more about this technology, schedule a virtual demo today.
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Introducing the INSIGHTqcx Controller
Ingersoll Rand has released the INSIGHTqcx Cordless Controller for critical assembly applications in manufacturing. THe INSIGHTqcx helps manufacturers who require advanced fastening strategies, such as those in automotive, aerospace and heavy equipment, easily take control of their assembly processes.
INSIGHTqcx integrates with the wireless Ingersoll Rand QX Series precision fastening tools. The Controller can also be used to program Ingersoll Rand QXC and QXN nonwireless tools via USB cable and serves as a convenient tool programming station so that operators don’t need to take the tool to an offline laptop for programming.
Additional features include:
- Intuitive, touch-screen programming and ready-to-use communication protocols
- Storage for 50,000 records of cycle data and 50,000 tightening traces onboard the device
- It is adjustable to meet any tightening control requirements
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How To Set And Verify The Torque Output of a Panasonic Mechanical Pulse Tool
In this video, Air Power Technical Specialist, James Stanley walks through steps to set and verify the torque output of a panasonic mechanical pulse tool.
Equipment utilized- Panasonic Mechanical Pulse Tool with Sturtevant Richmont Beam Wrench
- Determine target torque for application. Utilize beam wrench to tighten test joing to desired torque. Once desired torque is reached, “breakaway” the joint in order to properly determine breakaway torque.
- Complete until breakaway torque is consistent with joint.
- Run tool on joint
- Determine breakaway torque following tightening. Compare this observed breakaway torque with the breakaway torque determined in step #1 following a successful tightening on the application joining.
- Utilizing the Panasonic remote controller, adjust your Mechanical Pulse tool torque output up or down.
- Complete steps 3-5 until consistent tool torque tightening results are achieved.
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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.
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.
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.
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.
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.
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).
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.
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.
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.
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