A new machine requires a custom crane and hoist design..no problem

Problem:

The client, a local granite countertop supplier, was purchasing a new machine to custom cut their client’s countertops. Their existing workstation crane and hoist system didn’t allow the flexibility they needed to maneuver the granite into the proper position.

Solution

After on an onsite review, it became clear that a custom designed crane and hoist system was needed for the project.  Account Manager Justin Kuhn and Application Specialist Chris Nelson were able to custom design a 2 ton Gorbel crane and 1 ton Harrington Hoist system that allowed the power and flexibility the client needed.

Results

The Air Power solution is working perfectly and this will likely be the last crane the customer will ever need.  The added bonus was an annual maintenance plan for all of their existing cranes and hoists. The ability of our team to not only immediately identify the issues, but to also have the technical skill to design a customized system leads to the perfect Manufacturing Solution.

Once again the tremendous knowledge and experience of our Account Managers and Application Specialists not only solves the issue at hand, but creates a long term customer.

Custom Crane

Powder booth Airflow issues solved by an Air Power Dynamic Duo

Problem:

The client, a local manufacturer, was having air flow issues within it’s paint operation. This was causing major dust/powder buildup in the nearby areas of the plant. Not only this, but the inefficiency of the airflow was hampering overall plant performance.

Solution

After on onsite review with the customer, Chris Case (Account Manager) and Travis Stirewalt (Technical Specialist) were able to determine that the 2nd and 3rd stages were horribly neglected. In addition, we pointed out that although airflow with no filters and clean filters was excellent, the airflow with the clogged stage 2 and 3 were causing the issues.  We installed the Kemwove filters during a one day trial and testing period of the filter process. Two weeks later, we revisited the plant to check on the filters and then again a couple of weeks after that. The customer had moved into some of their old first stage inventory (paint pockets) but had left our 2nd and 3rd stages alone as requested. The 2nd stage filters were absolutely full and had spared the bulk of powder capture leaving the 3rd stage pocket filters in great shape.

Results

With the collected data over the test and review period, we were able to provide a concise filter plan and maintenance schedule for monthly, quarterly and annual review.  For this customer – better air flow, improved plant performance, and a reduction of annual filter costs!

 

Filter Troubles

A client needed faster color changes…Air Power and Gema to the rescue

Problem:

Our clients operators were already using Gema box units for their non-recovery powder booths. While the units worked wonderfully these booths were connected and would be considered opposing. Each time they need to change color the operator must lift a 50lb box on and off the vibrating platform. This was a huge ergonomic issue for everyone involved.

Solution

After reviewing the setup and assessing the clients daily needs it was obvious that a Gema 8 color quick change package would allow for faster color changes, reduced material handling of the boxes of powder and would better prepare hard to fluidize powders in hoppers verses vibrating box units.

Results

Any time you can make a client’s operation more efficient, save wear and tear on their operators and show the how quickly the ROI would balance out….they are going to be happy. You almost always have to spend money to save money so having a team that understands your operation and knows all the available options to increase productivity is vital. Team Air Power got the job done once again.

Gema Quick Color Change Systems

 

 

 

 

As temperatures begin to get hotter, viscosity is very much at play when picking the proper pump.

Problem:

When specifying the proper pump for any fluid application understanding the properties of the fluid to be handled is of the upmost importance.

Viscosity…. is one of, if not the most important variable when determining the proper specification of a diaphragm pump (or any pump) and associated flow rates. The viscosity of many materials fluctuate as ambient temperature’s change through the seasons and as plant conditions change month to month, so understanding the effect viscosity has on sizing pumps is important.

Solution

All AODD pump ratings are with water at the pump outlet. For example, a Graco 1050 pump is a 1″ ported pump rated at 50 gallons per minute (water at the pump outlet).  When looking to specify the above example pump, three things must be further evaluated to insure proper performance/specification – Viscosity (will alter flow rate), available air pressure at the pump, pipe or hose size (at pump outlet all the way to the point of discharge).  Once you have determined these variables you can properly select the perfect pump for your unique application.

Results

Getting the right pump will make a world of difference in the efficiency of your set-up. Not only will your flow rates remain stable throughout the year, but downtime will be reduced and the life of your pump will be extended.Perfect Pump

 

 

 

Graco Endura-Flo pump solves multiple issues for large paint booth

Problem:

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.

Results

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.

 

 

 

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

 

 

Carlisle Fluid Technologies – Winning with Airless

Problem

Flooring Manufacturer was looking to increase pass yield coverage while spraying their Waterborne Topcoat on their flooring.  Their old process was using two Automatic Anesta Iwata air spray guns.

Air Power Solution

Through Air Power’s partnership with Carlisle Fluid Technologies we were able to offer the customer a solution by providing two Binks Automatic AG-364 Airless Spray guns fed by a Binks MX Series Pump.  The results were tremendous.

Effect

The Customer Experienced the following benefits:

  • Increased Pass Yield Coverage by around 40% on average.
  • Reduced coating use by around 50%.
  • Reduced clean up with the reduced amount of over spray
  • Improved coverage on edges and profiles, eliminating the shadow effect.
  • Elimination of CFM air usage.

The above benefits save the customer TIME and MONEY!

 

ProDispense – Always accurate and Always Correct

Problem

An axle manufacturer has had ongoing issues with accurate filling of gear oils in axle hubs and center differentials due to the operator having to manually select the oil dispensed along with the quantity of oil being dispensed into a given axle. There would be issues with the operator selecting the incorrect oil or volume of oil which often resulted in quality issues of an axle or batch of axles. There was no way to confirm which oil and volume of oil was dispensed into a given axle, which operator did the dispensing on a given axle. All data was on the build sheet for the axle and it was the responsibility of multiple operators and quality technicians to ensure it was filled correctly. All build sheets would have to be read by operators on both sides of the line, then they would have to select the correct oil and volume of oil based on what they read or thought they had read. Quality tracing was extremely difficult using this method. Oil spills and drips were also extremely common, leading to waste and safety concerns

Air Power Solution

Multiple Graco ProDispense systems have been introduced to the facility to eliminate these issues by utilizing advanced technology and programming to ensure error free selecting and filling of fluids. The facilities engineering team will be integrating the ProDispense into their existing PLC’s with new HMI’s which will contain each axles information and location in real time on the line. This will allow each axle’s build sheet to be loaded into the system. By using the axle’s build sheets in the system each operator will touch each axle’s hub or center diff on the HMI which will automatically select the correct oil and oil fill volume for that particular component which will have been preloaded into the PLC and ProDispense by the engineering team. Once the location on the axle has been touched on the HMI the ProDispense will have the appropriate recipe selected via the PLC and the system will illuminate an LED light next to the correct hose reel which contains the appropriate oil. The operator will then unwind the hose reel and dispense valve and insert it into the appropriate oil fill port. Once that is done they will touch the start button on the HMI which will trigger the ProDispense to fill the appropriate volume into the axle. This information will be recorded in their network and will be easily traced back to the axle, oil used and operator performing the fill for traceability. The ProDispense will accurately dispense the correct oil every time within +/- 1%. This will reduce rework, defects and axle failures for the end user. We are utilizing no drip valves to ensure drip free operation to reduce waste and spills to improve safety at the line sides.

Prodispense

Effect

The ProDispense allows for accurate selecting, fill tracking, capturing data associated with each fill to prevent defects, failures, waste and improves safety and accuracy of the entire filling process. Repeatability of the process with operators both new to the line and veterans is much improved as each selection is now automated by the system.

Prodispense

 

Controlling Viscosity through Proper Temperature Control

Problem

Automotive manufacturer was having trouble controlling their paint viscosity with the change in temperature in their facility from morning to afternoon.  The customer was constantly changing fluid pressure to try and keep up.

Air Power Solution

Controlling Viscosity

With Air Power’s partnership with Saint Clair Systems we offered the customer a solution providing them with a Temperature Control Unit and heat exchanges for each color for each of their spray booths.

The Customer Experienced the following benefits:

  • Maintained constant viscosity at point of use to their automatic spray system.
  • Reduced re-works which reduced labor and paint costs.
  • Learned about other deficiencies by maintaining constant viscosity
  • Improved and kept a consistent appearance on all vehicles

Effect

The above benefits save the customer TIME and MONEY!

Controlling Viscosity Setup