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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https://www.airpower-usa.com/wp-content/uploads/2020/03/thumb_irWFH.png6651279Airpowerhttps://www.airpower-usa.com/wp-content/uploads/2018/06/Logo_AirPower-white.pngAirpower2020-03-31 09:27:052020-03-31 09:56:16Ingersoll Rand QCX Controller with remote access
Manufacturing facilities in today’s competitive market strive to reduce the ergonomic impact of their operators. In this case study, we will discuss the importance of recognizing every company’s desire to improve ergonomics and reduce injuries.
Customer
A global manufacturer, producing products for the heavy truck and bus industry.
Challenge
Operators were manually lifting 40-150lb truck hubs and rotors to palletize for their shipment to their end-users. The operators were refusing to use their current lifting method as it was slow and delayed their production during the days shift resulting in reduced throughput per operator per shift.
Air Power’s Solution
We proposed they moved to a single large floor supported structure with multiple bridges, air balancers, and welded end effectors. This allowed multiple operators to use a single structure with each having their own ”bay” containing a bridge, balancer, end effector combo. This gave everyone the room they needed to load pallets as well as the lifting method that allowed the ergonomic impact to be reduced while still allowing the productivity of the manual lifting application. The air balancers’ speed and the pendant control allowed the operators to move at the speed they deemed fit for each application and individual operator preference.
Result
Currently, we have installed 5 large lifts in this facility with more now being planned at their sister facilities, leading to many overall ergonomic improvements.
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
Ingersoll Rand In-Line Handle Air Balancer Control Kit
Designed for precise pick & place applications, the Ingersoll Rand In-Line Air Balancer Control Kit can integrate with all of Ingersoll Rand’s existing single rope basic unit air balancers.
– Compatible with 150, 200, 350, & 500 lb. capacity air balancers.
– Adjustable lifting and lowering speed based on pressure applied to up and down movements.
– Ideal for repetitive pick and place lifting applications.
– “Float” range allows for precise placement.
Contact Air Power today to get a live demonstration!
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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.
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.
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.
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As the summer heat is beginning to increase so is our Monterrey, MX team. These past few months have been full of exciting product launches, customer trade shows, and strategic partnership meetings. Our facility, located just outside of Monterrey, in Apodaca, consists of eight (8) employees’ within a 308 sq. meter (3,315 sq. ft.) branch location. This branch functions as a complete team offering: account management, technical service, field repair, bench repair, system startup and integration, training, and localized equipment stock.
Our team was honored to attend the John Deere Paint Summit as a strategic supplier for Deere within Mexico and the United States. This global summit included members from China, India, Brazil, Argentina, Canada, and the United States. It was a privilege for Air Power to be in attendance but more importantly a complement to be asked to be a part of the presentations. In partnership with Graco and St. Clair Systems, Air Power discussed the importance of paint kitchen visibility and viscosity control as it pertains to plural component finishing operations.
FABTECH Monterrey
Following the Global Summit, there was no time to waste in preparation for Fabtech, Monterrey. Held in Monterrey, MX on May 7th-9th; this event featured over 1,000 participants and more than 50 industrial vendors. This offered for an engaging and technology advancing manufacture fair. Air Power in partnership with Heraeus and Nitto Systems meet over 100 clients interested in further improving their current finishing operations.
Gema OptiFlex Pro Series Launch
Mexico City was the next stop as excitement continues to build over the launch of GEMA’s new OptiFlex Pro Series of powder coating equipment. This launch event highlighted the units unsurpassed Power, Quality, and Control Features.
Power – Powerboost Technology of 110KV
Quality – Precise Chare Control (PCC) and redesigned powder pump
Control – Bluetooth Capabilities with the GEMA E-APP
The below video, presented by GEMA, highlights the advantages of the new OptiFlex Pro.
Graco New Product Launch
Most recently, the team joined Graco in San Diego, CA, for the New Product of 2019 Launch. This event focused on new technology and product that Graco is implementing within the 2019 calendar year. Including highlights of:
Intelligent Paint Kitchen for Pneumatic Pumps
New Pro XP Gun Models
Radial Piston Agitators
Sealed 4-Ball Lower Plus
Active Surge Suppressors
Pro-Dispense
ProControl 1KE
This completes the New Product Launch 2019 for Graco and Air Power had representation within the Atlanta, Indianapolis, and San Diego event locations.
It’s cooking down in Mexico and we are excited of what is next to come. If you are familiar with Air Power and have locations within Mexico; please give us a call today. We would appreciate the opportunity to further discuss best practices, equipment standardization, and our system integration capabilities and advantages offered as a result of our unsurpassed coverage area between the United States and Mexico.
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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.
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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:
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.
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
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
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.
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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.
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.
