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