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Assembly Made Simple

In this case study, Air Power builds a custom integrated system that makes Ergonomics, Safety, and Quality simple with a team effort.

Customer

This customer is a supplier in the Truck and Bus industry.

Challenge

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.

 

Assembly

Results

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.

 

 

Ergonomics and Quality Control to New Heights

 
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.