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Programming your Ingersoll Rand QX Tool – It’s that Easy
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:
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- 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
- Strategy
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- Back-up and restore tool settings
- Retrieval of tool logs and the ability to send via email for post-processing
- Review audit logs
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2. Programming from the back of the tool
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
Graco Electric Fixed Ratio (EFR) Metering System
The Graco Electric Fixed Ratio (EFR) is an electrically driven proportioner for two component sealant and adhesives. The EFR provides advanced material control in applications requiring consistent shots and beads. Air Power Application Specialist Ronnie Lowe talks about the features of the EFR Metering System and the many ways it can improve your manufacturing process.
- Highly accurate, even with low flow rates
- Capable of shots, beads and continuous flow dispense
- Superior repeatability
- Capable of handling a wide range of materials
- Easy to configure, operate and maintain
Save Time and Paint with ProDispense
Manufacturing facilities utilize various types of coatings, some of which are two component paint. These formulas must be mixed properly in order to properly adhere and perform in the field as designed. This case study highlights a solution that allowed the customer to maintain tight paint ratios, minimize waste, and remove hand mixing from the process.
Customer
A leading manufacture within the truck and bus industry located in North Carolina.
Challenge
This truck and bus manufacturing facility has multiple paint booths due to their high volume, high quality, and high standards associated with the paint application. They use a two component primer and paint, and have to maintain automotive quality finish on their production line. The main paint line utilizes a Graco Proportioning System to dispense on ratio paint to operator; however the offline paint repair/touch up facility still relied on manually mixing (or “hot potting”). Hot potting tended to be very wasteful as the paint mixed wasn’t always sprayed prior to gelling, or the two parts were mixed off ratio causing imperfections within the finish aesthetics and quality. Due to hot potting the general work area was considered “messy” as operators were physically hand mixing paint and catalyst out of drums.
Air Power’s Solution
Air Power in partnership with Graco, proposed a solution utilizing the Graco ProDispense platform of product. This proportioning solution allows the offline operators to mix exactly how much they need for each application on ratio every time. There is no guesswork when it comes to material being mixed or how much is needed, and the work area is self-contained with little to no mess. The offline paint process has become streamlined as the paint operator only has to know how much paint he needs (in liters) and what color. They select the desired paint volume and color from a custom touch screen user interface. Once selected the exact amount is dispensed and mixed into the paint applicator. The operator then removes the paint applicator and performs the associated painting task.
Result
Operators are no longer mixing paint by hand. This alone has saved the company time and money due to costly mistakes associated with the hand mixing process. The waste output has been reduced due to the ability to accurately and repeatedly meter, mix, and dispense the exact volume of paint in which the operator needs on time and on ratio. Aesthetically the workspace is much cleaner. An added benefit to management is the ability to now view, track, and have visibility of paint usage, due to the ProDispense reporting capabilities, within an application which historically has had none. Allowing for better ontime tracking, shipment, and forecasting.
Graco’s ProDispense is a cost-effective and user-friendly electronic system that dispenses preset amounts of fluids. The ProDispense system allows durable goods manufacturers to quickly and accurately fill cavities with oil, grease, water, or other industrial fluids in assembly line environments where accurate dispensing is essential. ProDispense can deliver up to eight different fluids at multiple dispense points, and accurately measure volume.
- Consistent fluid dispense
- Reporting capability tracks volume and usage
- Easily connects to PLC and barcode scanners
- Return on investment assures that ProDispense quickly pays for itself
- User interface provides simple operation and data entry
- Local or integrated control
- Manual or automatic dispense
- Tracks dispense results for process verification
Can You Color Change Too Fast?
Manufacturing facilities strive to improve the quality of their finish while reducing color changeover time in an effort to produce the most desirable product quickly. In this study we will discuss the importance of recognizing every company’s desire to improve in these areas and how improvements can be made within a custom powder coating operation.
Customer
A local wheel remanufacturer and custom coater located within North Carolina.
Challenge
This facility was constantly losing valuable production time due to quality rejections. Once rejected, the part was reworked and coated a second time. This caused a cumulative effect on both powder usage and man hours proving rework within this facility a high cost and overhead factor. In addition, the existing manner of color change resulted in the facilities inability to keep up with current workload. Daily operation consisted of: 4 main colors, an occasional “custom” color, and a clear coat.
Air Power’s Solution
Air Power proposed a Gema OptiFlex 2 Wall Unit with multiple dedicated fluidizing hoppers. These fluidizing hoppers are plumbed for the 4 main colors. A Gema cup gun was provided for the “custom” colors and clear coat. Air Power was able to provide an onsite demo at the customers facility allowing the customer to test, prove, and inspect the proposed solution prior to investment. The improvement in both quality product output and line throughput was dramatic. In addition, the facility was impressed with Gema’s five (5) year manufacturer’s warranty and Air Powers local support and service.
Result
The immediate improvement was first observed within the finish quality which was noticed within the existing customer base. Due to this improvement, repeat business was observed more readily and additional customers were earned, growing an ever increasing need for a more expansive customer base. Even though workload was increased, production never had to slow down. The quick color change system, with dedicated pump/hose combination, allowed operation to change color quickly removing the former bottleneck. An added benefit of the system was the removal of pre-heating parts to achieve powder thickness and build. This result was observed due to Gema’s industry leading transfer efficiency, new found operator control, and recipe programing within the system.
Can you color change too fast? If you ask this custom coater the answer is no; and their ability to change colors faster with an increase in finish quality has taken the operation to new heights.
OptiFlex 2 Wall Unit color change system
Gema Gun with Cup for small and test batches
Goodbye to Manual Mixing
Introduction
This customer manufactures underground boring equipment for gas and water lines. They used “hot potting” or manually mix 2 paint components to spray two colors: yellow and black.
Background
This company has one booth for top coating and would manually mix the black and yellow paints. It took well over an hour to change out the colors. The parts being fabricated were staged all over the plant waiting to be painted. Due to backlog and space contingencies, some items were stored outside. Rainy days would slow down the process even more.
Air Power Solution
Air Power’s solution recommended using a Graco Promix 2KE with gun flush box and using drum pumps they already had. Mixing on demand out of a 55-gallon drum of each component, improved the ability to change colors in less time than it takes to bring a new part to be coated.
Low Headroom-Low Pickup Solution
Customer Need
The customer installed new winders in a low headroom area which presented the final product at a low pickup position. Rolls weighing 100lbs were required to be lifted from a horizontal position and placed into a vertically stacked position onto a pallet. The existing process required manual handling.
Area of equipment installation presented a restricted, low headroom area requiring the need to reach under, and around more OEM equipment required for the winding process.
Air Power Solution
Upon evaluation of the process, and area requirements, a dual extruded aluminum runway, with low profile carriage and custom adjustable stops were specified, and installed to offer coverage for the pickup and placement of rolls across a bank of six(6) winding machines. A custom steel frame was fabricated and installed to properly mount/position both runways for roll handler, and aspirator lines for the winding equipment. Due to area restrictions, an articulating arm with an integrated air balancer was mounted to allow for reach under, and around process equipment, to allow for pickup and placement of the finished product. A Dotec RH90Z45 Roll Handler (for low pickup) was provided which allows ergonomic pickup/placement of rolls to eliminate bending and manual handling by the operators of the finished product.
Roll Handling Solution for Flexible Packaging
Customer Need
An Arkansas based, Flexible packaging converters palletizing process required manual lifting and tilting of rolls being presented in the horizontal core position, onto a pallet- stacking to vertical orientation. The rolls being processed have weights up to 200 pounds, with roll widths up to 40 inches.
An existing overhead steel track was to remain in the process zone, which had to be considered for the process area location due to heights/clearance obstruction.
Air Power Solution
Upon initial discussion with the manufacturer, the end-user contacted Air Power Inc, the Southeastern US Full-service provider of Dotec Roll Handling Solutions, to discuss the project needs. Sample rolls were provided by the end-user for evaluation.
A video demonstration by Air Power personnel was provided to the end-user, of the equipment proposed and in process.
A TurnKey solution was purchased, which included: One(1) Dotec RH90 Roll Handler – with auto roll engagement, ergo-handle controls, powered tilt function, One(1) Dotec 700LH Low headroom jib (to allow for coverage and clearance under the existing structure), Installation and Start-Up training.
Results
Plant Manager Rod A. noted: “this is a welcomed tool for our operations, we have already identified other areas which can benefit from this solution. Thanks to all for a job well done!”
Adjustable Shut Off Clutch – Quick Clip
Adjustable Shut Off Clutch
A demonstration of how air pressure can effect the adjustable shut off clutch on air powered tools.
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Ingersoll Rand Advanced Tightening System
Air Power, Inc. presents a demonstration of Ingersoll Rand’s Advanced Tightening System by Kyle Crawford
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