In this case study, Air Power builds a custom integrated system that makes Ergonomics, Safety, and Quality simple with a team effort.
This customer is a supplier in the Truck and Bus industry.
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.
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.
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.
One of the main causes of injury in a manufacturing facility is due to lifting heavy objects. In this case study, Air Power helps a customer eliminate the risk of injury with an Ingersoll Rand custom monorail lifting system.
A local machinery manufacturer has had issues finding a suitable solution to include as part of their OEM machinery builds. They had a history of using electrical hoists and I beam trolleys which have not been well received by their end-users. The previous offerings by others were hard to maneuver and difficult to position the load for final placement.
Air Power Solution
Air Power proposed an Ingersoll Rand Zimmerman rail system, which are easily adaptable, cost-effective and easy to use. We designed a system for them that included 4 individual monorails with rigid mount hanger kits to increase clearance and ZAW air balancers with pendant controls for load lifting and proper part positioning. The solution allows each of the 4 sides of their machine to be covered from end to end.
The proposed solution provided the necessary benefits including:
- The ZRA1 monorails utilized minimum push/pull forces, allowing ergonomics on the operator and ease of use.
- For future integrations, the individual monorails provide an easily adaptable solution, should the OEM design change over time.
- The aluminum profile ZRA1 provided a reduction in solution weight.
- The ZAW air balancers allow the end-user to position the load close to its final destination then use the “float” of the balancer for final (and exact) placement of the part; further enhancing the user experience.
Assembly solutions often require an array of different equipment to get the desired result. In this case study, Air Power was able to design a fully ergonomic dispense solution for this customer.
Manufacturer of HVAC Equipment
This customer was planning an expansion that included adding 2 additional assembly lines for panel foaming. They wanted to have a more robust Gantry System, contrary to solutions discussed previously with other distributors. Air Power’s ability to integrate the Material Handling portion of this project along with the Dispense/Fluid Management system allowed us to be the sole solution provider the customer was able to find through the initial quoting phase. After digging into the project, the customer realized our potential and requested the Mix, Meter, and Dispense System to supply two separate assembly lines, thus adding more complexity to both portions of the MOVE project. Factors like pressure loss, high-pressure piping, distance, ergonomics were key when bringing this project from theory to paper to real life.
Air Power Solution
Our team was able to design a custom solution that utilizes a Unified Dual Cantilever Overhead Rail System, paired with a Hennecke High-Pressure Metering Machine designed to dispense the full range of rigid foams and flexible foams. This dispense system controls 2 mix heads to fill panels with a Polyurethane Foam on 2 assembly lines. This system pumps the foam through high-pressure hoses mounted overhead with an Ingersoll Rand Suspension Balancer and Z-Servo Balance Control.
This system has the ability to have cross-lateral movement spanning the entire workstation, pump foam throughout the 1000+ feet of piping/hoses, ergonomically sufficient enough to navigate the 100lbs mix heads North, South, East, West with minimal effort, and produce foam with the touch of a button. We were able to deliver all of the key factors with a combination of our vendor support, customer communication/guidance, and our internal resources to deliver a unique one-of-a-kind turnkey solution!
More about: Southworth Products
With the acquisition of Zenmar Power Tool & Hoist Systems, Air Power Manufacturing Solutions has expanded the brands that we offer our customers. We are now an authorized distributor for 6 new product brands, including Ajax Tools, Enerpac, Gorbel, Harrington Hoists, Michigan Pneumatic, and Southworth Products. We are excited to offer these products throughout our entire Southeastern territory.
Ranking among America’s finest quality manufacturers of industrial and construction tools, Ajax is a highly regarded brand name for forged specialty tools and accessories. Ajax is ISO 9001 certified and all products are engineered to meet or exceed OEM specifications.
Founded in 1946, Ajax Tools built on its expertise in heat-treating, forging, and machining; earning an image of uncompromising dedication to quality. Ajax is a full-service American manufacturer, and offers a modern manufacturing facility and advanced production equipment, to support our quality products and our focus on customer’s needs.
Ajax Tools is your Global Resource for:
- Chisels (Pneumatic, Electric, and Hydraulic)
- Pry Bars (Lining bars, Connecting bars, Pinch bars)
- Wedges (Stock, Flange, Banana)
- Drift Pins (Broad Head pins, Barrel Drift pins, Pull pins)
- Drill Steel (Speed Bits, Drill Rod, Rock Bits)
- Retainers (Chipping Hammer, Rivet Buster)
Enerpac is a global leader in the engineering and manufacturing of high-pressure hydraulic tools, controlled force products, and solutions for precise positioning of heavy loads that help customers safely and reliably tackle some of the toughest jobs in the most demanding environments without compromise.
For mission-critical applications, Enerpac provides tools and solutions that make your work safer and easier to perform.
Gorbel offers a comprehensive line of overhead material handling, crane technology, ergonomic lifting products, and fall prevention systems. You can count on Gorbel to be on the cutting edge of manufacturing; constantly seeking out new ways to innovate and elevate their products and processes.
Gorbel’s mission is simple: They improve people’s lives. That mission guides everything they do, from the products and services they provide to their outside customers to the tools they create for their sales force and the work environment they foster for their employees.
Located in Manheim, PA, Elizabethtown, PA, South Holland, IL, and Corona, CA, Harrington Hoists, Inc. is a leading manufacturer of revolutionary manual, electric and air chain hoists as well as wire rope hoists, crane products, and below-the-hook devices. Known in the industry for world-class products, a driven sales focus, and outstanding customer services that are unmatched in today’s market, Harrington is committed to doing whatever it takes to satisfy customer needs.
Michigan Pneumatic Tool is a full-service air tool company celebrating 75 years as a leader in the design, distribution, manufacture, repair and rebuilding of industrial air tools. At MPT we service construction, industrial, demolition, bolting, and foundry tools. Michigan Pneumatic Tool also has an unrivaled parts inventory that includes brand name, hard to find, obsolete, and discontinued parts. We have the parts you need when you need them.
Southworth Products Corp is a world leader in the manufacture and distribution of vertical lifting and positioning products including lift tables, container tilters, pallet level loaders, manual lifter transporters, and many more. The company headquarters are in Falmouth, Maine with manufacturing located in Manila, Arkansas.
They are a supplier of innovative products designed to improve worker productivity and safety through the practical application of ergonomics in work positioning applications; including scissor lift tables (hydraulic, pneumatic, mechanical), portable lift tables, low height lift tables, container/basket tilters, pallet loaders, turntables, roll and coil cars. These products are sold under some of the industry’s most recognized brand names; including Dandy Lift & Leveler, PalletPal, EZ Reach, and Floor Height Lifts.