Recently, C. H. Reed helped a major truck manufacturer improve a hose clamp fastening application at one of their assembly plants. This truck manufacturer had been using a reputable brand of cordless mechanical clutch tools to meet the torque and speed specifications required for their application, but, after a careful evaluation, it was evident that the process could be leaner. In order to improve efficiency and provide quality assurance, the application specialists at C. H. Reed assisted with the implementation of the Ingersoll Rand QX Series.
The QX Series has five value-adding features that made the implementation an easy decision:
1. Instant Operator Feedback: One of the biggest advantages of the QX Series is that the tool tightens to the programmed torque every time, all while providing visible feedback to the operator. If the assembly tool does not tighten to the specified torque, the operator is alerted immediately by responsive LED lights on the tool. This is hugely advantageous, as it eliminates the guess work at the tool’s point-of-use and removes the need for rework. The Ingersoll Rand Controllers also feature data recording, providing documentable results and total control over the fastening process.
2. Angle Control: While providing visible feedback is great, it is meaningless if the tool achieves torque too early or the fastener becomes cross-threaded. The QX Series monitors the angle of the fastener, which enables the tool to detect these defects. This ensures that only correctly fastened products move down the assembly line, further eliminating costly rework.
3. Different Fastening Speeds: Another great feature of the QX Series that can significantly improve efficiency is its ability to tighten at two different speeds on one program. That means the tool can swiftly tighten to a specified torque and then switch to the recommended speed for the final tightening sequence. This improves the overall efficiency of the process because the tool does not have to run at the slower, application-mandated speed the entire time.
4. Multiple Fastening Programs: Another efficiency boosting feature of the QX Series is its ability to run multiple fastening programs, all on one tool (up to 8). Instead of reprogramming the tool for every application, the operator simply selects a new program right from the tool’s interface, enabling the user to tighten to a different torque setting or run the tool at a different speed. This feature enabled the operators at the truck manufacturing plant to take one tool with them while working on several different fastening applications around the truck, doing each with exact precision at the recommended speed.
5. Affordability: Typically, tooling systems with this level of sophistication are incredibly costly, but because the QX Series is only marginally more expensive than this manufacturer’s previous mechanical clutch tool, its implementation was an easy decision. The truck manufacturer has implemented over 20 QX tools in their plant to date, which has helped improve efficiency and provide consistent quality assurance, all at an affordable price.
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Posted by Clinton Shaffer