When it comes to using pneumatic tools, the right airline infrastructure is vital. Without it, your whole production will suffer and could cost you thousands of dollars per year. Discover the ins and outs of producing with pneumatic tools and the correct airline infrastructure to optimize your production facility.
There are many advantages of using air tools. They have superior ergonomics, an impressive power-to-weight ratio, and many other benefits. However, when using pneumatic tools, the airline installation is of utmost importance for the tool's performance. Without it, you will suffer from low productivity and poorly functioning tools, which will affect your quality, profitability, and much more.
In order to achieve your productivity goals, your pneumatic tools need to run with the correct air volume and air pressure. This will enable increased quality, productivity, and thus improved profitability and sustainability. Now, you may be wondering what good airline infrastructure looks like. If that’s the case, then this article is for you! Below are the dos and don’ts of proper airline infrastructure and the impact they can make on your manufacturing process.
The importance of CFM and PSI
At the heart of this list is supplying your tools with the correct CFM (air volume) and PSI (air pressure). Your assembly will suffer without the correct air pressure, and several factors can affect it. While running at a low CFM or PSI won’t stop your tools from running (in most cases), however, it will inhibit them from running properly. This can have two different outcomes.
The first possible outcome is that your operators will have to work longer to achieve the same outcome as they would if they were using properly running tools. This added time affects your productivity and profitability since you will get less work done in the same time frame.
The second outcome is your assembly tools' pulse or clutch mechanisms not shutting off when they should. They may shut off too soon, too late, or not at all. This leads to several issues like not reaching the correct torque and added rework and scrap. When your tools shut off too late or not at all, you will notice an increase in broken bolts and parts. This issue will increase the amount of rework to your daily assembly processes, thus increasing downtime, scrap, and increased costs. All of which negatively affect sustainability efforts.
Have an FRL at each drop point
Having a filter, regulator, lubricator (FRL) or filter, regulator (FR) at all drop points is vital to maintaining your airline infrastructure. This regulates the air and ensures that your tools are running with dry, clean air and the proper PSI (91 PSI or 6.3 bar).
This is essential for optimizing your manufacturing. Did you know a pressure loss of just one bar leads to almost 30% less material removed because the tool can’t operate at its max power? That means the operator must work 40% longer to do the job!
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2-3x
Extended Service Intervals
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10-15%
Increased Output
Furthermore, FRLs are important for supplying the correct amount of oil to the tool. This ensures that your tools are being correctly lubricated, prolonging the service life. By taking care of your tools, you can extend its service intervals 2-3 times and increase the output by 10-15% in vane motors. This reduces service/maintenance costs, promotes profitability, as well as supports sustainability efforts as you will spend less time and money on fixing the tool itself, and by using a tool for longer, you’ll have less waste and you will save on your overall operational costs.
Having end stops vs. a loop design
A common issue we see with manufacturers having incorrect airline infrastructure is having end stops on the line. These are devastating to your bottom line. They increase downtime and reduce your production quality. This is because the air pressure isn’t evenly distributed between all the tools on the line. By the time you get to the end of the airline, the air pressure and volume are too low for the tool to operate properly.
The solution is to install the main airline in a loop design. The difference with the loop design is that the air pressure is evenly distributed throughout the line, ensuring your tools run with the correct PSI. This leads to less downtime related to underpowered tools, defects, and scrap.
Stop leakages before they become a bigger problem
A well-designed and maintained air distribution system should experience less than 5% air leakage. Unfortunately, that isn’t always the case. Manufacturers often experience leakages reaching 15-20%! Since a leakage translates into a loss of air capacity, the compressor has to work harder to compensate, which leads to significantly higher energy costs. This also means your material removal tools won’t operate properly due to the lack of air pressure.
Whether you have a hole measuring 1 mm in diameter or 10, the cost can really add up. The more leakages you have, the greater the cost. While a hole measuring 1 mm in diameter will only cost an extra $101 a year on average, if you have 10 of them throughout the line, it can cost you an astounding $10,285!
Have one drop point per operator
A large drop in air pressure occurs when several couplings and connectors are at the drop point. This is why it’s essential that there is only one operator per drop point. Otherwise, you will begin to notice that it affects the operation of your tools and production quality. This means it will take operators longer to get the same job done and you’ll likely see a spike in downtime related to tools that are lacking power, not reaching the correct torque, or not even working at all.
To sum it up
Often improving your profitability and supporting sustainability efforts go hand in hand. When you optimize your airline infrastructure to better support your pneumatic tools, you’re achieving many of your productivity, quality, and profitability goals. This helps to reduce waste and downtime, enabling your facility to better support sustainability efforts while reducing your overall costs.
Achieving optimized airline infrastructure is easy with Atlas Copco. We have the resources, accessories, and expertise to guide you toward the right path. Contact our experts today to learn more about the importance of correct airline infrastructure!
