Precision and efficiency are paramount in the world of oil and gas, nuclear, and wind applications. One technique used is bolt tensioning. This is due to the loads it can reach and the accuracy it can achieve.
However, due to the bigger nuts and bolts and the critical nature of the applications, hydraulic bolt tensioning is becoming even more prominent in these industries. Smart tensioners have undergone a remarkable transformation with the advent of smart solutions and technology, becoming compatible with Industry 4.0 and offering a wide array of benefits for assembly.
Atlas Copco’s Smart Tensioning System (STS) is the first of its kind, highly intelligent, operator-guided bolt tensioning system. This hydraulic tensioning system guides the operator through all tensioning steps, measures the pressure inside the hydraulic tensioner, measures the torque and angle of the nut rotation, and collects data throughout. The smart system keeps track of the number of bolts being tightened in real time while prompting the operator for product service checks.
The dilemma
The Smart Tensioning System is made up of:
- Smart Tensioner: specially designed two or three-stage tensioner with integrated electronics and sensors with a very high load capacity. This range of smart tensioners has the ability to go up to 100% of yield capacity in 10.9 category bolts and is designed to fit on tight spaces with size-to-fit coated bolts.
- Intelligent Hand Controller: an industrialized electronic unit with software built inside an ergonomic hand controller. This allows the operator to take complete control of the process. Its durability to handle continuous production and present accurate results has been vigorously tested.
- Power Pack: equipped with accessories including a torque-controlled battery nutrunner, and manual torque wrenches. Together, these make a complete package calibrated to deliver consistent results.
Challenges
Sure, we can tell you how great the Atlas Copco tensioners are, but why do you need them? There are many challenges that manufacturers face where hydraulic tensioner features could provide benefits:
- Frictional losses
- Big M36 to M72 size bolts
- Variable joint conditions
- Access to applications
- Low operator dependency
- Max utilization of bolt strength
This hydraulic tensioning system can enable OEMs to plan longer intervals between services, saving money on equipment and manpower which is mobilized to check 10% bolts. This technology delivers consistent and accurate results, which enables engineers to optimize fasteners and flanges, instead of building in a safety margin to compensate for friction effects, human error, or environmental effects.
To sum it up
Smart tensioners represent a significant advancement in industrial technology, offering benefits that encompass safety, efficiency, and cost-effectiveness. These intelligent devices are capable of providing real-time monitoring, remote control, and data-driven insights. As industries continue to embrace smart technology, smart tensioners are poised to play a pivotal role in enhancing performance and reliability across the board. Embracing this innovation is not just a choice, but a necessity for staying competitive and efficient in today's fast-paced industrial landscape.
If you’re interested in learning more about Atlas Copco Tensioner Systems, contact us to schedule a demo today!
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