A growing challenge in the automotive industry is maintaining consistent quality across assembly operations. This is especially true as production environments evolve toward more connected and data-driven operations. The ability to capture, interpret, and act on fastening data becomes critical to maintaining quality at scale, making visibility and operator feedback essential. When fastening processes lack real-time visibility, and operator feedback is unclear or delayed, even small deviations can lead to rework, inefficiencies, and increased quality risk.
In this article, we will analyze the importance of these capabilities and their impact on production.
From assembly challenges to controlled performance
In the automotive industry, maintaining consistent torque quality while reducing rework remains a persistent challenge, especially when production variability is involved. With these factors in mind, one manufacturer in particular sought to further enhance process control and data management within their brake tube, pipe tube, and 2-way valve tube applications. Initially, they were using an MWR connected to a Focus 61 controller, and while their existing solution supported operations, they identified opportunities to further optimize communication range, system responsiveness, operator feedback, and battery performance.
The opportunity to further enhance performance led them to explore available solutions to effectively bridge the gap between their current capabilities and their future goals. An advanced mechatronic wrench that could ensure accuracy, connectivity, and uptime would fit well into their current goals. This realization brought their team and the Atlas Copco specialists together to discuss possible solutions and evaluate how they compare with the existing solution.
This led the team to evaluate how smarter, connected fastening tools could improve visibility, strengthen process control, and support more consistent torque application across their operations. Through this evaluation, a connected wrench emerged as a strong fit for their requirements: a wrench with clear OK/NOK confirmation at the point of fastening, able to provide clear guidance for operators, and aid in minimizing the risk of missed or incorrect tightening sequences. Additionally, this wrench would require reliable long-distance communication to support uninterrupted data capture and process validation, as well as a long-lasting battery to keep the tool powered throughout a shift.
This approach was enabled by the MTRwrench, Atlas Copco’s mechatronic wrench, which proved further compatible when connected to ToolsControl and ToolsNet 8, thereby developing an integrated Atlas Copco ecosystem for data management and process control, providing real-time torque monitoring and clear operator feedback on each fastening.
This solution proved to be a strong fit, addressing several areas identified for improvement. The communication range was significantly improved, enabling them to achieve up to 40m of stable communication, about 20m more than they needed for their assembly. This solution was designed to help mitigate overload events and improve tool reliability, thereby increasing uptime and providing confidence in the solution among operators. By integrating a stacklight, operators would have clear, real-time visibility into tool status and assembly progress. From OK/NOK feedback to battery life, these capabilities support more efficient assembly processes. Lastly, with up to 16 hours of battery life, they would reduce the likelihood of production interruptions related to battery life.
Separate myth from reality in joint quality with advanced reporting insights.
The MTRwrench: Driving consistency and traceability in every joint
With the implementation of a connected mechatronic wrench, the manufacturer strengthened process visibility and positioned their operation to improve traceability, reduce rework, and achieve more consistent fastening outcomes. Furthermore, they would achieve improved OK/NOK LED visibility, more stable long-distance communication, and more than 16 hours of operation between charges. This is expected to reduce rework associated with fastening deviations, improve line stability, and enable data-driven decision-making.
Explore what smarter fastening could mean for your operations
Are you ready to unlock greater control in your fastening processes? Connect with our experts to discuss how improved visibility, control, and traceability can support your assembly goals.
