Improved product quality and ergonomics thanks to Low Reaction Tools

Atlas Copco recently helped an Automotive manufacturing customer solve quality issues in their heat shield securing process. Issues experienced included missing fasteners and incorrect torques.

The heat shield that is being secured is needed to prevent high direct heat to potential combustion-prone materials from the catalytic converter underneath the vehicles. High heat could cause these materials to catch fire, and missing fasteners or improperly secured fasteners could cause failure of the heat shield.

Previously, a pneumatic pulse tool was used to install the heat shield with 12 fasteners times 700 vehicles per day. Fasteners were sometimes forgotten or not tightened to the correct specification, which can lead to heat shield failure, causing excessive heat and potential combustion. Work is performed above operators' shoulders, tightening fasteners to 30 Nm. Because of the workstation layout and assembly process, a direct drive tool cannot be used for ergonomic reasons.

Atlas Copco TBP - our wireless, error-proofed, one-handed Low Reaction Tools, combined with the Power Focus 6000 controller, the core of Smart Connected Assembly, our vision for Industry 4.0. The Power Focus 6000 is connected to the customer's MES system and with the addition of the ToolsNet 8 data collection and analysis software suite, is everything that is needed to implement the Industry 4.0 concept. The TBP pulse tool is transducer controlled. The tool records important tightening data, including angle and pulse count. This ensures correct torque and detection of any assembly errors and possible joint issues. Common assembly issues, such as cross threads or missing fasteners, can be avoided. Annual customer claim costs: $33,900 Annual manpower cost for analysis and data records: $5,540 Total annual savings: $39,440