Most industrial manufacturing processes start with that very first tightening of a single joint. There is a lot to gain from a quality and profitability standpoint if this repeatable process could be automated from the very start and throughout the entire assembly line. Let's look at why automated tightening pays off in manufacturing.
An assembly line often starts with a single joining process where two or more objects are mechanically fastened. In doing so, it is absolutely essential to get the tightening exactly correct the very first time. But tightening presents manufacturers with a series of challenges. Different tools are needed for different tasks at the assembly station, reporting is performed manually and with tasks being conducted manually follows potential quality issues and work-related injuries.
Historically, assembly line tools were developed for manual production methods so to address these mentioned tightening challenges manufacturers often aim for enabling different torque settings per tool, full process control and implementing ergonomic assembly processes. However, with todays increased complexity driven by mixed production and product variance and lower margins for human errors, industrial manufacturers are instead looking to alternative ways of addressing the challenges of tightening. And that would be automation.
Automation can be implemented on all levels in the manufacturing process. With most manufacturing processes starting and ending with a multitude of fastening operations, tightening is in particular an area where automation pays off. Automation of the tightening process allows for the greatest level of control which improves quality, efficiency and reduces costs caused by reworks and recalls. It is a way of getting the desired level of quality right from the very start and throughout the production process.
And automating the tightening process is gaining traction. In for instance the semiconductor manufacturing industry, thousands of screws are manually placed by an operator. With quality margins measured down to the billionth of a metre automation offers an obvious and measurable operational advantage. The industry that however in many ways has taken the lead in automating the tightening process is the automotive industry, but it is safe to say that these solutions definitely bear relevance to other manufacturing industries.
Things to keep in mind when automating tightening
Automating the tightening process comes with many obvious advantages but there are still some things that are important to consider and take into account when taking that automation step:
- Automated tightening requires very often the integration of a screw feeder, something that calls for competence to implement and optimize in a correct way
- With a wide range of product variances comes the need for tools, equipment and solutions such as integrated machine vision to enable required levels of flexibility throughout the tightening process
- Knowledge and solutions to handle the reaction forces from tightening impacting the mechatronic equipment
- In some cases the automatic tightening solution needs to interact with an operator, this requires an understanding of operator safety and ergonomics
The Atlas Copco automation offering
Product and process solutions by Atlas Copco facilitate the integration of automated tightening technology systems. Engineered to meet the needs of new and existing assembly processes, our automation offerings provide peak quality and efficiency, extensive flexibility and high cost effectiveness in every application.
To learn more about the Atlas Copco automation offering for the tightening process, contact us today!
