Quality and reliability form the foundation upon which new companies build their futures and stake their reputations. As consumers, we are largely unaware of the painstaking pre-production steps and choices that companies make in order to develop products and assure their reliability. One of the most challenging steps that face these fledgling manufacturers is the selection of the tools that they will be depending on to maximize production, guarantee product quality, and assure the productivity and safety of their workers.
Tool selection posed a challenge for a slot machine manufacturer that was developing a new computerized gaming system. The new slot machine contained delicate and sophisticated electronic components. It needed to be built to withstand the rigors of twenty-four hour a day use by enthusiastic gamblers.
Before going into full production, the slot machine manufacturer initiated an extensive prototyping program to establish assembly procedures, and torque specifications using hand torque tools. However, before full production could be started, it had become apparent that more attention was going to have to be given to tool selection with an eye to the issues of productivity, quality and worker comfort.
The Flex Power pulse tools by Mountz are designed to enhance quality through precision torque control. But if the tool is not set up correctly, the pulse tool will not operate properly. Here are some quick tips for connecting a pulse tool to an air line. Be sure to use the proper air fitting and air hose size as stated for each pulse tool model.
Teflon tape is needed when installing the air fitting. Always use the proper air hose length for the pulse tool. The length of an air hose shall not exceed 5 meters from the air line or the air pressure will reduce, which impacts the torque setting.
Not all torque wrenches are alike. When selecting a torque wrench or operating a wrench, it’s important to understand the functions of the tool being used for the fastening application. Take time to read all instructions provided to fully understand the working features and manufacturer recommendations.
The design of certain wrenches, make the tool “length dependent”. What does that mean? It means that the actual torque applied to the fastener varies if the hand position on the wrench is varied (even if the wrench is preset). This occurs if the pivot point of the wrench mechanism is not coincidental with the center of rotation of the fastener or bolt.
Therefore if an operator is holding a “length dependent” torque wrench at the end of the handle, the torque output might be 25 foot-pounds applied for the fastening application. If the operator then changes his or her grip position and holds the wrench at the middle location of the handle, the torque output might be 50 foot-pounds applied for the fastening application.
The signal output wrench is process control tool that sends a signal each time the torque wrench achieves its pre-set torque value. These wrenches offer manufacturers greater control over the production process. The signal output wrench provides confidence that the tightening process has been performed by validating that the torque wrench has been operated. Upon each successful activation of the wrench a signal is sent, which can be used to control production flow or count the number of completed fasteners that are tightened.
The wrench is a cost effective solution as these tools can be integrated into most production lines. The cable from the signal wrench can connected to a PLC or error proofing system.
Options for Using a Signal Output Torque Wrench Production Line Control: Allowing only components with fasteners that are correctly torqued to pass through a work station. This could be a simple matter of actuating a gate switch or sending a signal to an automated controlled assembly station.
Counting Function: Count the number of times the torque wrench has successfully torque fasteners and check against finished goods.
The failure of a threaded stud that isn’t properly welded can lead to failures further along the assembly process or latent failures with a stud breaking in finished products, which costs manufacturers money and time with warranties and rework. Unfortunately, many manufacturers don’t use a quality control tool to test and verify if a threaded stud is securely welded or if it will simply break off. The Weld Stud Test Tool by Mountz, Inc. is designed for a quick and easy controlled test of the integrity of welds holding threaded studs onto sheet metal.
A simple way to test the shear torque of threaded studs is apply a straight pull of the Weld Stud Test Tool (no side load). When the wrench breaks-over and the stud is still attached then it passed. If the threaded stud breaks off – then it failed.
For assembly applications that utilize sheet metal or other metal products during the manufacturing of metal enclosures, appliances and automotive parts, threaded studs that are welded are a component that may be used. A company that manufacturers popcorn machines, conveyor ovens, and toasters wanted the capability to test the integrity of welds used on the threaded studs in the products it produced before the assembly process was completed. The manufacturer was experiencing repetitive problems with studs breaking in the products it produced. It cost the company time and money, which ultimately affected their bottom line.