We could write a book of success stories.

We’re trying to improve manufacturing one company at a time with practical and innovative solutions. Call us today! With the highest quality product lines, our years of experience providing manufacturing solutions, and our excellent network of industry connections, we are assisting top companies in Minnesota, Iowa, Wisconsin, Nebraska and North and South Dakota reach their fullest potential. You could be our next success story.

Assembly Technology

Advanced Tightening Solution for Bus Wheels

Advanced Tightening Solution for Bus Wheels Advanced Tightening Solution for Bus Wheels

As the builder of some of the best-selling coaches in the U.S. and Canada, Motor Coach Industries (MCI) trusted Atlas Copco’s LTP 51 precision set of pneumatic tools to secure the wheels to MCI’s coaches for years. Recently, MCI took its commitment to assembly quality and the safety and comfort of plant personnel to the next level, upgrading to Atlas Copco’s Advanced Tightening Solutions, ETP ST101-750.

As the builder of some of the best-selling coaches in the U.S. and Canada, Motor Coach Industries (MCI) trusted Atlas Copco’s LTP 51 precision set of pneumatic tools to secure the wheels to MCI’s coaches for years.  Recently, MCI took its commitment to assembly quality and the safety and comfort of plant personnel to the next level, upgrading to Atlas Copco’s Advanced Tightening Solutions, ETP ST101-750. This new tool sets the precise torque, counts the number of tightenings, and ties that information to the serial number of the coach.


However, the weight of the new tool, at 15 lbs., created an unforeseen challenge.  MCI needed to figure out how to maneuver the tool and its controls, making it flexible enough to work around a 45-foot coach. MCI contacted Technical Tool Products (TTP) to find a solution.
TTP and MCI considered multiple possibilities before settling on the Equipoise Zero-G arm, which provided weightless tool balancing at an affordable price that fit within MCI’s budget.  TTP also designed a custom cart, providing the final solution to overcome access challenges.


When the system was implemented at MCI, Quality Technician Dwayne Peters began to notice improvements right away.  “We have found that our torque audits have become much more reliable since we implemented the new tool,” said Peters.  In fact, MCI found its second re-torque after-road to no longer be necessary.  Though MCI still performs the second re-torque test as a precaution, it may be eliminated in the future.  “In the beginning the employees did not like the new tool,” reflected Peters. “Now, you can't take it away from them. They really love it.”
 

+ (read more)

Multiple Tools Replaced by a Single Atlas Copco Transducer

Multiple Tools Replaced by a Single Atlas Copco Transducer Multiple Tools Replaced by a Single Atlas Copco Transducer Multiple Tools Replaced by a Single Atlas Copco Transducer

KEB America assembles many different motion control products, offering customers "the flexibility to create numerous customized configurations to meet their individual application needs." As a result, the company handles as many as 80 different configurations and over 50 different jobs in each assembly station.

KEB America assembles many different motion control products, offering customers "the flexibility to create numerous customized configurations to meet their individual application needs." As a result, the company handles as many as 80 different configurations and over 50 different jobs in each assembly station. In the past, this meant that operators had to choose from as many as 8 different clutch shut-off tools, each with a separate torque setting adjustment based on material and product. In addition, fastener quantities could be different for every assembly, requiring frequent checks and calibrations. The workstation was cluttered with tools banging into each other and the operator was faced with multiple choices when each new product appeared in the station.

All of this posed a huge challenge in training operators, implementing quality control measures, and providing standardized process documentation.

KEB contacted TTP looking for a better solution. Through in-depth consultation it was determined that all the tools in the station could be replaced by a single tool – an Atlas Copco SL DC Electric Transducerized Tool. Using a plug-and-play bit selector and bar code technology each application is given a unique job. The tool is told electronically what the torque will be, so no external torque adjustment is required. The operator just pulls the trigger and looks for a green light. When a product comes into the station, the operator simply selects the correct job and proceeds. The number of fasteners can be counted. Re-hits and bad fasteners can be caught "in-station" and repaired. And the assembly station has a neat and professional looking appearance.

According to Rodney Wong of KEB America, "Set up was very straight forward. The quality and efficiency in production has increased since the use of the system."

+ (read more)

Sophisticated New Tool Stand Provides a Simple Solution to Errors and Downtime.

Sophisticated New Tool Stand Provides a Simple Solution to Errors and Downtime. Sophisticated New Tool Stand Provides a Simple Solution to Errors and Downtime. Sophisticated New Tool Stand Provides a Simple Solution to Errors and Downtime.

In order to create a “world-class” assembly line, a customer was replacing old, multiple-click-style torque wrenches which were left in drawers, on the bench and often misplaced. In their place, the engineer wanted a single, digital ST Wrench, Controller and Stacklight in a central location that would provide easy access, operator ease of use and safe storage. It would also eliminate production errors and downtime caused by workers searching for the old wrenches.

In order to create a “world-class” assembly line, a customer was replacing old, multiple-click-style torque wrenches which were left in drawers, on the bench and often misplaced. In their place, the engineer wanted a single, digital torque Wrench, Controller and Stacklight in a central location that would provide easy access, operator ease of use and safe storage. It would also eliminate production errors and downtime caused by workers searching for the old wrenches.

To meet the customer’s needs, TTP recommended a custom ST wrench holder made of extruded aluminum. In the past, tool stands were an afterthought – simply welded and painted steel. They were often bulky, ugly and poorly functioning. Any changes required cutting and more welding. So operators were frequently left with something they didn’t like but couldn’t effectively change.

By comparison, stands like the one recommended by TTP, are made of extruded aluminum components that bolt together. If change is required, a stand can be quickly unbolted and moved up or down. And, if needed, one or more components may be easily replaced by other standard components. The custom
ST wrench holder ensures that the expensive tool is kept safe, clean and always in the same place. In the words of the engineer, “This was a clean and easy-to-use accessory. The aluminum extrusion provided a more professional and state-of-the-art appearance over a welded steel stand.”

+ (read more)

Material Handling

Gorbel G-Force / Overhead Bridge Crane for Recycling Application

Gorbel G-Force / Overhead Bridge Crane for Recycling Application Gorbel G-Force / Overhead Bridge Crane for Recycling Application Gorbel G-Force / Overhead Bridge Crane for Recycling Application

K & K Metal Recycling, a non-ferrous metal recycler in Minneapolis, MN, has implemented a new lifting solution from Technical Tool Products. The company was looking for a more ergonomic way to lift heavy batteries weighing up to 150 lbs. After discussing their needs with a TTP sales engineer and seeing Gorbel product demos, the company decided on a 500 lb capacity ceiling mounted bridge crane and G-Force intelligent lifting solution from Gorbel.

K & K Metal Recycling, a non-ferrous metal recycler in Minneapolis, MN, has implemented a new lifting solution from Technical Tool Products. The company was looking for a more ergonomic way to lift heavy batteries weighing up to 150 lbs.

After discussing their needs with a TTP sales engineer and seeing Gorbel product demos, the company decided on a 500 lb capacity ceiling mounted bridge crane and G-Force intelligent lifting solution from Gorbel. K&K was also able to design a custom end effector and custom hangars in-house of their own.

The solution was well received in the plant. What had once been a two-person manual lifting operation can now be accomplished safely by one operator. It has improved ergonomics, worker safety, and productivity. K&K now lifts 44,000 – 48,000 lbs per week and 2 million+ lbs annually. Other benefits they have noticed include ease of use, operators being able to work longer, and using less man hours.

+ (read more)

Bus Window Material Handling Solution

Bus Window Material Handling Solution Bus Window Material Handling Solution

A large North American bus manufacturer was looking for a safe, more efficient and ergonomic method to install windshields and large side windows in their transit and shuttle buses during assembly. Prior to contacting TTP, each 100-plus pound window had to be unpacked, manually lifted into position by two people and held in place while another installer secured the window from the inside of the bus. This was repeated as many as 20 times per bus. And the company produces up to 10 buses a day.

A large North American bus manufacturer was looking for a safe, more efficient and ergonomic method to install windshields and large side windows in their transit and shuttle buses during assembly. Prior to contacting TTP, each 100-plus pound window had to be unpacked, manually lifted into position by two people and held in place while another installer secured the window from the inside of the bus. This was repeated as many as 20 times per bus. And the company produces up to 10 buses a day.

Overhead clearance presented a challenge for incorporating cranes in the assembly process. Additionally, the windows were installed at the very edges of the assembly area, which presented even more issues since many bridge and runway systems tend to bind when used at their outer limits.

To meet the challenge, TTP specified, engineered and installed a Freestanding Bridge and Runway system manufactured by Demag. Demag’s patented articulated connections between the crane girder and end carriages create a smooth operation that even operates on tracks that are not parallel, especially at the ends of the runway, where the work was being done. The low deadweight and low friction trolley wheels allow the operator to move significant loads. To precisely handle each window, a Schmalz VacuMaster Lifting Device was coupled to a Demag Infinitely Variable Speed Hoist. The VacuMaster includes a 90-degree tilt and extended handles to allow maximum flexibility in placing the window. Finally, to save headroom, an integrated buss bar (vs. a festoon system) was used to supply power to both the hoist and vacuum lifter.

The result is increased flexibility and productivity, safer handling, and improved ergonomics.

+ (read more)

Material Removal

Atlas Copco LSV Grinders Provide More Power in Half the Time with Half the Cost

Atlas Copco LSV Grinders Provide More Power in Half the Time with Half the Cost Atlas Copco LSV Grinders Provide More Power in Half the Time with Half the Cost

Angus Palm in Watertown, SD, is a world-class manufacturer of cabs for forestry, mining, construction, agricultural, & military equipment. The company prides itself on the quality of its construction and the resulting safety that its products provide to the operators who use them every day.

Angus Palm in Watertown, SD, is a world-class manufacturer of cabs for forestry, mining, construction, agricultural, and military equipment. The company prides itself on the quality of its construction and the resulting safety that its products provide to the operators who use them every day. That quality and safety starts at the ground level – in the fabrication of the cab body. By using Atlas Copco pneumatic grinders, Angus Palm is able to ensure a professional finish, a high level of productivity, and ergonomic benefits that translate to a safer, more comfortable environment for its employees.

The decision to switch to Atlas Copco grinders was not made in haste. The weld and fab leaders took time to compare pneumatic tools based on rate of material removed, weight, vibration and noise levels, and abrasive/disc consumption. The Atlas Copco LSV48 was a hands-down winner, with high marks given in all of the above categories. According to Randy Jewell, Weld Supervisor at Angus Palm, “In our pre-purchase tests we were able to remove the exact same amount of material in half of the time with one disc than we could with two disks using a less powerful Grinding tool. We estimate since the purchase of these tools we have reduced our use of 7" discs by nearly 50%.” These tools are now replacing all previous 7" angle sanders/grinders in the plant and are being put to use in cab fabrication for the world leaders in industrial machinery…
including the Atlas Copco 45-50 Mining Machines.

The Atlas Copco LSV48 is a 2.5 HP, pneumatic angle grinder with sealed angle head, speed governor, vibration-dampened handle, auto-balancer and low profile is designed to tackle the heaviest of jobs while reducing stress on the operator and increasing the life of your costly abrasives. Call Technical Tool Products for personalized demonstration of this power at your own facility.

+ (read more)



If you need assistance with a technical problem, please click on Request A Solution or visit our Resources page.