We could write a book of success stories.

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."

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.

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.”

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.

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.