Making the Switch from Pneumatic to Electric Tooling

Providing control and reducing risks

Switching from Pneumatic to Electric tooling

Traditionally, the rail industry has been reliant on pneumatic tooling and manual torque wrenches. In the drive towards decarbonisation and traceable, sustainable operations, a phased transition to electric and battery-powered smart tooling for high-torque, joint fastening applications, offers a compelling proposition.

Whilst the needs of a specific application define the optimum tooling solution, there are advantages of using electric and battery tools over legacy pneumatic ones.

Switching to DC tools with a consistent power source allows manufacturers to improve their sustainability efforts by achieving high productivity rates for less energy consumption. The more efficient processes are, the lower the carbon footprint, which contributes to a better environmental performance for the industry as well as the organisation.

Firstly, pneumatic tools require more infrastructure, including compressors and air hoses to operate them, which as well as taking up space, also requires ongoing maintenance and monitoring.

Another way electric tools can help reduce rework and scrap is with data collection. Unlike pneumatic tools, electric tools can collect tightening data. This information is then used to identify and correct issues made on the line and prevent them from recurring.

Reduction in Defects

No manufacturer likes dealing with defects, scrap, and rework. They are all extremely detrimental to productivity, profitability, and sustainability goals. When operating with air tools, businesses could be at higher risk of dealing with scrap and rework. This is because electric tools are developed with error-proofing aspects, that air tools generally don’t have. Additionally, electric tools are more accurate and utilise defined tightening programmes to ensure torque accuracy.

Error-proofing

Data-collection

Fewer Tools

Importantly, a switch to DC powered tooling means that fewer tools are required to get the job done. Atlas Copco’s range of ‘smart tools’ provide operator guidance so that the tool indicates when the exact torque levels are achieved. Additional torque wrenches are therefore not required for final checking. Operations still using pneumatic tools will also require manual torque wrenches to ensure the quality of joints. Typically, this approach is still the standard within the rail industry.

Smart Tools

Smart Electric Assembly Tools for Every Application

Designed with a focus on improving operator ergonomics, safety and productivity, Atlas Copco has innovated a range of battery-powered low reaction tools, electric and cordless screwdrivers, nutrunners and wrenches, which cover applications across the rail industry.

Among the recent additions to its portfolio of smart tooling solutions, in pursuit of zero-defect assembly and maintenance, is the launch of the SRB HA battery powered nutrunner. Featuring a dual trigger that prevents the risk of finger pinch injury, a first for the manufacturing industry, operators are able to control and measure torque in real time with precise accuracy, that not only improves safety but also reduces the time spent on tasks.

With three models available, the entry level SRB HA 'Digital' version has a set and go function, ready for use straight out of the box. 'Smart' and 'Connected' models feature an internal Wi-Fi server, allowing the tools to be linked to any mobile device, enabling torque, angle and batch data collection without the need for additional software.

For low torque applications, Atlas Copco’s Tensor ITB-P pistol cordless nutrunner takes productivity, assembly quality and user experience to the next level. ITB-P offers manufacturers and maintainers added value value-through features such as TrueAngle angle compensation, faster tightening speeds and improved wireless signal strength. The tool also offers multiple forms of operator feedback via a coloured front LED, vibration and an embedded user display.

ITB-P is part of the Tensor IxB tool family, which are equipped with integrated controllers that enable direct integration with station accessories and the production system without the need for an intermediate physical controller box.

Providing full data connectivity, the STRwrench ensures high quality fastening by covering a wide range of torque applications and providing clear operator feedback, making them less prone to errors. The tool’s enhanced accuracy ensures compliance with the most challenging tolerances, taking safety and critical application tightening processes to the next level.

Ensuring quality assurance (QA) of safety critical joints for both assembly and maintenance operations is essential. Whereas conventional mechanical ‘click wrenches’ have typically been employed for joint checks, Atlas Copco’s new electric STRwrench, enables the correct torque-based tightening to be achieved first time, every time.

Presented as the world’s most advanced and productive battery nutrunner, SRB HA is powered by Lithium-Ion 36V technology with built-in charging and health indicators. The powerful nutrunner has a torque rating of up to 4000Nm and an internal torque transducer for maximum control and reliability. The tool provides clear user feedback via multi-functional LEDs which display OK/NOK status messages based on torque and angle readings, while its powerful Tensor motor technology also ensures that operators are not exposed to the risks of hand arm vibration syndrome (HAVS).