Robotics, computerization, and electronic mechanization have brought state-of-the-art automation to modern industrial plants. Thus, the need to perform quality control testing and torque measurement is even more critical to achieve a return-on-investment. Quality control testing has been neglected or downplayed by manufacturers for many years; however, a greater need for high-quality merchandise and competitive pricing has made high-level quality control absolutely necessary, a requirement that demands more testing and measuring right on the assembly line.
One area of quality control that is extremely critical is torque control. It is critical because it is a major component for quality manufacturing and has a direct impact on bottom line issues like product quality, reliability, safety, and even liability. Controlling torque precisely keeps a fastener from vibrating or working loose, or if tension is too high, from snapping the bolt in half or stripping its threads. A off-road vehicle manufacturer was all too aware of the requirements of precision torque control.
The quality manager for an off-road vehicle manufacturer said, “The way we were torquing fasteners was not very accurate and was very time consuming, so it was easy to over- or under-torque a fastener on any given joint. We knew we needed to improve our ability to accurately measure torque, especially when we got into the ATV market where quality control criteria was more stringent.”
For many years, torque control on their assembly lines consisted of using impact wrenches to snug down fasteners, then applying final torque using click wrenches. And the facility didn’t perform torque tests or audit the tools.
“The nature of a click wrench is such that if you don’t feel or hear the click, or know that it’s clicked, you can continue to turn the wrench, and then all of a sudden the nut is over-torqued,” the quality manager explained. “Over- or under-torquing is always going to be a problem because the possibility of human error is always there with a click wrench.”
The quality control personnel needed a torque testing system that could be used on the assembly line for auditing the torque tools and the fastening applications, as well as being used in a calibration lab.
It was obvious to the quality manager, company engineers, and QC inspectors that a more sophisticated torque testing device and assembly tools were necessary if they were going to increase productivity and eliminate the possibility of inaccuracy.
“We did a lot of searching and research for a torque analyzer and a torque wrench that would increase our production capabilities,” the quality manager commented. “We had a demonstration on just about every torque tester and wrench available on the market before we made our final decision. We finally decided on the torque testing system and the cam-over torque wrench by Mountz after consultations with all concerned departments. Mountz came in and gave us training seminars, telling us what we should and should not do when clamping fasteners.”
“The torque tester is very easy to use anywhere in the plant, and it’s very user-friendly,” said the quality manager. “It didn’t take long before we started improving our quality and productivity, and it was versatile enough to use in engineering, calibration lab, and on the production line.”
To eliminate the inaccurate torque control that they experienced with impact wrenches and click wrenches, the off-road vehicle manufacturer selected Mountz cam-over torque wrenches. The accurate cam-over torque wrenches prevent a fastener or bolt from being under and over tightened. As quality control tool, the torque wrench allows any user to deliver the correct torque with confidence regardless of task and operator skill level.
“We were able to eliminate the impact and clicker wrenches so that the assembly person could no longer over- or under-torque a fastener,” the quality affirmed. “Our people now have tools that apply torque accurately and consistently. And quality staff now have the ability to test and calibrate the torque tools, which gives us repeatability and accuracy.”
The off-road vehicle manufacturer’s engineering department has seen efficiency increases with using a torque tester during the R&D process for new products They can simulate a particular joint in one of their fastening applications, and then try to get the fastener to jam, strip-out, or break to test its strength.
“It’s really speeded up the time that our engineers take to do their testing,” the quality manager said. “There’s really a lot of value and quality built into Mountz’s equipment, and we feel that we’re getting a lot for our money.”