CASE STUDY HVAC MANUFACTURER FOR THE VEHICLE INDUSTRY
Challenges They were interested in a power tool to enhance process reliability and production efficiency to prevent product defects and reduce scrap rates. The engineering team was looking for a torque control system with error-proofing capabilities and the ability to program multiple torque settings. The automotive AC product required screws tightened in a fastening sequence and three different torque settings ( 2 N.m, 3.6 N.m, and 4.2 N.m). The fastening process also needed an electric screwdriver with a programmable “soft start” setting. This feature would let the power tool start slower, allowing a fastener to engage the threading properly and eliminate the risk of cross-threading events occurring. The power tool’s speed would ramp up automatically afterward. With ongoing issues of a product getting rejected because of incomplete fastening events and missing screws during the QA review stage, the engineering team needed an error-proofing tool that provided real-time monitoring of the assembly process and a method for recording and storing the torque and fastening data. Solutions To ensure the correct torque with every fastener tightened in the proper sequence, Mountz provided a smart electric screwdriver solution that safeguards against fastening failures. The ECT intelligent screwdriver system is a transducerized tool that features a built-in sensor that continually measures torque in real-time and feeds data back into the system. The tool’s I/O interface enables them to integrate the system’s digital signal output for real-time process monitoring and data collection. They could program the three preset torque settings with a single tooling system instead of using multiple electric screwdrivers to complete the different tightening events. Grouping the fastening sequence, soft-start settings, and the three torque settings into one multi-sequence event allows them to achieve multiple fastening tasks with a single automated fastening workflow. Manufacturing the product with consistent quality requires equipment to execute production tasks with high precision and repeatability. The screwdriver system provides error-proofing capabilities that track each screw the tools fasten. They could program
The error-proofing system eliminates manufacturing risks and prevents fastening errors like cross-threading, omissions, unfinished rundowns, stripped screws, and cam-outs.
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