Tensor DL screwdrivers - Atlas Copco

Cutting costs and improving quality at Johnson Controls
Tensor DL ensures process
security at Viessmann
Among the first to use the
new Tensor DL screwdriver is
German heating component
manufacturer Viessmann. At
the company’s assembly plant
in Allendorf/Eder (north of
Marburg), Tensor DL is used
to fit 80 burners per shift to
condensing boilers.
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Manfred Pinhard, responsible
for design and resource planning
at Viessmann Werke
GmbH & Co., chose the
Tensor DL “in order to ensure
process security even at low
torques”. He also appreciates
the fact that the screwdriver
configuration can “easily be
programmed or reprogrammed
on a laptop at any time”.
Johnson Controls is a major
supplier of integrated seating
and interior systems for the
automotive industry. At Lakewood
in Michigan, USA, the
company produces headliners
for large car manufacturers.
Prevailing torque, different
screw lengths, and varying
joint types are typical
challenges the production
engineers face when planning
the assembly process. “This
previously led to problems
such as cross threads, missing
components and damaged
parts,” states manufacturing
engineer Phil Green.
Several Tensor DL systems
were introduced, allowing for
integration to the line. Johnson
Demag Cranes & Components is the world
market leader for cranes and hoists. Its Wetter/Ruhr
facility manufactures both electric
hoists and other hoist and crane types. In an
effort to reduce the large amount of pneumatic
tools needed to assemble the many
different models, the company invested in
several Tensor DL systems. High uptime and
Controls now has full line
control and feedback.
Six conventional tools were
replaced with only three
Tensor DL systems per
station.
Phil Green explains that the
new tools have improved
quality control and taken away
the need for final inspections.
The investment paid off in less
than eight weeks by eliminating
assembly problems, cutting
preventive maintenance
service costs by 70%, and
reducing downtime. “The
ability to change rundown
speed and torque settings
with the tool has given me
the flexibility we never had
before,” he says.
Four sets of screws, comprising 15 Allen screws in four
sizes, are tightened to a specific angle and torque within
±10% over 6 Sigma. The screws are tightened using
just one Tensor DL at different torques of 5.1 Nm and
below. The bit selector tells the operator which tightening
parameters apply as each respective screw bit is selected.
Lifting quality and lowering costs
at Demag
lowest “total” cost are of great importance
for Demag when investing in tools. Atlas
Copco also provides regular preventive
maintenance on the tools, giving Demag no
unexpected or costly repairs. In addition
Demag has significantly reduced downtime,
lower inventory costs and higher quality in
their production processes.