Whether an automotive plant churning out hundreds of engines daily or a machine shop supporting heavy equipment rebuilds, fastening precision matters. Consistent and accurate torque application prevents leaks, failures, and accidents - but no single tool provides a perfect solution. Assembly pros know that pairing anair motor's speed and power with atorque wrench's verification capabilities delivers huge quality and efficiency dividends.
This guide covers key considerations when selecting complementary pneumatic and manual tools to dominate critical fastening challenges. Let’s review:
Balancing air impact wrench benefits and limitations
- The right features for manual torque wrenches
- Tips for matching capabilities to applications
- Special demands of high volume assembly
- The complete Flexible Assembly advantage
Understanding Air Impact Wrenches
It’s nearly impossible to walk through an automotive garage or machine shop without seeing air-powered impact guns in frequent use. Mechanics and technicians clearly love their capabilities for driving and removing stubborn fasteners much quicker than possible manually. However, some downsides exist.
These ultra-useful tools rely on sudden hammering force created when pressurized air flows into the chamber. An internal hammer repeatedly smacks an anvil transmitting torque spikes to the fastener. While this allows incredible speed, it also means unpredictable and scattershot torque delivery with each hit. Operators may get the needed torque figure once then too little or too much on subsequent uses.
Factors influencing inconsistencies each trigger pull include:
- Hose condition and length
- Lubrication
- Air pressure changes
- User grip and angle
- Socket wear and fit
- Variations in air supply
Additionally, cheap bang-for-buck brands likely cannot hold calibration for long before creeping out of torque specification. So while impact wrenches positively enable efficiency, relying on them exclusively courts quality issues.
Complementing With Torque Wrenches
Manual torque wrenches entered the maintenance scene by providing two vital capabilities air impacts broadly lack – precision and verification. From tiny instrument versions requiring only 6 ft-lbs for delicate calibration, up to 1,000+ ft-lb heavy duty models, torque wrenches allow incredibly accurate preload.
The manual operation paired with a precisely calibrated gauge makes hitting tight tolerances easy wrench after wrench. Torque testers like the Flexible Assembly Flex-GT bring digital data output, statistics, and control matching aerospace standards like ISO 6789. Always doublechecking final torque figures with a manual tool prevents fastening failures and accidents before products leave facilities.
Some key torque wrench benefits:
- Hit specific torque values consistently
- Prevent under or overtightening
- Avoid yield and fracture defects
- Access torque data for analytics
- Custom adjustment to various fasteners
- Portability between applications
- High level torque traceability
While a bit slower than air impacts, dedicated torque wrenches precision provides the assurance needed for critical assemblies.
Navigating Tool Selection
Finding the right fastening tools for a given environment depends greatly on the actual products being fabricated and specifics required. Building gaming PCs for enthusiasts allows more torque variance than say, cylinder heads at an engine remanufacturing plant. However, certain best practices apply universally:
Always use air impacts for initial driving and breaking loose stuck fasteners only. Their speed and power excels here for efficiency.
Follow up using low force electric or manual wrenches to “touch up” already tightened bolts to specification. High torque pneumatics should not finalize torque.
Invest in dedicated torque testers with data tracking for accountability on every fastening. This also enables statistical process control monitoring for continuous improvement.
Match tool capability range to the typical fastener torque requirements expected. A 500 ft-lb air gun suits most automotive uses but goes overly aggressive for electronics.
Consider ergonomics for reduced fatigue and injury. Low weight wrenches with comfortable grip prove vital when technicians repeat similar motions all day torquing fasteners.
Welcome input from shop floor teams using the tools daily as you evaluate options. Their firsthand user feedback often uncovers considerations missed from the engineering or supervisor perspective.
Special Demands of High Volume Assembly
Higher volume assembly plants pose unique needs to balance rate requirements and quality control. In auto plants cranking out 400-800 engines daily or contract manufacturers supporting dozens of different customers, flexibility and ergonomics prove vital. Workers spend entire shifts torqueing fasteners accurately at multiple stations – their productivity directly impacts production schedule and profitability.
Here pneumatic torque controllers typically integrate with tool balancers or box mounts to reduce fatigue. Pre-set torque figures allow the tools to automatically stop at target values without guessing. Advanced electronic torque testers also confirm measurements while storing data for analytics around capability and continuous improvement.
This pairing focuses worker efforts on proper technique and safety rather than reading gauges after every fastening. It also lowers injury risk from attempting to manually verify hundreds of exact torque specifications throughout long shifts.
Choose The Flexible Assembly Difference
For over 20 years Flexible Assembly Systems has engineered assembly efficiency, ergonomic, and torque quality solutions for leading manufacturers. We understand achieving repeatable fastening quality, safe torque verification, lower fatigue, and process improvements to make rate demands.
Need an air impact alternative providing better torque consistency? Our Flex Pulse electric pulse tools use advanced electronics and software for accuracy matching manual wrenches. Customizing specific torque, angle, and time parameters guarantees precision across thousands of cycles.
Require portable verification to confirm your pneumatic or electric tools hit specifications perfectly? The digital torque tester provides wireless data tracking, statistics, and troubleshooting everywhere assemblies occur.
Ready to prevent injury, empower consistent quality, and upgrade productivity for torque intensive applications? Contact the Flexible Assembly team today or request a quote online to get started. Our specialized engineering and 80+ combined years of assembly insight helps tailor the ideal solution just right for your operational needs.