PULSE TOOL VS IMPACT TOOLS

PULSE TOOL VS IMPACT TOOLS

Pulse tools & Impact drivers both are Pneumatic tools whose source of power is Air. They are different only on the basis of their working mechanism. Impact wrenches have hammer based mechanism & Pulse tools have Oil pulse mechanism . But impact tools are using on a large scale in the world because they are less expensive, produce great power, small in size, consume less air for their operation. But they have many disadvantages, they are very noisy, high vibration level, not good for critical assembly processes, torque control is not possible, the accuracy level is ±40-50%. In their working motor rotates when trigger pressed & then a motor moves the hammer assembly inside the tool, then hammer blows each other & produces great power, hence the main maintenance component in impact wrenches is a hammer. The operator can’t run the tool without using earbuds because they produce great sound, so this is very unhealthy for the environment & for the process too. Sometimes they cause to damage the application.

On the other hand Pulse tools have great advantages over impact. There Oil pulse mechanism make them perfect. When trigger pressed motor rotates then motor move oil pulse assembly then blades in oil pulse assembly compresses the oil & generate power. They are very smooth in working, no noise, no vibration, consumes less air, you can control the torque through torque screw, shutoff is also available in these tools, the accuracy level is ±10-15%, never damage the application, develop high torque like impacts, very low maintenance cost, only need to pinch oil after some defined cycles, less expensive, very good for the environment & operator too.

Now question comes that which pulse tool is best in the market , so we talk about YOKOTA IMPULSE wrenches on behalf of our experiences on them.

BEST IMPULSE TOOL IN MARKET

YOKOTA impulse wrenches are the best in the market . Yokota established on 1919 headquarter based in Osaka Japan . So they have great experience in assembly air tools. Based on their experience they have produced high speed, high torque, high accurate system wrenches who have the Impulse mechanism & accuracy level is ±5% which are using worldwide on large scale. But we now only talk about simple impulse wrenches which are very compact, light-weighted, produce great power, working on zero percent noise & vibration level & who are very cost-effective according to their high performance. Below are some main features of Yokota impulse wrench :

·         Less maintenance cost – They have the highly durable oil pulse mechanism, using high-quality blades, the superior quality of their own invented & tested oil. The new mechanism which releases pressure on the sealing to lower pressure chamber during the time not generation pulses.

·         High Efficient Motor: Newly designed double chamber energy-efficient air motor who consumes less air & gives more power, control noise & vibration level even on high RPM.

·         Less oil Mist: No more additional lubrication oil & oil mist trouble because of the self-lubricating blades & cylinder

·         Life Time is Double: Specially coated rotor blades with excellent self lubricity last two time longer than the conventional ones who doubles the life of the tool

·         Great Ergonomics: Significant reduction of tool weight, the trigger force, reaction, noise & vibration

These all above are the main features who make Yokota different from others.

WHERE TO GET

M I C R O N T E C H

YOKOTA all tools are available in Microntech. Microntech is the Sole distributor of YOKOTA in India for many years & gives the great quality of service & support their customer every time. They have 30 years of experience in assembly solutions. The Head office situated in Delhi, Noida is the training center & branches are located in 10 cities in India. TOYOTA, HYUNDAI, NISSAN is 100% user of Yokota because of Yokota’s quality & Microntech service & sales support.

Reaction in Pneumatic Screwdrivers

The reaction in Pneumatic Screwdrivers

In today’s blog the discussion will be about the reaction generated by pneumatic screwdriver while tightening and why does it happen and its effect on application and worker.

Pneumatic Screwdriver is one of the most conventionally used tools in manufacturing industries for assembling various applications on a large scale. Pneumatic the screwdriver does not pulse unit, unlike many pneumatic tools, due to which they generate torque reaction while tightening.

 The operation of the pneumatic screwdriver is very simple it consists of an air motor which runs on the compressed air and clutch mechanism consisting of sun and planetary gears in motions that produce the torque in the spindle.

 The clutch mechanism is the most important part of the screwdriver it limits the amount of torque required for tightening for different applications. A clutch mechanism is usually located between the output shaft of the torque screwdriver and the air motor. The main component of the clutch mechanism is the coil spring which basically controls the whole mechanism. When the torque generated by the tool reaches a certain level, the elastic force of the spring is overcome and the clutch mechanism slips. Thus, the maximum torque that can be applied to a fastener is limited by the setting of the clutch mechanism.

 Torque Screwdrivers are available with several types of the clutch, including “cam-over”, “cushion clutch”, and “auto shutoff”. Most of these clutch types are used in electric screwdrivers, air screwdrivers, impulse screwdrivers, manual torque screwdrivers, and cordless torque screwdrivers.

Pneumatic screwdriver generates reaction while tightening due to the newton third law, when the tightening gets complete the rotating mechanism stops suddenly and the momentum generated while tightening gives the reaction force. The more the tightening torque is, the more will be the reaction force generated.

There is no reaction in pulse tool because it has a pulse unit with oil filled in it which generates torque & when the tightening is completed and the tool gets stopped the reaction gets dissipated by the oil in the pulse unit.

If the reaction generated after tightening is small it can be sustained by bare hands but if the torque gets larger it gets difficult for handling with hands. The reaction generated can also damage critical and small applications. It can also injure the worker who is handling the tool while tightening. Due to these drawbacks, the pneumatic screwdriver having large torque can affect the work efficiency of the manufacturing unit and also the workers.

 To counter these drawbacks reaction arms are used along the tool to dissipate any reaction coming after tightening. They can also be used as a positioning arm to increase work efficiency.

Microntech Engineers Pvt Ltd is a respected brand for assembly solution have branches all over the India. They have pneumatic screwdriver from YOKOTA and electric screwdriver from KILEWS both are respected brands. Microntech also offers torque reaction and positioning arms. To know more about the assembly solution provided by the Microntech you can visit the company’s website www.microntechgroup.com or you can contact your nearest Microntech branch.

PROTECTION AGAINST ELECTRIC NOISE IN ESTIC FIXTURED

PROTECTION AGAINST ELECTRIC NOISE IN ESTIC FIXTURED

We often look in our high-cost systems that they are getting damage through some unwanted signals but we not able to identify them. We always invest in a high-quality product for improving our work of quality, but we didn’t think about their protection. Protection from who ?? This is a question. So here we represent a hidden enemy for our systems is “Electrical Noise”. Noise or Disturbance or Interference are some unwanted signals who interfere with an original signal. They slowly killed our systems, but sometimes kill instantly . High-quality products have enough protections to avoid these signals or control the fluctuated voltage. But sometimes these noises are very big. Like in ESTIC they have enough protections, fluctuations in voltage also can’t harm these systems & noise also. But it only depends on how big these noise & fluctuations are.

As we already know that our Estic system is superior in Quality so  ESTIC systems always show an error on the screen when the controller feels some unwanted signals from the equipment who are running together or some unwanted fluctuations coming from the power supply. These errors stop the process & wasting your production time. But always ignoring these signals can be very harmful to your system. These signals can permanently damage your high-cost system. So taking enough precautions are necessary to avoid these signals & for saving your quality time. 

Types of Noise 

Noise can be generated from within the system itself (internal noise) or from an outside source (external noise). Examples of these types of noise are:

1. Internal noise

• Thermal noise (due to electron movement within the electrical circuits)

• Imperfections (in the electrical design).

2. External noise

• Natural origins (electrostatic interference and electrical storms)

• Electromagnetic interference (EMI) – from currents in cables

• Radiofrequency interference (RFI) – from radio systems radiating signals

• Cross talk (from other cables separated by a small distance).

Some other devices can also interfere with the performance of many devices like they can produce surge, regenerative overload or spikes means a quick change in voltage or current or harmonics. Some of these areas follow:

                                                     

• Welding Equipment: When they run, they produce a quick change in voltage 

• Multiple Equipments: Many types of equipment from one power sources can also disturb the line

• Earthing: Earthing can also disturb the device, so make sure that the device is properly grounded or not 

• Solid-state converters or Drive systems: Some high voltage drives like servo drive or motors can also cause interference.

RECOMMENDED FILTERS FOR PROTECT ESTIC FIXTURED SYSTEM :

• Noise Filter: It filters unwanted signals that are lower or higher than the original frequency

• Clamp Filter: It also controls the noise. A clamp filter consists of a ferrite core that is divided into two parts, contained in a plastic case that has elasticity and durability.

• Zero Phase Reactor:  Zero phase reactors help reduce radiated noise from the inverter wiring. The wiring must go through the opening to reduce the RF component of the electrical noise. These are effective for noise reduction on both the input and output sides of the inverter.

This wiring the diagram is recommended by Estic for its Fixtured tool which uses Noise filter, Clamp filter & Zero Phase Reactors.

ACCESSORIES TO BE USED WITH ESTIC NUTRUNNER

ACCESSORIES TO BE USED WITH ESTIC NUTRUNNER

With its NUTRUNNER system, ESTIC CORPORATION leads the industries in the field of design, production, and maintenance of energy-saving auto-assembly machines.

It is not easy for a manufacturer to keep up with an industry that is constantly evolving. As technologies advance, the manufacturer needs to develop advanced technologies to meet industry requirements.

             

M I C R O N T E C H

EsticHandheld Nutrunner Handy2000Lite is developed with sophisticated electronics control and mechanical, software technologies, and manufactured under high-level quality control. Based on the concepts required by users such as fastening accuracy, environment friendliness, handheld nutrunner as accurate as fixtured nutrunner is now available with minimized reaction force. Every estic tool’s performance is tested with the equipment complied with ISO5393 and fastening accuracy +-3% or below at 3 sigmas X-bar (on direct mode) is received. The manufacturing of estic tools is in accordance with ISO9001. Power consumption is 1/20 compared to conventional pneumatic tools with no oil mist. The reaction force is remarkably reduced with patented pulse drive technology. Ergonomics design is adopted to reduce user's workload also Tracer Arm and Reaction Arm are available for Poka-yoke and assisting work.

Now the question comes that where we get the complete accessories of ESTIC NUTRUNNER in India. So Microntech is the Sole distributor of ESTIC in India for many years. Microntech is well known for “ON time service & Quality work” & customers are appreciating this company for many years. Their headquarters is in Delhi & they have many branches in India, present in 10 states in India and provides professional technical and sales support to its customers. The facility in Noida UP is home to their state of the art service facility and training center. They are mainly situated in Banglore, Chennai , Aurangabad, Hosur, Pune, Gujrat, Pantnagar, Lucknow, etc.

 The company goal is to add value to the customers with most innovative assembly solutions and help them to use less while accomplishing more.

Microntech has over 30 years of experience with a proven track record for success. Microntech technical engineers are able to assist with complete assembly applications. They are recognized as technical experts for assembly solutions across India. At Microntech, their mission is to provide high-quality assembly solutions and a high degree of responsiveness to empower our customers to be more productive, build a better quality product, and maintain a safe environment for their workers.

Now we talk about the accessories which we need during using estic tool.

FOR HANDHELD NUTRUNNER

Handheld accessories include Tool Cable, Hanger for pistol & Angular tool, Reaction plates, Support handles, cable Adaptors, Reaction locking nut, protection cover for tool, Controller stand, Socket tray, software, Connectors & Net cables etc.

FOR FIXTURE NUTRUNNER

Fixture accessories include Transducer, Resolver & Motor cables, Net cables, connectors, Estic HMI, Serial communication cable, termination resistor, Relay cables, batteries, Socket, Adaptor, etc.

SIX BEST DC NUTRUNNERS IN MARKET

SIX BEST DC NUTRUNNERS IN MARKET

When we talk about the Quality in reference to the assembly of a product it simply means tightening accuracy, Control methods, Pokayoke features, less NG’s, Zero defect process, complete integration, synchronization, NG detection at the right place & on the right time for saving the product to damage, Multi-step tightening and many more . These all features & essentials are only possible when you use a DC Nutrunner in your process for tightening, sometimes reversing, it depends on your process of work. So now we do ranking the DC nutrunners on behalf of their performance & features. We are ranking depend on our experiences towards these DC nutrunners.

1.      ESTIC

ESTIC is only focused on manufacturing DC Nutrunners for the last many years. It is Japanese based company headquarters situated in Osaka. They have a wide range of DC nutrunners , Fixtured & Handheld both. As they are only focused on DC nutrunners so they have many unique features in their product some of these are patented also . They are delivering their product in all over the world & they are TRUST MARK for their customers.

Unique Features :

• Fastening accuracy ±3% at 6 sigmas is guaranteed. ±2% in fixtured

• Response Time of torque transducer & angle resolver is 1/2000 sec

• 8 strain gauge type torque transducer with noise cancellation function for high accuracy

• Patented Pulse mode function with high-speed motor without any jerk up to 140 Nm.

• Angle resolver can rotate 0.01 degree

• Consumes 1/20 % power with a comparison with others 

• Titanium body with Highly durable planetary gears

These above are some main core features of ESTIC that makes it unique from others. Microntech is the Channel Partner of ESTIC in India. Microntech has many branches in India situated in 10 cities of India. Microntech is addicted to giving its customers a Quality & hassle-free service. Microtech's goal is to get the trust of its customers by giving them a high quality product with reliability. Microntech headquarter situated in Delhi. They are from 30 years in an assembly solution.

2. ATLAS

Atlas Copco (Copco from Compagnie Pneumatique Commerciale) is a Swedish industrial company that was founded in 1873. It manufactures all industrial tools including Pneumatic, electric, cordless, clutch type and many more and also the industrial equipment like a compressor. Headquarters situated in Nacka, Sweden. Atlas is a global leader for DC nutrunners. They have a very wide range of nutrunners and also deal in current control DC Nutrunners.

3. DAIICHI

Daiichi DDK is also a Japanese based company.  They are specialized for fixture nutrunner & have a very wide range up to 5000Nm. Accuracy is ±2% at 3 sigmas. Daiichi is famous for multispindle fixture nutrunners in India.

4. DESOUTTER

Desoutter Industrial Tools founded in Great Britain in 1914, now headquartered in France, is an industrial manufacturer providing electric and pneumatic assembly tools. They also manufacture current control tools with ±10% accuracy. They also have the complete range of Handheld & Fixtured DC nutrunners. Desoutter CV13 controller gives a new standard of value in efficient tightening. CVI range has the most powerful & flexible transducerized handheld tools & fixture spindles.

5. IR

Ingersoll Rand (formerly Gardner Denver Inc.), founded in 1859, is an American worldwide provider of industrial equipment, technologies and related parts and services to a broad and diverse customer base through a family of brands. IR is the manufacturer of all types of Pneumatic, electric & DC nutrunners. They have a tool range up to 400Nm. , tools available in angular, pistol, straight & offset also with high RPM.

6. CLECO

Cleco has also manufactured all types of tools like Pneumatic, electric & DC. They have a wide range of DC Nutrunners with multiple cordless options are also available.