Assembly tools

Choosing the right tool for the job

Success means making the right choices

The right systems, the right tolerances, the right quality there are a lot of choices that affect your bottom line. What is the optimal solution for your productivity, cost-efciency, reliability? And what about ergonomics? What is the best tool for your assembly process? Pulse tools or nutrunners? Air or electric? Most tools can do the job; the difference is how well they do it. In todays competitive market, margins are getting smaller making every nut count. With thousands of joints to tighten, even the smallest gains in productivity can make the difference between success and failure.
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The ve steps to zero fault fastening

A general rule of thumb is the further into the assembly process a defect reaches, the more costly it is to repair. A worst-case scenario is the defect reaching the end-customer causing irreparable damage to the brand and image of the company. An assembly line can be divided into ve steps to zero fault fastening. The higher on the scale, the more sophisticated the tool and production system must be. Different joints require different levels of safety and quality. Steps 1-3 cover what is referred to as quality critical joints while step 4 is for safety critical joints. Achieving step 5 requires a zero fault fastening philosophy. This brochure covers the joints that comprise the vast majority of bolts: Steps 1-3, the quality critical joints.

STEP 2
To assure that all screws are tightened.
A common cause of faulty assembly

STEP 1
To assure correct torque.
Tightening torque is controlled by an assembly tool that delivers a pre-determined torque. A shut-off air tool is usually used which turns off by using a clutch. Electric tools can be used.

is that screws are forgotten. There are two solutions; either to use an air tool with both pressure and time controlled automatic shut-off with RE-control, or an electric tool.

Batch OK Torque OK

STEP 3
To assure that the joint is correct.
The joint may be improperly tightened due to for example a damaged thread or a missing washer. This can be detected by using an electric tool such as Tensor DS or Tensor DL that monitors the rotational angle of the screw as it is tightened.

Joint OK

Finding the best solution to meet your needs

How do you choose a tool? Productivity, quality and ergonomics are important factors to consider. The relative importance of each factor depends on the application. We understand that you have different priorities and therefore have tools for all your needs.

LUM Screwdriver Tensor DS

Electric Direct driven Torque range 1-4000 Nm Pneumatic Direct driven Torque range 0.1-18 Nm

Tensor DL
Electric Direct driven Torque range 0.3-10 Nm

Ergonomics Productivity Quality

BTV Nutrunner
Battery Direct driven Torque range 1-28 Nm Incl. in range: ETB

LTV Nutrunner ErgoPulse

Pneumatic Impulse Torque range 4-450 Nm Pneumatic Direct driven Torque range 2.5-575 Nm Incl. in range: LTD/LTP 5-4100 Nm

Productivity Is free speed a true measurement?

The answer is not the same for all types of applications. Impulse tools are the most productive tools for hard and medium hard joints, while nutrunners are more productive for medium soft to soft joints.

Tensor DS/DL
An electric tool is capable of maintaining speed under load throughout the tightening. Strategies and speeds are programmable. Doesnt loose power for soft joints or prevailing. Flexibility and quality for productivity.
<30
HARD

LTV/LUM
Thanks to the powerful motor in our direct driven nutrunners and screwdrivers, target torque is reached quickly and with an ergonomic feeling. Works well on all types of joints. Fast motor and clutch for productivity and accuracy.
<30
PREVAILING HARD

30-360
MEDIUM

>360
SOFT

30-360
MEDIUM

>360
SOFT PREVAILING

ErgoPulse
The fastest free running tool. It builds up torque through impulses, where it is the most productive between 5-15 pulses. For softer joints, a more powerful tool is preferable. Excellent one hand tool, no reaction arm needed. A minimum of 3 pulses is required for a reliable results.
<30
HARD

BTV
No cable is needed. Its exibility gives increased productivity. Productive in areas that are difcult to access. Fast and reliable shut-off solution.

30-360
MEDIUM

>360
SOFT PREVAILING

<30
HARD

30-360
MEDIUM

>360
SOFT PREVAILING

is the best choice.

Ergonomics Reduce your absenteeism.

Good ergonomics is good economics. Ergonomics awareness has increased in recent years, but there are still improvements to be made.

Tensor DS/DL
Electrical tools contribute to a quiet and clean environment. Reaction force for higher torque applications needs to be taking care of by using balancers or reaction arms. Note: Correct programming of the tool will help to reduce reaction forces and strain on arm muscles. For low torques, the tools have low weight.

LTV/LUM
Both nutrunners and screwdrivers work well on most applications. Direct driven motor creates a reaction force, but the fast clutch and powerful motor help to off-set this affect. For high torques, balancer or reaction arm is needed. Note: Can handle reaction force well on hard joints. For low torques, the tools have low weight.

REACTION FORCE

WEIGHT

VIBRATION

ENVIRONMENT

NOISE

REACTION FORCE

WEIGHT

VIBRATION

ENVIRONMENT

NOISE

ErgoPulse
The major advantage of using an impulse tool is that there is no reaction force and the power to weight ratio is so high that it can easily be operated one handed, even for very high torques. Easy movements help the operator in daily work. The disadvantages can be vibration and noise. Note: Guided sockets can reduce vibration and noise considerably.

BTV
Battery tools are suitable for applications that are difcult to reach. The battery adds weight to the tool but the operator will not have to carry a cable. Note: Can handle reaction force well on hard joints. No cable creates exibility.

REACTION FORCE

WEIGHT

VIBRATION

ENVIRONMENT

NOISE

REACTION FORCE

WEIGHT

VIBRATION

ENVIRONMENT

NOISE

is the best choice.

Quality Reduce your re-work and warranty costs.

Are you having quality problems in your assembly? There are a number of assembly issues that can affect the end customer.

Tensor DS/DL
High accuracy due to software programming and Atlas Copco DigiTork formula. Can monitor the rundown angle to assure no faulty joints (missing washers, cross threads, etc). Can easily be programmed to count bolts. Tightening strategies minimize the relaxation by a 50 ms pause, which lets the creep stabilize. Line integration through relays are available.

LTV/LUM
High accuracy due to the fast clutch. Tools can be connected to a RE-controller to count bolts. RE-controller can give feedback through relays.

JOINT MONITOR

RELAXATION

FEEDBACK

BATCH COUNT

ACCURACY

JOINT MONITOR

RELAXATION

FEEDBACK

BATCH COUNT

ACCURACY

ErgoPulse
Accurate enough for the majority of quality critical joints. Relaxation can be kept to a minimum through gradually increased torque by impulses. Tools can be connected to a RE-controller to count bolts. RE-controller can give feedback through relays.

BTV
High accuracy due to the fast clutch. After torque shut-off, LED on the tool indicates that the result has been achieved.

JOINT MONITOR

RELAXATION

FEEDBACK

BATCH COUNT

ACCURACY

JOINT MONITOR

RELAXATION

FEEDBACK

BATCH COUNT

ACCURACY

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is the best choice.

The best choice for your quality critical joints

The pros and cons of pulse tools versus nutrunners and air versus electric is a hot topic in the assembly industry. Atlas Copco offers a complete line of tools. This means we will give you straight advice on what is best for your operation.

Nutrunners
The new LTV range is the most reliable and powerful air nutrunner on the market. There is an electrical alternative with optional features for both basic and advanced applications. Controlling your tightening operation is the key to avoiding costly re-working.

The best nutrunner there is...

Reduce absentee costs
Absenteeism can be a major expense. Our LTV nutrunners lower weight, ergonomically shaped handle and faster shut-off help to create better working conditions. Faster overall operation reduces operator exposure time, which increases productivity and improves ergonomics.

Get rid of your bottlenecks today

With a speed and power increase of up to 50%, the new LTV 9 series can remove production bottlenecks and keep your cycle time to a minimum.

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...with a possible exception

The solution to assembly problems

Warranty costs and rejected parts often cost signicantly more than buying the right tool from the start. An electrical tool allows: Multiple torque settings and advanced tightening strategies. Easy line integration to contain problems where they occur. Operator feedback and batch counting to catch problems as they occur. A clean and noise-free working environment.
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Impulse tools
Our ErgoPulse tools apply torque to the nut, not the operators wrist. The impressive power gives a fast, controlled rundown and still leaves one hand free for other tasks. ErgoPulses perfect balance and small size minimizes operator strain and the tool is still robust enough to handle the toughest jobs.

Reliability in varying conditions

The ErgoPulse PTX has a very reliable shut off mechanism which is based on an inertia mass located outside the pulse unit. This solution gives excellent accuracy and repeatability for the toughest applications. PTXs Auto Trim valve minimizes mean shift for applications with variation in joint hardness.

Balanced and robust

Care-free maintenance A joy to use
With ErgoPulse PTX, operator comfort is always in focus. The weight is extremely low with balance that makes it seem even lighter. The handle is a joy to use and if our guided sockets and extensions are used, vibrations and noise will be kept to a minimum. Our patented cam guided piston pulse solution means that ErgoPulse PTX has fewer wear parts for longer service cycles. The motors are lubrication free and the tool is designed for easy and economical service. True to the Atlas Copco tradition, both tool and attachment life set the standard for the industry.

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Pulse tools vs. impact wrenches

The hammer-anvil solution of impact wrenches gives unbeatable power-to-weight ratio and allows for quick, one-hand operations with low reaction force. However, hydraulic pulse units provide major advantages by eliminating metalto-metal contact, which gives: Improved accuracy and repeatability. Reduced sound level. Longer life time due to less wear on parts. Dramatically reduced vibration.

Shut-off vs. non shut-off pulse tools

Shut-off pulse tools should always be your rst choice for their many benets: Accuracy and repeatability. Eliminates operator inuence. Shorter cycle time means less wear on tool and operator. Connection to RE-controllers (Poka-yoke) for line feedback. Non shut-off pulse tools are suitable when the operator must physically evaluate the location on the joint. The dimensions are somewhat smaller compared to shut-off tools.

Screwdrivers
With thousands of man-hours spent on tightening screws, investing in the right screwdrivers is more important than ever. Since every production process is different, weve developed a wide assortment of both electric and pneumatic screwdrivers that can boost both speed and quality.

The best productivity, ergonomics and quality...

A toolbox of productivity
Our LUM line has established a new standard for pneumatic screwdrivers. Its small size and impressive speed signicantly increase productivity. Designed for tough conditions, the LUM has a lightning fast clutch that eliminates joint sensitivity.

For the best possible ergonomics

Screwdrivers are often used for high-frequency work that creates demanding working conditions. The LUMs low weight and ergonomic design make it the operators choice. The LUM features: Lowest weight with great balance. Soft grip and soft trigger. Widest range on the market.

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... and also with a choice of electric

Electric screwdrivers ensure process security

Zero fault production can save considerable money both in production costs and in customer goodwill. Tensor DL is the most intelligent tool you can get for demanding quality-critical jobs. Detects screw errors and gives operator feedback. Controlled speed and tightening strategies for demanding applications i.e. sensitive plastic.

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Battery tools
The best place for a joint in terms of quality, design and manufacturing costs is not always the best for the operator who tightens that joint. In cramped quarters on the assembly line, battery tools are often the best choice for safety and productivity.

For both productivity and ergonomics

Our BTV models have many of the strengths of hose and cable tools with none of the weaknesses normally associated with battery tools. The highest productivity available from a battery tool. Excellent ergonomics raise operator performance. Metal casing gives the most durable tool, yet is still the lightest on the market.

Innovative design gives you higher quality and a reliable tool

The highly accurate clutch emits an acoustic sound which is detected by a microphone that switches off the power. It is as simple as that! Acoustic Clutch Detection gives you an instant, reliable, non-wearing shut-off function.

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Choosing the right tool for the job

In the tables below we summarize the qualities of Atlas Copcos Assembly Tools. The numbers in the tables (0-3) are meant to give an indication of what the tools can offer and how well they can perform on various tasks.
Multiply the priority with the performance of the specic tool, i.e. Tensor DS/DL=1x3 Multiply all the numbers and summarize them, i.e. Tensor DS/DL=0x3+1x3+1x2+1x3+3x3+3x3=26
OPERATOR FEEDBACK LINE INTEGRATION

Example
BATCH COUNT JOINT MONITORING RELAXATION ACCURACY SUM

Tensor DS/DL LTV/LUMa) ErgoPulsea) Battery a) Connected to re-controller

3 1 1 0
Prioritize the importance with a number between 0-3. - 3 means very good - 0 means not applicable

2 1 3 1

3 2 2 2

3 2 2 0

3 2 1 2

0 x

2 2 0

+ 1x + 1 x + 1 x + 3 x + 3x

26 16 15 9

The highest value gives an indication of the best option for this application when it comes to quality

Quality
BATCH COUNT JOINT MONITORING RELAXATION OPERATOR FEEDBACK LINE INTEGRATION ACCURACY SUM

Tensor DS/DL LTV/LUMa) ErgoPulsea) Battery a) Connected to re-controller

2 2 0

x1 +
0

1 3 1

x2 +
2

2 2 0

2 1 2

Productivity
HARD JOINT MEDIUM JOINT SOFT JOINT PREVAILING TORQUE EASE OF USE SUM

Tensor DS/DL LTV/LUM ErgoPulse Battery

2 3 1

x3 +
1

2 1 1

2 1 1

2 3 3

Ergonomics
REACTION FORCE WEIGHT VIBRATION
b)

OIL

NOISE

SUM

Tensor DS/DL LTV/LUM ErgoPulse Battery

2-3
a)

x 1-3 + 3
1-3

2-3 3 1

b)

x 1-2 +
c)

1 1 3

x 1-2
3

c)

a) Hard joint is 3, soft joint is 1. b) For low torques, the tools have a low weight. c) Guided sockets reduce vibrations and noise.

Cost
INITIAL COST SERVICE ENERGY INSTALLATION SUM

Tensor DS/DL LTV/LUM ErgoPulse Battery

3 3 3

3 2 2

1 1 2

2 2 3

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Wherever fastening takes place Atlas Copco is there

Customer Centers in approximately 70 countries on ve continents. Distributors in a further 80 countries. More than 25,000 employees. 49 manufacturing units on ve continents. Revenues of MSEK 48.654. Listed on Stockholms stock exchange. Established in 1873.

www.atlascopco.com

9833 1517 01

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