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commodity sampler
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Impact Air Tool Issue

09/03/2009 12:15 PM

We are using IR 2135TiMax impact tools. They last approximately 2 week before they self destruct while being used on a Production Line. They apply Fwd Torque Rang of 50 -550 ft-lbs at a free speed of 9800 rpm at 1250 blows per minute. They weight about 3.95 lbs with an air consumption @ load of 5 cfm / 142 1/min and 24 cfm / 680 1/min respectively. Does anyone know of a better solution to our problem or does anyone know what the big boys like automotive assembly lines use for this application. Any suggestions would be appreciated
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ozzb
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#1

Re: Impact Air Tool Issue

09/03/2009 1:41 PM

Not sure that IR 2135TiMax is the product i would use for a production line. May be good for auto shop or home auto repair. IR does manufacture production impacts.

Other you may want to look at Atlas Copco, Cleco(Cooper Tools), Sioux(Snap-on), Master Power(was Black & Decker now Cooper Tools) have about 40 of their screwguns used in production have held up well with little problem some in use for over 20 yearsn

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commodity sampler
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#2
In reply to #1

Re: Impact Air Tool Issue

09/03/2009 2:58 PM

Thank you for your timely reply... We are using these impact tools for 8-10 hours per day removing 3/4 " and 1 1/4" bolts they get an incredible amount of usage daily.
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ozzb
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#3
In reply to #2

Re: Impact Air Tool Issue

09/03/2009 3:03 PM

With bolts that big I would be looking at 3/4" drive or larger. Also because of the weight of the tool a counter balance if you are not already using them.

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ronseto
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#8
In reply to #2

Re: Impact Air Tool Issue

09/04/2009 11:56 AM

"We are using these impact tools for 8-10 hours per day removing 3/4 " and 1 1/4" bolts"

Are you using impact wrenches for just removing? No torquing required?

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commodity sampler
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#9
In reply to #8

Re: Impact Air Tool Issue

09/04/2009 8:22 PM

Yes sir we do, both remove and torque tighten bolts, tapered pins and mould covers. The process is a carousel steam kiln for pre-cast concrete moulds. We make concrete CSO underground tunnel liners. Between the end of the kiln there is a multi station proprietary process area where the moulds are emptied and the reassembled with deformed wire cages...it's a very cool process.
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Doogleass
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#4

Re: Impact Air Tool Issue

09/03/2009 10:46 PM

Do you have an auto-lubrication system as a part of your air supply? If not, they are probably dying from lack of lubrication. If you do have such a system, it should be checked for fluid level and flow rate.

Also, ozzb is right, you should be looking at 3/4"-drive and the industrial grade.

Finally, have you contacted Ingersoll-Rand for advice? It seems to me that, unless you have a lubrication problem, you should be getting far more than 2 weeks out of these units, and that they would suggest other possible causes and/or advise you that you need a different tool model.
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commodity sampler
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#5
In reply to #4

Re: Impact Air Tool Issue

09/04/2009 12:59 AM

Thank you...
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commodity sampler
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#10
In reply to #4

Re: Impact Air Tool Issue

09/04/2009 8:33 PM

We have driers, filters and a auto-lubrication system all are to spec. IR has been contacted and they are about to come in a check the air/pressure flow rate of the system. The weight of the 3/4" drive is a killer because of weight of the 1/2" gun is at 4 lbs. The 3/4" is 7-8lbs., the guys would drop like flies because of the weight...
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Bushdriver
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#6

Re: Impact Air Tool Issue

09/04/2009 4:30 AM

Step one is to get the right tool.. Impacts are never consistent in the torque they apply, specially on big bolts. I suggest you convert to air motors with reduction drives and use a light unit to set up the nuts and then a calibrated torque converter to do the final torque setting of the bolts. Also make sure all bolts have anti-seize lubricant on them. "Torque Tool" and Norbar http://www.norbar.com/ have a variety of units, as do the companies in the previous replies.

You airline MUST be clean and dry. Set it up overhead, to run down at 50:1 slope away from the main reservoir/compressor. At the end of the line fit a drain valve with a little (water trap) on top of it. All the air take off points must go up off the mainline and then turn down. The down leg must have a T for the take off and drop down with another water trap valve at the end. Equip the T with 1/ Pressure regulator & water filter, 2/ T with clean air take off 3/ airline oiler and then the take off for tools. The flex line to the air-tool must have sufficient capacity and NOT be longer than 3m/10ft from the oiler. If your flexible rubber lines need to be longer, make up portable stations for the tools and include the regulator/filter/oiler combo mentioned on a stand for the worker to carry around and still have only 3m / 10ft oiled pipe to the tool.

Use different fittings for clean dry air and oiled air. Also make sure the main line is big enough, rather oversize. An additional reservoir will help at any machine that takes big impulses of air, like air rams/cylinder actuators. Run the main line at 800kPa and the take off point regulators should be at 600kPa unless the machine specification it different. Use the highest quality fine machine oil you can get. Drain all the water traps at least every hour if you do not have auto drains installed.

Finally check on the air consumption of all your appliances and make sure the compressor is adequate for the task. If not, add another in tandem, with the biggest supplier set to slightly higher start up pressure.

Correctly applied and maintained air tools last for years, are safe, light and economical. Mess up on any of the points I have listed above and you will just waste time and money.

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commodity sampler
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#11
In reply to #6

Re: Impact Air Tool Issue

09/04/2009 9:24 PM

Thank You. There will be a little something extra in your paycheck next week. Truely Very Best Regards, Jim
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HILL
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#7

Re: Impact Air Tool Issue

09/04/2009 5:42 AM

IT SOUNDS LIKE YOU NEED TO INSTALL A WATER TRAP & OILER IN AIR SUPPLY.
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Jerry New Hampshire
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#12

Re: Impact Air Tool Issue

09/05/2009 9:34 AM

Not to say that everything previously stated isn't helpful or true, but I've seen lots of air tools die prematurely because of too much air pressure. The only thing saving them was the small opening of the quick-connects. Open that up like I did with 3/8 "T" fittings or direct connection, and you can count on grenading tools quickly and efficiently when run substantially above their design pressure.

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commodity sampler
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#13
In reply to #12

Re: Impact Air Tool Issue

09/05/2009 12:31 PM

I am very glad I posted my problem you guys are great...
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ronseto
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#14

Re: Impact Air Tool Issue

09/05/2009 12:37 PM

Are you presetting the torque or just running until it stops? An impact wrench that is used as much as you are using it, should only be run 75 or 80% of maximum torque. It's like running a car at maximum RPM. It won't last long under those conditions.

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commodity sampler
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#15
In reply to #14

Re: Impact Air Tool Issue

09/05/2009 9:42 PM

They labor force is very raw...They max out the guns on every use. They are constantly stripping the nuts to where they (the nuts which are welded to the moulds) are being replaced often.
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Bushdriver
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#16
In reply to #15

Re: Impact Air Tool Issue

09/06/2009 4:36 AM

Your last comments confirm my previous comment. 1/ Get rid of impact wrenches. Use 1/4" drive AIR MOTORS for small bolts up to M5, 3/8" drive for M6 to M8, 1/2" drive M10 to M15, 3/4" drive for bolts M16 to M22, and 1" drive for larger bolts. Don't have spare sockets lying around, only buy the ones you need that fit the drive that is correctly set for the nuts intended. Use a big stick or tyre iron to remind the "Raw labour" to lube the bolts and things will improve.

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commodity sampler
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#18
In reply to #16

Re: Impact Air Tool Issue

09/06/2009 12:49 PM

Ditto, Regards...
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BoltIntegrity
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#17

Re: Impact Air Tool Issue

09/06/2009 11:09 AM

Seems like you've got everything under control. However, I'd like to add one small comment:

Although torque tools are much more accurate in delivering the proper "torque" to a bolt than impact tools are, torque is often meaningless in terms of what you're really looking for: Proper Bolt Load. Here's a link expanding on this : Torque Danger

I would assume that in your case, accurate bolt load isn't critical and verifying it is over-kill. However, there are many cases where ensuring that one has proper bolt load is very important. Assuming that even calibrated torque wrenches will produce the desired load may result (and has resulted) in failed joints.

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commodity sampler
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#19
In reply to #17

Re: Impact Air Tool Issue

09/06/2009 12:52 PM

Thanks to all you, the people who took the time, It is very much appreciated!

See my finished product being installed

http://www.youtube.com/watch?v=T7glPaK8odI&feature=email
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Users who posted comments:

BoltIntegrity (1); Bushdriver (2); commodity sampler (9); Doogleass (1); HILL (1); Jerry New Hampshire (1); ozzb (2); ronseto (2)

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