Assembly - November 2008 - (Page 55) Training System Combines Electronic, Hands-on Learning Using computer-based lessons, real fastening tools and sample assemblies, a new training system teaches workers how to tighten joints safely and accurately. The system was developed by Amatrol Inc. (Jeffersonville, IN), a company that specializes in equipment- and computerbased technical and vocational training for high school students, college students and industrial workers. The system consists of eight modules: torque basics, torquecontrolled tools, O-ring seals, lip seals, hydraulic fittings, hose and coupling assembly, hose installation, and tubing installation. Each module is divided into three to five segments, and each segment teaches several objectives and skills. The lessons use text, images and video to demonstrate how to operate various fastening tools and how to install various threaded components, such as hydraulic fittings and zerks. For example, the module on torque-controlled tools covers pneumatic pulse tools, electric direct-drive tools, computercontrolled DC electric tools, stall bars, and torque wrench applications. After completing the segment on pulse tools, operators should know how a pulse tool operates, how to inspect the tool, and how to use the tool to tighten a threaded fastener. The modules are uploaded to a central server, so workers can access the lessons anytime and anywhere via an Internet connection. A key aspect of the system is that workers can immediately try what they’ve learned on a custom-made training center. The center can be equipped with sample assemblies and a variety of fastening tools, from manual torque wrenches to DC electric nutrunners. Through sensors and computers, the center can tell workers if they are using the tools correctly. Safeguards prevent novices from breaking tools or stripping tapped holes. “Each module takes an average learner 3 to 5 hours to This training center can be customized with sample assemblies and various fastening tools, from manual torque wrenches to DC electric nutrunners. Photo courtesy Amatrol Inc. complete,” says Joe Reid, vice president of Amatrol. “We believe you should learn a little, then practice, learn a bit more, then practice that. It’s the best way to retain what you learn.” The system was originally developed for Caterpillar Inc. (Peoria, IL), but the modules and the training center can be customized to meet the needs of any assembly operation. For example, if assemblers are having difficulty installing bolts at a difficult angle, the training center can be equipped with a sample assembly that duplicates that position. For more information, call Amatrol at 800-264-8285 or visit www.amatrol.com. hands. One hand should be near the head of the tool; the other should be at the base of the handle. “Pistol tools are generally applied to horizontal applications at lower torques, [in-line] tools are for vertical applications, and angle nutrunners can be used for both,” says William Staiger, manager for marketing and product development at Bosch Production Tools North America (Mount Prospect, IL). “In all cases, the tool must be held firmly. If the operator lets the tool spin or wobble excessively, this will have a detrimental effect on both comfort and torque accuracy.” Regardless of the configuration, fingers should be kept away from rotating parts and pinch points. Operators should avoid using a tool over their shoulders or reaching to tighten a fastener. Knowing when a fastener has been tightened correctly depends on the tool. Stall tools have a clutch that ratchets at a preset torque. “A stall tool stops when you let go of the trigger,” says Andre Melis, product manager for electric tools at Atlas Copco Tools & Assembly Systems (Auburn Hills, MI). “The more you hold on, the more force is applied to the fastener. For ergonomic reasons, operators don’t want to hold onto the trigger too long, so they tend to stop prematurely and torque accuracy is all over the map.” Shut-off tools stop automatically when a preset torque is reached. These tools also provide visual and audible signals when a fastener has been tightened correctly. For example, many tools have LEDs in their handles. Green LEDs illuminate when fasteners are tightened correctly; red ones light up when they aren’t. Other tools can signal to a light-stack or video monitor to tell the operator that the joint was good or bad. www.assemblymag.com November 2008 / ASSE M B LY 55 http://www.amatrol.com http://www.assemblymag.com
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