The nuts and bolts of 100 per cent joint reliability in the mining industry.
No matter how big and complex machinery gets, it’s the humble little bolt that is holding everything together.
Bolts are really the only way to join big pieces of equipment while still allowing operators to take them apart for maintenance, but they offer their own set of challenges.
Once put together, bolted joints must stay together until a decision is made to take them apart. And even if the design is good, maintenance practices can become complacent, jeopardising the integrity of the connection and the overall machine.
The key, then, is 100 per cent joint reliability.
In the rugged realm of mining, where safety and productivity intertwine, the reliability of bolt joints is a fundamental concern. And CAPS offers greater accuracy, safety and accountability with Ingersoll Rand’s range of QX torque multipliers.
A critical but costly exercise
Mining companies around the world are faced with the challenge of quick and accurate bolt fastening for torque-critical joints. These joints can be found site-wide, from excavators, dump trucks, earthmovers, and wheel loaders to conveyors, tunnel-boring machines, infrastructure, pipework, and upstream equipment.
It goes without saying that in a heavy-duty, high-risk environment such as a mine site, accuracy of torque applied is critical.
Bolt fastening has traditionally been a labour-intensive and costly exercise, using impact wrenches that can over-torque joints; hydraulic wrenches that are externally powered and bulky, requiring two people to operate; or air and corded electric nutrunners, which require changing torque via a bench torque tester.
Still, inefficient operation is only part of the challenge, with the added issues of indeterminate control and monitoring. Many companies are currently using dated guesswork of manually recording torque goals with paper and pencil in the field.
Time may be valuable for productivity, but accuracy, consistency and traceability of performance are the cornerstones of a compliant and safe work site. Without a precise auditing method, how can you be sure your tool is doing its job?
A fresh approach to bolt fastening
Fortunately, commercial and compliance difficulties often drive innovation, and in recognition of these challenges Ingersoll Rand developed the QX Series cordless torque multiplier. This ground-breaking tool has been specifically designed to replace less accurate manual fastening methods with a traceable method that is quicker and more effective.
Relatively new to the Australian market, the QX Series torque multiplier employs advanced technology, communication and control features to ensure accurate, repeatable bolting for industrial applications. The tool is available in a range from 200–4000Nm in 20V and 40V options.
The multiplier features a brushless motor paired with a premium Norbar gearbox. At the heart of the torque multiplier is the Ingersoll Rand closed-loop transducer, which is the key to delivering torque precision, supreme accuracy and traceable results.
The tool operates on the Ingersoll Rand IQV20 and 40V Series battery system and each 20V battery charge will rundown an average of 100 bolts.
The multi-function display module provides visual feedback via red, yellow and green lights to signal whether the bolt has met the specified torque limit or angle, or if the proper gang count was reached. The only tool using a closed-loop transducer for precision, it delivers accuracy to +/- 0.1Nm without use of a test bench.
Operators will benefit from improved efficiency and ability to hit nuts in faster sequence.
Multiple user-programmable configurations such as torque (Nm, Ft-lbs, in-lbs, prevailing), angle and gang count reduce the number of tools needed for multiple applications. Up to 32 presets can be stored, and these functions can be navigated directly on the tool or programmed from the Insight app, a computer or data controller, or remotely via web.
The quiet, cordless and compact QX torque multiplier eliminates the need for a hydraulic pump or breaker bar and reduces noise and vibration levels.
The risk of injury and operator strain is minimised as users move freely without the inconvenience of bulky air or hydraulic hoses or power packs, and the 360° adjustable handle provides a comfortable grip and provisions for a tethering point, allowing maximum flexibility when working on multiple joints and accessing odd angles.
Replacing potentially flawed and time-consuming manual record-keeping practices, the multiplier tool itself can store records for up to 1200 fastenings, which can be downloaded to a computer via a USB cable or wirelessly transferred to a dedicated process communication module. Reliable compliance data is now available for review, analysis and record keeping at any time.
The CAPS commitment
CAPS is the only Australian distributor of the Ingersoll Rand QX torque multiplier, which has successfully been utilised across mining, heavy equipment, rail, construction, infrastructure, military, and process automation industries around the world.
Established in 1980, CAPS boasts more than 43 years of experience in compressed air and power generation. With 10 branches around Australia and 24–7 service for maintenance and emergency breakdowns, CAPS endeavours to lead the industry in service and solutions.
The QX Series of smart tools also includes right angle wrenches, pistol wrenches and precision screwdrivers, all offering improved process control, operator comfort, and data communication while increasing productivity, lowering costs, and ensuring quality.
This feature appeared in the October 2023 issue of Australian Mining.
