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Last month, we assisted a client that's part of the German Hatz group, active in the production of diesel engines for agriculture. The client is involved in assembling and disassembling steel parts on gears for lapping, a mechanical process where a metal or ceramic surface is worked to minimize its roughness. The various parts are highly stressed, making assembly an operation that requires maximum precision and attention to detail.

In the past, the company used a pneumatic screwdriver hanging from a balancer for this operation. However, the operator performing this activity experienced health problems due to the vibrations to which his arm was subjected (the steel-on-steel coupling makes this application particularly burdensome). This situation necessitated measures to improve the ergonomics of the workstation and reduce the risk of exposure to vibrations.

Kolver's proposal to the client was to conduct a comparative test with a system consisting of a PLUTO10D/TA screwdriver with torque and angle control, an EDU2AE/TOP/TA control unit, and a LINAR1 reaction arm, a system designed to reduce vibrations and improve ergonomics during fastening operations.

For the test, a specialized consultant was hired to carefully measure the results and compare the old and new setup in terms of vibrations and workstation ergonomics.
Here's what he found.
Compared to the status quo, the LINAR1 reaction arm alone had already reduced the risk index by 25%, from 3.6 m/s² to less than 2.7 m/s², just above the alert value set at 2.5 m/s².
Switching to our complete system, the test results further improved, bringing the risk index to 1.7 m/s², a 30% reduction compared to the alert value and less than half the original value. These results were received with outspoken enthusiasm by the customer and made the Kolver team proud. Even the specialist who monitored the test was surprised by the magnitude of the final improvement.

It is important to emphasize that the operation in question involves steel-on-steel fastening, a type of coupling that makes screwdriving particularly burdensome in relation to vibrations, due to the friction created between the two pieces. Under less severe conditions, the data would improve even more.

At Kolver, we are grateful for the opportunity to provide innovative and safe solutions to improve the working conditions of our customers, and we are committed to continuing to develop cutting-edge technologies and ergonomics for the assembly industry.
Whether you need an out-of-the-box torque tool or a custom solution, do not hesitate to contact us!

For more information on our current-controlled lines, check out the PLUTO, MITO and NATO product page.