Special tool secures earthmover counterweights
A
Norbar Torque Tools product story
Edited by the Engineeringtalk editorial team
Oct 31, 2001
Securing large counterweights to Komatsu UK's hydraulic excavators has been made faster and more accurate with the development of a bespoke torque tool.
Securing large counterweights to Komatsu UK's hydraulic excavators has been made faster and more accurate with the development of a bespoke torque tool.
The new twin axis tool, designed and built by W Christie, is based on two Norbar Torque Tools Pneutorque air powered torque wrenches that effectively and reliably apply the correct torque to the bolts securing counterweights of up to 12.8 tonnes.
W Christie of Rotherham, south Yorkshire, is a long established Norbar Torque Tools distributor, and specialises in the design and assembly of torque systems for unusual applications.
Komatsu UK builds excavators, with buckets capable of shifting up to 10 tonnes of material, at its factory in Chester-le-Street, Co Durham.
These massive machines require counterweights to be bolted to the rear of the machine to counterbalance the weight of earth in the bucket.
Depending on the model of earthmover, the weights are secured by six M32 or M40 bolts, requiring torque settings of 1400 N.m or 2800 N.m respectively.
This operation, which was labour intensive, required operatives getting under the excavator to tighten the securing bolts with a manual torque handle driving through a slow and cumbersome 7:25 ratio gearbox.
Following a review of all critical bolting applications, Komatsu UK commissioned W Christie to design and build a torque tool that could be used in the narrow, confined space between the vehicle tracks and would apply the correct torque quickly, efficiently and, above all, safely.
The solution is a wheeled rig incorporating two Norbar Pneutorque air-powered torque wrenches driving through Norbar PT7 reduction gearboxes and controlled by Norbar annular electronic torque transducers.
The rig also includes a pneumatic ram to lift the Pneutorques up to the three pairs of bolt heads on the underside of the counterweights.
All Norbar powered torque tools are designed to stall at the correct torque setting, as it does not make impact or impulse wrenches that can cause excessive vibration.
This means that an almost equal and opposite reaction to the torque applied to the fastener has be absorbed by a reaction plate, which needs to rest on a fixed point strong enough to cope with the force generated.
The Pneutorques are linked by a solid 21/2 inch steel plate, which acts as a reaction arm and enables each tool to react on the opposite bolt via the other torque tool.
The relative position of the two Pneutorques can be adjusted by the operator to accommodate the different spacing between the bolt heads found on different size counterweights.
The tool is controlled by a 110V panel, which uses a programmable logic controller (PLC) to automate the procedure as far as possible.
The operator first keys in the model type and serial number of the earthmover on an alphanumeric keypad.
The PLC then selects the correct torque to be applied to the counterweight bolts and displays it in on the LCD screen.
The operator positions the tool under a pair of bolts and uses the "Raise" button to lift the tool heads.
To ease location on to the bolts, the Pneutorque tools begin to slowly rotate as they are lifted, and fast lead sockets are used in conjunction with 11/2-inch square drive telescopic nose cones.
When both tools are safely located, full torque is applied.
A "Pass" light on the panel tells the operator when the torque transducers have signalled that the correct torque setting has been reached and the air supply shut off by the pneumatic valves.
The tool then disengages from the bolts and lowers the heads ready to be moved to the next set of bolts.
The results of each operation can either be printed off locally by the built in printer or stored by the PLC for downloading via a serial port to a PC for analysis later.
The new rig enables one man to safely and accurately tighten all six bolts in less than five minutes.
"The high construction standards and reliability of Norbar products always make them first choice for applications of this nature," said W Christie design and promotions manager Chris Stevenson.
"The bolting rig has been well received at Komatsu UK, with the company seeing improvements in efficiency, accuracy and safety.
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Contact Norbar Torque Tools
Tel +44 1295 270333
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