What Makes a Smart Tool ‘Smart’?

Many cross-threading or tightening errors will likely go unnoticed at first, requiring additional quality checks and rework. These errors also increase scrap and material costs and can cause production disruptions and even recalls.

Setup is an inherent challenge for traditional tools. Individual stations may require different tools to meet precise torque specifications. This increases the chance of operator error, especially if one operator is moving from one tool to another. Each tool will likely need to be manually configured which takes a lot of setup time.

Ingersoll Rand’s smart tools like the IQi Series addresses these problems head-on. This cutting-edge technology will transform your production process leading to improved quality, faster setup, increased efficiency, an optimized process, reduced rework and downtime, and a healthy cost of ownership.

Instead of manually configuring each tool by hand, you can deploy programming changes quickly using an intuitive user interface. You can access all features through a web browser so you can be 100% remote – you don’t need to be physically present at the controller.

Ingersoll Rand Advantage: Reduce programming time by 50% using our intuitive touch-screen user interface. Setup programs in less than 2 minutes. If desired, you can set up values right on the controller versus using a computer or separate programming interface. No additional software is required, so there are no additional software installations, admin or licensing costs, or paid IT support necessary. You save money and reduce dependency and unnecessary complexity.

Smart tools can detect and prevent tightening errors (such as cross-threading, over-tightening and under-tightening) in real time using advanced torque, angle and seat control strategies. This advanced error-proofing technology improves quality throughout the production process, reduces the need to rework, reduces the risk of recalls, decreases scrap and material costs and reduces production disruptions.

Ingersoll Rand Advantage: The IQi Series features the industry’s first tilt angle that ensures precise tool alignment at the correct angle against the joint. This improves thread alignment and reduces cross thread errors.

With smart tools, you no longer need to use different tools for different models. You can automate tool and job selection through MES or Fieldbus integration to eliminate manual errors, reduce production downtime and increase operator efficiency. MES will send a message to the operator to set the correct specs. You can enable real-time visibility of production fastening data for enhanced quality control and faster issue resolution.

Ingersoll Rand Advantage: IQ Stop, featured on the IQi Series, is Ingersoll Rand’s advanced shiftdown mode. It eliminates production inefficiencies by delivering a seamless transition from rundown speed to final tightening speed—without stopping. This instant transition features smooth, controlled speed adjustments with faster cycle time (up to 77% faster!) and remarkable accuracy that eliminates overshoot.

IQ Stop is designed for high-speed assembly lines. It redefines fastening by providing a faster, more efficient, and highly accurate tightening process, allowing you to maximize output without compromising quality

While any new tool or technology requires some education, smart tools work very similarly to traditional tools. They just have additional features and functionality that provide big benefits. The learning curve is small and manageable. Proper training and support will ensure a smooth adoption process. Training is available by Hampton and distributors which includes in-field support and education in fastening theory.

Similarly, the cost of smart tools is lower than people expect. When you look at the long-term savings (improved efficiencies, reduced downtime, lower scrap and material costs, reduction of errors, rework and potential recalls) and overall operational improvements, the cost of smart tools is money well-spent.

Companies who have adopted smart tools have provided positive feedback stating that the tools were easy to setup, their operators adapted quickly, and they saw impressive operational improvements with the new tools.