How to conduct a Gage R&R on DC Tools to Torque Bolts

D

dan_negrea

#1
Hi to everybody.
I work in a company that does a lot of assembly and here we are using a lot of DC tools to torque bolts to a specific required value, which is displayed on a LED screen. Once the tool achieves the requiered value, the torquing operation stops and part moves to the next process.

These tools are calibrated on a regular basis, and the result of the torque is verified once a day using a regular dial torque wrench.
Our company wants to get certified for TS16949, and as you know, all measuring systems used have to be calibrated and statistical studies conducted on them.

I have two questions:
1. What kind of statistical study is more appropriate for this kind of tool? Gage R&R doesn't seem appropriate to me, torquing the same bolt over and over at the same required torque will always end up with the bolt in a different position.
2. Is a statistical study required?

Thank you for your help!
 
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bpritts

Involved - Posts
#2
We used to have this problem (we were TS certified at the time) and treated the torque guns as a manufacturing process (subject to statistical process control) and then considered the torque wrenches as measurement process. We built out the job that used the device, so I don't have to worry about it now.

I did give our machines quite a bit of study (to the point of being able to bore an innocent onlooker to tears) about just how the torque guns actually worked (ours measured the electrical load of the motor, and through software calculated a theoretical torque.) (ps. another TS item: ensuring that software involved in "measurement process" has been validated. Done by the torque wrench check.)

As a practical matter, what you want to do is to make sure you *really* understand what's going on, how it's really controlled, and what can go wrong. It sounds to me like you're on the right track... just do your homework. It's also important to avoid getting into circular discussions (e.g. we check the torque guns using a torque wrench, and then check the torque wrench using assemblies which we measured using the torque guns!)

good luck!

Brad
 
D

dan_negrea

#3
Brad,

Thank you for your detailed answer, that's a good idea to go that path!

Cheers,

Daniel
 
D

dev1983

#4
We have a similar process and are TS. We use a torque transducer to verify the read out on the LED screen and readout on the transducer during tightening process and do a comparison study.
 
F

fabricator

#6
Hi to everybody.
I work in a company that does a lot of assembly and here we are using a lot of DC tools to torque bolts to a specific required value, which is displayed on a LED screen. Once the tool achieves the requiered value, the torquing operation stops and part moves to the next process.

These tools are calibrated on a regular basis, and the result of the torque is verified once a day using a regular dial torque wrench.
Our company wants to get certified for TS16949, and as you know, all measuring systems used have to be calibrated and statistical studies conducted on them.

I have two questions:
1. What kind of statistical study is more appropriate for this kind of tool? Gage R&R doesn't seem appropriate to me, torquing the same bolt over and over at the same required torque will always end up with the bolt in a different position.
2. Is a statistical study required?

Thank you for your help!
1. GR&R will work and the data should prove capable as long as you use a calibrated transducer to verify the DC tool and DRO. My suggestion is to use a joint simulator as this is a hard joint and very repeatable. If you cant use a simulator then make sure you use distinct readings from, say, 30 individual parts. This is key because, as you noted, torquing a joint and then relaxing and then torquing it again will rarely give the same reading or angle.

2. If you have KPC joints, then capability of the tool is required. I'm not sure of the specifics of the TS standard, but showing that you performed the analysis on the tool would be a benefit nonetheless and show any auditor that you have confidence in the tooling system to perform as designed.
 
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