The Ford engine plant at Dagenham has relied extensively on torque control products provided by Crane Electronics for about ten years. In the latest stage of this on-going relationship, Ford has invested in new tool controllers for use in conjunction with the Crane IS heavy duty torque wrenches. This combination is used on Ford’s Puma Line which produces diesel engines for Ford Transits, Jaguar (X-type) and The Land Rover Defender.

The TMAC Opta replaced an original TMAC ll torque controller that had been used by Ford for many years. The TMAC Opta was introduced on to the Puma Line in February 2007.

The controller and wrench combination has to be able to process data and withstand the harsh environment of a production line assembling up to 1500 diesel engines per day - representing some 6000 critical fastening operations on critical fuel injector assemblies. The heavy duty torque wrenches, Crane’s WrenchMaster, apply torque to 13mm nut fastening operations and communicate the data to the TMAC Opta for verification and communication with lineside PLC confirming that the fastening status is within limits allowing the engine to proceed to the next station on the production line. Fastening status including date and time can also be stored on the unit.

The TMAC Opta has a number of features that help to ensure maintenance requirements are minimised and therefore production is not interrupted. These include robust and highly intuitive software, isolation of internal circuits and a tough housing with protective trim to prevent accidental damage. A second TMAC Opta is also to be used on the Ford’s Lion line where EU5 Engine Compliance work is undertaken.

The success of the relationship between the two companies has also been based upon the on-going support provided by Crane Electronics. This has included application advice and monthly site visits by Crane’s dedicated Customer Service Department to ensure any required repairs or recalibration work is carried out without delay or interruption to Ford’s production schedules.

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