Alcon Components is a specialist manufacturer of high performance brakes and clutches for transport and performance road vehicles. Brakes are one of the most safety critical components on a vehicle and the correct assembly depends on the correct tightening of the mounting bolts. Original equipment manufacturers like Alcon can not just look at torque in isolation but also have to consider commercial, manufacturing and technological issues.

Compared to high volume car manufacturing, Alcon produces exclusive and high tech solutions in small runs, one of which is the largest brake caliper in the world. At present the production volume for this particular product is still very exclusive, but as prestige car manufacturers recognise the benefits of these performance brakes, production volumes are going to grow in the future.

In particular Alcon want to ensure that all mounting bolts are tightened to the correct angle and torque as part of an audit and documentation system. The commercial benefit of such a system is that the OEM can prove compliance with the car manufacturers’ quality standards and international legislation. From a manufacturing point of view man hours can be saved as “after checks” of the produced goods are no longer necessary. From a technical point of view the angle and torque measurement offers the highest accuracy as it uses two parameters for the fastening process.

Alcon conducted a broad review of the market and considered DC controlled torque devices which could also offer torque and angle measurement. Due to the high torque involved this was considered a far too high investment for the present production levels and offered no quick return on investment. Furthermore the DC solution would have limited Alcon to one particular brand of tool controllers and power tools.

Due to its experience across different types and sizes of manufacturing industries, torque specialist Crane Electronics suggested a customised solution that provided the same level of quality control as DC tools. Further advantages of this system were lower investment costs and a far shorter time to implement the project. Alcon determined that Crane Electronics’ proposal offered the best balance of measurement capability and price.

Crane Electronics’ long term solution consisted of its tool controller, TMAC Opta, with a rotary transducer, CheckStar. In conjunction with a bespoke bar the bolts of the brake caliper are tightened to the correct torque and angle. The TMAC Opta gives the operator a clear visual and acoustic indication when target and angle settings are achieved. At the same time, the tool controller records the torque and angle readings, giving Alcon full traceability on all its products.

In making this investment, Alcon has future proofed its torque control applications as the TMAC is one of the few “neutral” tool management control systems in the market. The TMAC Opta is not only compatible with other torque tools from Crane, but also with most pneumatic tools.

If the production volumes change, Alcon will not be restricted. They will be able to choose from a wide range of makes and types of power or pneumatic tools which will work in conjunction with the existing solution from Crane Electronics. “This is the first time that we have purchased products from Crane Electronics. Their location, approach and personnel have helped to ensure a highly successful result and as a result we are highly likely to use them again. They have helped us to maximise the quality and integrity of our product ensuring we provide a totally reliable and cost competitive product too, “ says Andy Smith, Project Manager, Alcon Components.