Counting screws is not the new song title from the rock band “Counting Crows.” Screw counting is a quality control process utilized in the manufacturing environment. Tightening hundreds and hundreds fasteners daily, assembly operators can forget to fasten some screws here or there during the monotonous routine. For complex fastening regimes with multiple screws on fast moving assembly lines, often fasteners may not always be installed and seated properly. These are common symptoms that plague many manufactures. How to get it right the first time?
The goal of the screw counting process is to ensure that all fasteners are accounted for during the assembly process. Further a fastening error is identified on the assembly line, the more it costs in rework time and expenses. If a fastening error is committed and detected during the assembly process, the operator can correct it or prevent the faulty product from moving along the manufacturing line or being shipped out to a customer.
A screw counter helps manufacturers detect and eliminate costly screw-fastening errors during the assembly process. Using a screw counter is like putting the eyes and ears of a quality control manager where they are needed most – right in the assembly area.
The new BLG-BC1 Series by Mountz, Inc. is an unique electric screwdriver, as it features a built-in screw counter. Whereas most screw counting systems require an external device be connected to the electric torque screwdriver. The BLG-BC1 doesn’t. This power tool verifies that all fasteners have been installed and seated properly.
Lapses in preventing fastening errors can affect the bottom line. Fastening errors can be realized as catastrophic or latent failures. Catastrophic failures may be easier to detect and resolve. With this type of failure the part will not function properly. It may be costly to repair but is easy to manage. With latent failures the problem is much worse as the failure may not be detected in the quality review process, but is a “time bomb” waiting to happen.
Designed to detect cross-threading, omissions, unfinished rundowns and cycle incompletes, the BLG-BC1 electric screwdriver ensures the assembly process is done correctly the first time. The assembly tool provides precision torque control with an automatic shut-off clutch once the preset torque is achieved.
The BLG-BC1 tool is a brushless electric screwdriver designed for high production environments at an affordable price. The power tool features a high performance brushless motor design that provides durability and reduces the standard maintenance costs associated with other electric torque screwdrivers.
Screwdrivers with brushless motors have an extremely long operating life and provide consistent reliable performance. The screwdriver requires less maintenance with no need for replacement of expendable parts (carbon brushes, rotor, switches and other contact points). Mountz offers various models covering a torque range of 0.9 to 17 inch-pounds.
The BLG-BC1 screwdriver provides the basic screw counting function. For fastening applications that require advance monitoring needs, Mountz offers the Scout screw counter, which can be used for multiple tools and features outputs for machine and PLC interface for line control.
Overall, a screw counter improves production yields, manufacturing costs, product quality, product reliability, reputation and profitability by ensuring that every assembly has been subjected to a quality control review process right in the assembly area. The screw counter takes the control of the assembly process out of the operator’s hands.
Using a screw counter makes a safer world through accuracy and precision. Controlling torque is essential for companies to ensure their product’s quality, safety and reliability isn’t compromised. The failure of a three-cent fastener that isn’t properly tightened can lead to catastrophic or latent failures. Fasteners that are insufficiently fastened can vibrate loose and excessive torque can strip threaded fasteners.
If you need any assistance with your fastening application, contact us as we are happy to help.