Quicker
The shrink disc tensioner can offer 2x faster process speed to help you reduce costs.
Safer
Find a solution which will decrease noise pollution and operator fatigue on the shrink disc application.
Smarter
Atlas Copco will enable you to have traceability on tightening joints, ensuring you have the best quality.
Pain point for the shrink disc application
The main pain point for the shrink disc application is the limited amount of space there is to tighten. Normally, only a a hex type torque wrench can work due to the limited amount of space.
Both tension and torque can work on the application, however the value from tension is much more significant. However the issue is, tensioners are difficult to lift and mount on the application due to the lack of space.
Introducing the shrink disc tensioner
Atlas Copco have developed a solution in the shrink disc tensioner. This system only reqiures two people and a hoist to complete the process.
With this solution in place, it can cut the process down to two hours and also reduce operator fatigue.
Save £85,000 per year implement shrink disc tensioner
A world leading wind energy company had a major problem tightening their shrink disc application. With limited space availble to pull the housing it was taking a lot of time using hydraulic torque wrenches, requiring two operators to carry out the process for 4-6 Hours.
Using their current method, they couldn't track the data of the final torque. As a solution, Atlas Copco produced the unique shrink disc tensioner to complete the process, combined with the RTA smart hydraulic wrench to validate the torque reading at the end of the process.
Applying direct tension to the stud can easily pull the shrink disc housing out, making it much more robust and ergonomic.
With the shrink disc tensioner efficiently running, the company will save £85,000 a year and reduce their operating time down to 2 hours. The quality of their product has naturally improved , as they can accurately check each component has been tightened sufficiently with it all being recorded digitally.
£65,000 a year saved after shrink disc tensioner discovery
Once the shrink disc tensioner solution was established, we're able to apply it to any shrink disc applications suffering with similar issues. Another company within the wind energy sector had the same problem regarding using a torque wrench for this application and wanted to speed up their process.
For the solution, Atlas Copco supplied the company with shrink disc tensioners along with training on how to use them efficiently. We also supplied an SP1500 smart tensioning pump to help improve the speed of the process.
With the shrink disc solution in place it improved the process time, reducing it from six hours to 1 hour 30 minutes. On top of that is also improved the state of the work environment with less noise and reduced operator fatigue.
With this time saved, they were able to re-allocate the workforce to complete other tasks, improving the efficiency of the operators and their workload. In total the comapny will save £65,000 a year due to the shrink disc tensioner improving their overall operations.
