In space manufacturing, where precision and reliability are vital, prevailing torque compensation and secondary retention methods play crucial roles in ensuring the structural integrity and safety of bolted connections. The unique challenges of the space environment, extreme temperatures, vacuum conditions, and intense vibrations, demand that every component be securely fastened to prevent failures that could jeopardize an entire mission.
By using prevailing torque compensation and secondary retention methods, we were able to help one major aerospace manufacturer elevate production capabilities with Atlas Copco’s low torque solutions.
Prevailing torque refers to the resistance encountered when a fastener is threaded onto its mating part, often due to factors like friction or deformation of the threads. In space applications, this resistance must be precisely controlled to ensure that bolts and fasteners are tightened to the correct specifications without being over- or under-torqued. Incorrect torque can lead to loose connections or stripped threads, both of which can be catastrophic in the harsh conditions of space.
Compensating for prevailing torque is particularly important because space components often use locking mechanisms, such as prevailing torque nuts, which are designed to resist loosening under vibration and thermal cycling. These locking mechanisms inherently create additional resistance during installation, which must be accounted for to achieve the desired clamping force. Proper torque compensation ensures that the fastener is neither too tight, risking thread damage or fracture, nor too loose, risking separation or movement under load.
Secondary retention methods provide an additional layer of security for bolted connections in space manufacturing. These methods are essential because even a single loose bolt can have disastrous consequences in space, where maintenance or repair is often impossible. Common secondary retention methods include safety wires, locking plates, and adhesives, each designed to prevent fasteners from backing out due to vibrations, thermal expansion, or other forces.
Safety wires, for example, physically secure the bolt in place by threading through holes in the bolt heads and securing them to a fixed point, ensuring that even if the bolt begins to rotate, it cannot fully unthread. Locking plates achieve a similar effect by physically blocking the bolt from turning. Adhesives can provide both locking and sealing functions, bonding the fastener to its mating surface and filling any gaps that could allow for movement or loosening.
Atlas Copco’s team of industry professionals incorporated prevailing torque compensation and secondary methods with IxB tools, ToolsNet 8, ToolsTalk 2, and other screw-feeding solutions.
These tools were utilized across three pivotal production areas. In the customer’s clean room, the laser precision and quality control are ensured with low-torque solutions and IxB tools. The automation area integrates controllers for seamless and streamlined operations for main panels and subcomponents. In the dynamic integration space, IxB tools enable agility and flexibility, essential for assembling intricate satellites.
This success was a strategic shift. Recognizing the importance of quality control, process control, and traceability, our customer underwent a profound change in their production culture. Every fastener became critical, as satellites couldn’t be repaired once in space. Thus, a new tightening strategy needed to be implemented, to meet their commitment to excellence requirements.
If you’re interested in learning more about Atlas Copco’s aerospace industry solutions, contact us to schedule a demo today!
