Saltus GFA: Precision & Productivity in the Automotive Industry

Atlas Copco’s Saltus Geared Front Attachments (GFA) are outperforming the competition: Discover how our experts enhanced engine assembly with a failure test.

As is often the case in many industries, the smallest details can have the most significant impact. The same holds true for the automotive industry, where even the smallest error can result in costly failures or safety hazards. This is especially true in engine manufacturing, where even the most minor errors can lead to much larger issues later. In such applications, operators need consistent, reliable tooling to get the job done, thus reducing downtime related to tool failures, due to constant gear changes.

When one of our local Atlas Copco representatives saw a potential area of improvement within a major OEM’s automotive manufacturing facility, they jumped at the opportunity to improve their assembly with our Saltus Geared Front Attachments (GFA). Read on to uncover why our solution proved to be superior to their current tooling line-up and why switching to Atlas Copco tools and assembly solutions is the key to improving your production.

Geared Front Attachments are primarily used to tighten tube nuts in hard-to-reach areas. Atlas Copco’s Saltus GFAs are made with high-grade steel to ensure the durability and long-lasting life of the product. Compared to traditional Geared Front Attachments, Saltus GFAs offer a higher return on investment due to longer tool usage. They offer extended periods between greasing intervals, allowing the GFA to remain operational for longer.

Saltus GFAs feature a lighter, smaller frame for improved ergonomics in hard-to-reach areas. They are also equipped with magnetic siding to capture steel debris during tightening.

When you purchase Saltus GFAs from Atlas Copco, you can source the complete solution from us. We offer our customers the option to receive both the GFAs and Atlas Copco tools pre-calibrated and line-ready.

Related: Learn the fundamentals of GFAs in our article, ‘Geared Front Attachments (GFA): An introduction.’

Originally, a major OEM in the automotive industry used competitor solutions for their engine assembly. When our experts discovered this, they realized our customer would greatly benefit from our solution.

In this battle of longevity, our customer pitted the competitor tool against the Atlas Copco Saltus GFA solution. During the course of this test, our solution underwent maintenance and calibration after every 85,000 to 90,000 runs and recorded zero gearing failures or issues after an impressive total of 567,789 runs! In comparison, our competitor's tool requires a gear change after every other maintenance and calibration check or may simply fail on the plant floor.

Initially, the experts brought in a couple of 3D-printed GFA versions to showcase our offering as a whole and to walk the line. This interaction opened up a greater opportunity when our experts created a custom Closed-End Geared Front Attachment (COT) specifically for this application. They gave it to the customer to run until the product failed and provide feedback.

Analyzing this test failure demonstrated that our solutions are superior for several reasons. The first is the magnetic technology integrated into our GFA products. This helps keep debris from entering the motor and improves the tool's longevity.

Furthermore, our competitor’s solution places more strain on the motor, negatively impacting the tool and causing it to overheat. In contrast, the Saltus GFA operates significantly cooler, demonstrating its optimized and more efficient design while improving our customers' experience.

When every second counts, you need a solution you can rely on to get the job done. With Atlas Copco tools and assembly solutions at your stations, your operators can spend more time on assembly and less time switching out failed tools.

Are you ready to start utilizing Atlas Copco's superior solutions? Contact us today to consult with our experts and arrange a product demonstration!