November 05 News
October 05 News
The Worlds first ‘Superjumbo’ Jet -the Airbus A380 took to the skies on the 27th April 2005 and is a collaboration between the European Aeronautic Defence and Space Company and BAE Systems, and is due to enter service in 2006.
The impressive wings with an overall span of 79.8m (a full 15.4m more than the competition), include a major structure that has been designed, manufactured and assembled by BAE Systems Aerostructures business based in Prestwick, Scotland and Samlesbury, Lancashire. This crucial part of the plane is of course built with strict quality guidelines- including the torque value of each fastening that holds the wings together! Too tight, and you risk breaking the joint, too loose, and the fastening could vibrate free. Each of these fasteners must be tightened using a torque tool.
With the use of torque tools brings the need for torque tool calibration equipment. This vital inspection equipment is used to make sure all the torque tools are set at exactly the right value. With 149 confirmed A380 customers by January, ease of use was on the priority list when BAE Systems came to replace their old calibration equipment. There was also a new need to print calibration certificates for each tool, giving traceability to their quality procedures.
MHH Engineering- manufacturers of Torqueleader Torque Tools, (Based near Guildford in Surrey) introduced BAE Systems to P.E.T.A (Personal Electronic Torque Analyser) Version 3 ‘Super’. P.E.T.A allows businesses to work far more effectively and efficiently, and offers the ability to test and produce Calibration Certificates to ISO 6789:2003 for every single tool used- straight away. This means accurate inspection records can be kept and called on when needed. The tool details are stored in a database, which can be quickly re-called, saving time when the tool requires re-calibration. Data can also be stored and analysed automatically, using Microsoft Excel®, instead of having to accrue and analyse information manually. This means information can be analysed and presented quickly and easily, using all the familiar tools of Excel®.
P.E.T.A can be hosted by a Laptop or Palmtop as well as a PC. This means that it is fully portable. BAE Systems found this extremely useful, and created their own portable calibration laboratory. This enables equipment to be calibrated without taking it off the production line. The result is less downtime since the calibration is carried out where the tool is used. There is also less need for duplicate tools to allow for tools being sent to the Calibration Laboratory, and this all means manufacturing costs can be kept to a minimum.
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PETA in use at BAE Systems Aerostructures business in Prestwick to calibrate tools used in the construction of the prestigious Airbus A380.
Using technology that was not previously available allowed BAE Systems to also use PETA to provide a realistic assessment of the performance of power tools. PETA can graph in Power tool mode, enabling analysis of impulse and other power tools in operation. This process is enabled by the use of XB Static Transducers plus Rundown Nose Assembly (Also available from MHH Engineering), and allows for the full range of tools to be assessed.
Some torque tools (notably 'clicker' wrenches) tend to cause an over-run or impulse as the mechanism operates, often leading to the actual torque applied being much higher than expected.
PETA in 1st Peak Mode displays both the 1st Peak as the mechanism breaks, and the Final Peak or maximum torque applied. Thus, during calibration an accurate reading of when the tool ‘breaks’ can be achieved regardless of operator.
The ability of PETA to record both 1st Peak & Final Peak readings also highlighted just how easily a joint could be over-tightened on the Production Line. BAE Systems implemented the use of Torque Safe Slipper Wrenches (also manufactured by MHH Engineering) where possible. These wrenches ‘slip’ when the predetermined torque setting is reached, completely eliminating over-tightening.
A Torque Safe 'slipper' wrench being used to apply a specific torque to the fasteners on the A380 wing sections.
By introducing P.E.T.A Version 3 ‘Super’ as well as the Torque Safe Slipper Wrenches, BAE systems are able to assure safety as well as improving efficiency and reducing costs. This has contributed to the successful construction of the world’s largest jet, with the ability to carry 555-840 passengers, and fly 15,000km at a time. John Kimm, Aerostructures Tooling Manager says 'We have been working with MHH in the development of their new PETA product. By use of the PETA system we have been able to make the torque test facility totally portable allowing us to provide a better service to our customers on site, by reducing down time. The system allows for a more comprehensive study into the performance of the units'.
