Aimco Brakes AcraDyne Torque Cart Manual

							 
 
 
 
 
Torque Verification Cart 
Operations Manual 
 
 
 
 
 
 
 
 
 
 
 
 
 
PO Box 16460, Portland OR 97292-0460 • 800-852-1368 • Fax 800-582-9015 
www.aimco-global.com 
						

							 
Table of Contents 
 
 
Setup and Operation: 
 
1 Introduction 
2 Safety 
3 Installation 
4 Warranty 
5 Setup Procedures 
7 Connecting Tools 
 
 
ToolsTrac Installation, Operation and 
Configuration: 
 
Installation 
9 Basic standalone installation 
10 Installation when using a centralized server 
Operating Procedures 
13 Logging In 
13 Security Levels 
14 Changing Passwords 
15 Adding / Editing User Accounts 
Inventory / Information Management 
16 Manufacturers 
17 Suppliers 
   17              Device Models 
19 Assets 
20 Tool Operations 
22 Associating Operations to Applications 
24 Setting up and Configuring Transducers 
25 Setting up and Configuring a Torque Cart 
Torque Verification and Auditing  
27 Tool Verification 
29 Viewing a Curve 
30 Using the quick verification tool 
30 Auditing 
Maintenance 
31 Service 
32 Calibration 
Viewing Historical Data 
34 Torque Verification 
35 Audits 
   36       Statistical Graphing  
Reports  
37 Viewing and Printing Reports 
ToolsTrac Configuration Settings 
38 Alerts & Custom Labels 
39 Lookups & Sample Size 
40 Using an External Transducer
Maintenance: 
 
41 Maintenance 
42 Troubleshooting 
43 Parts List 
44 Photos  
45 Glossary 
 
 
 
UFT Series Joint Simulator: 
 
46 Operation Instructions for the UFT-S10 and UFT-S16 
S-series Joint Simulator Breakdowns  
47      Breakdown of the UFT-S Joint Simulator 
48       Breakdown of the UFT-S10 Joint Simulator 
49      Breakdown of the UFT-S16 Joint Simulator 
50 Operation Instructions for the UFT-6, UFT-10, UFT-16, and UFT-24 
51 Breakdown of the UFT-BC Joint Simulator (Front and Top Views) 
52 Breakdown of the UFT-6 Joint Simulator  
53 Breakdown of the UFT-10 Joint Simulator 
54 Breakdown of the UFT-16 Joint Simulator 
55 Breakdown of the UFT-24 Joint Simulator 
56 Maintenance 
57 Certification of the UFT Joint Simulator  
58 List of Hexagon Head Bolts 
 
 
 
Utility Cart: 
 
59 Safety Precautions 
60 Specifications 
61 Adjustments 
62 Installing Batteries 
62 Accessory Panel 
62 Pre-Operation Checklist 
63 Maintenance 
63 Charging Batteries  
64 Service Policy 
64 Load Limits 
65 Warranty (currently DJ Products Inc.) 
67 Operating and Training Instructions  
						

							- 1 -Torq
ue Ca rt:   Introduc tion  The AIMCO/AcraDyne Torque Validation Cart is a mobile torque validation device used in automotive,  
aerospace and other manufacturing plants globa lly.  The Cart houses repeatable joints and provides  torque 
analysis and data for assembly tool verification purposes. The software included generates reports to  
assist manufacturing personnel with selecting and maintaining tools for their assembly proces ses.  
The AcraDyne Torque Validation Cart is a comprehensive instrument for verifying and analyzing a ll  
types of assembly tools, including continuous drive, pulse tools, static torque wrenches, and click-type 
wr enches.  The “torque analyzer” on the Cart is eithe r an embedded or lap
top PC. A comprehensive  
database of all tools along with their performance data and history is stored and accessible at a ll times. 
The Torque Cart’s database can reside local on the cart’s computer or on a plant n etwo rk.  
The Torque Cart is available in several models which include a drivable model, a power-assist model, and 
a “push” mode l.  
The cart with the laptop option provides a secure lockdown plat e. The cart with the embedded computer / 
touch screen option allows for quick navigation without the need to use a touch pad or mouse. The torque 
measurement equipment included with the Cart includes joint simulators and rotary torque transducers  
with capability from 1-1000 Nm.  
When the operator chooses a tool from the database, the program suggests which transducer to use to 
verify that tool.  
The database can be loaded with information on all of the tools in the plant. This database is keyed on the 
plant asset number / tool number, tool manufacturer, mod el 
and ser ial number. Additional information  
includes the tool type, operation number, operation name, transducer I.D., and the torque specifi cation.   ToolsTrac software collects and stores detailed torque, angle, and pulse readings. When a number of  
specified rundowns are reached, the results of the test and user notations are displayed and subseque
ntly 
archived.   A torque graph and printable report is available at the conclusion of each t
est
. All data within the database 
may be purged, as required, based on date/age.   
						

							- 2 -Torq
ue Ca rt:   Safety  Always wear company and government mandated personal protective equipment, including safety 
glasses/goggles, when working on or near the Torque Ca
rt.  
Make sure all guards, safety gates, and warning labels are in place prior to operating the Torque Cart. 
Keep hands and clothing clear of all moving parts (even guarded parts)  at 
al l ti me s.  Be aware of all “pinch” points before running power tools!
 
The Torque Cart should not be operated by any person or persons unless they have read and understand 
this manual, and have been given proper instruction on operation and safety
.    
						

							- 3 -Torq
ue Ca rt:   Installati on  Af
ter un-crating the Torque Cart, inspect it for visual damage caused during shipment. AIMCO has tak en 
the utmost care in packaging the equipment to ensure that it arrives in good condition
. However, AI MCO 
cannot be responsible for damages that occur during shipping and handling. If the Torque Cart appears to  
have been damaged during shipment, contact the carrier and your AIMCO representative as soon as  
possible.  
ELECTRICAL  Electrical Installation should only be performed by or under the close supervision of a qu
alifi
ed 
electrici an.   Depending on the cart configuration, power to the cart should either be: 

110 volt, single phase, 60 Hz, 50 Hz, 15amps OR 

220 volt, single phase, 60Hz or 50Hz Verify AC/charger rectifier is in the correct voltage position before connecting to power sour
ce. 
Whenever the Torque Cart is not being used, it should be plugged in to an electrical outlet to ens ure full 
battery charge
.   
TRANSPORTATION  The Torque Cart is mounted on a battery-powered chassis operating 
at 
24V  DC. See section on Parts 
Caddy for more detailed informa tion.   
						

							- 4 -Torq
ue Ca rt:   Wa rranty  AIMCO warrants, to the original purchaser, that the device will be free from defects in material and  
workmanship for a period not to exceed one (1) year from the date of the purchase (warranty pe
riod). 
Any parts that are determined by AIMCO to be defective during the warranty period will be  repaired or 
replaced at AIMCO’s sole discretion, free of charge  
(F.O.B. AIMCO).  
Th is warranty does not cover damage or failure that is determined by AIMCO to be the res ult of  abuse, 
intentional misuse or use of the cart in any application other than the one for which i t wa s de signed.  
AIMCO will not be responsible for repairs made in t he purchaser’s plant by non-au thori zed personnel, 
without prior written consent.  
Repair or replacement of the device or its components is the exclusive remedy to the costum er
. No other 
expressed or implied warranties exist, including warranties or merchantability or fitness for a particular  
purpose. 
In no event shall AIMCO be liable for consequential or incidental damage s.  
						

							- 5 -Torq
ue Ca rt:   Set -up  Procedures Installing the Com puter 
1. Laptop Option:
A. Secure the laptop into the holder to prevent damage.
B. Plug the power cable into the back of the laptop.
C. Plug the RJ-45 network cable into the CAN-dongle
D. Plug the USB cable into a USB port on the laptop
Embedded Option:  A. Verify Touch Screen secured to Cart.
B. Verify RJ-45 network cable plugged into CAN-dongle ( C), located inside cart below t he
transducers.
C. Verify USB cable ( D) is plugged into embedded PC, located inside cart below the
transducers.
2. Connect transducers
3. Make sure Torque Cart’s electronics are in the ‘on’ (clockwise) position.
4. Press the power button on the laptop keyboard to start the computer. The touch screen option w ill
automatically turn on when the cart electronics ar e turned on.
Note: For the touch screen option, when the cart electronics are turned off, the compute r wi ll
continue to stay on for approximately 1-2 minutes if it was not shut down through Windows.
5. Launch ToolsTrac by double-clicking the ToolsTrac icon on the desktop.
C 
D  
						

							- 6 -Torq
ue Ca rt:   Set -up  Procedures  (cont.)Connecting the Transducers 
1. Transducers are mounted in the transducer tra y.
2. Note the labels on the transducers and the corresponding labels on the front of the joint simulator.
Place the male square drive of the proper transducer into the female square drive of the
appropriate socket.
3. Install the other three transducers in a similar manner.
4. Plug in each transducer cable into the connection under each corresponding socket inside the tra y. 
						

							- 7 -Torq
ue Ca rt:   C onnect ing  Tools  to  tran sducer Connecting  Power Tools - Using Onboard Joint  Simulators 
(For pneumatic and electric tools)  
1. Choose the transducer.
2. Make sure estimated tool torque output does not exceed the transducer maximum rating.
3. When possible; match the tool square drive size with the transducer square drive size, minimizing
the use of adaptors .
4. Place the male square drive of the tool into the female square drive of the installed transduc er.
5. If ToolsTrac is set up for the tool, a green LED light above the proper transducer will indicate t he
correct selection. No
te:  Power tools require rotation before reaching torque for proper measurement. The joint  simulators provide a consistent angle of rotation for tes
ting power 
tools .  
Connecting  Power Tools - Using Trans ducers on App lications 
(For pneumatic and electric tools)  
1. Choose the transducer.
2. Make sure the estimated tool torque output does not exceed the transducer maximum ra ting.
3. When possible, match the tool square drive size with the transducer square drive size, to
minimize the usage of adaptors.
4. Place the male square drive of the tool into the female square drive of the transducer.
5. Place proper socket for application onto the male square drive of the transduc er.
6. Place the socket on the application on which tool will be tested.
7. If ToolsTrac is configured for using tool on an application the green LED light will i ndicate
suggested transducer.
8. If the transducer cable is not long enough to reach the application, a secondary exten sion cable
may be used. Note:
  Transducers on this cart are designed so that they can be used on actual assembly   applications.  Please be aware that part and process variations will effect the repeatability of 
torque, angle and or pulse count data.  The Cp & Cpk values will never be as good on  
applications as they are when testing tools on test joints
. 
  
						

							- 8 -Tor
que  Ca rt:   C onn ecting  Tools  (cont.)Connecting Hand Tools  – Using Static  Joint Plate  
(For click wrenches, dial wrenches, digital wrenches and transducerized wrenches.) 
1. Choose the transducer.
2. Make sure estimated tool torque output does not exceed the transducer maximum rating.
3. When possible, match the tool square drive size with the transducer square drive size minimizing
the use of adaptors .
4. Place the male square drive of the tool into the female square drive of the transducer.
5. Place the male square drive of the transducer into the appropriate square drive recept acle on the
adapter pla te.  Best results will be achieved if wrench actuation or load is applied towards ground. No
te:  Hand tools do not require rotation before reaching torque for proper measurement
. Use of square drives without joint simulators is sufficient for testing of hand tools
.