Cordless Limit Wrench (CLW)

Learning Objectives
 Participants can state the importance of CLW

 Participants can explain CLW process

 Participants could state the benefits of following CLW

on floor
 Participants could identify CLW on shop floor

 Participants follow the do’s and don’ts accurately to get

maximum benefits of CLW
 What is CLW

C Cordless
L Limit
W Wrench
 What is CLW
 CLW stands for Cordless Limit Wrench

 It is a nut-bolt fastening full proofing tool which tightens

up to pre-determined amount of torque

To summarize - It is a radio frequency based torque fool-

proofing system to eliminate Maru-A tightening faults
resulting from manual operation
 CLW Hardware

RECEIVER TRANSMITTER & LIMIT

WRENCH
 CLW Process

A worker
tightening with
Torque Wrench

CLW box showing 3

bolts to be tightened

CLW box showing

0 bolts to be
tightened,
operation finished
 Explain CLW Process

 The VTS system has all details of model codes of each car
fit into its system

 At a single point of time there may be various models

running in a line

 When a particular car model reaches within boundaries

of CLW box, through radio frequency it picks up number
of bolts required to be tightened in it
 Explain CLW Process
 The limit wrench he uses; has a chip which communicates
with the CLW machine chip through radio frequency

 He will then start tightening the bolts

 Each time the bolt reaches the right torque, the CLW
machine gives a beep and a number gets decreased on
display showing remaining number of bolts to be
tightened

 This is essential and is done for every MARU-A operation

as well where tightening process is involved
 Explain CLW Process
 Every CLW machine has connected chips at wrenches used
at a station, it cannot be used anywhere except the station
where the CLW machine is installed

 If proper torqueing is done at stop limit switch PLC gives

End signal to CLW box, showing green light

 If proper torqueing is not done before stop limit switch hit

CLW box gives N.G signal to PLC which may lead to
stoppage of conveyor line, showing red light on CLW box

 All records are maintained

Basic Composition of CLW System
 Limit Wrench

 Radio frequency Transmitter (FM generator)(inside

torque wrench and CLW box)-picture on next slide

 A Receiver unit
Operational Details
TORQUE WRENCH

LIMIT SWITCH
(TRANSDUCER)

TRANSMITTER
Receiver Unit

MODEL SELECTION DISPLAY

COUNT DISPLAY
 Why use CLW
 It prevents over tightening of parts, thus, preventing stress

on nut and bolt

 CLW with the coordination ANDON also prevents the

passing of untightened nut or bolt passing from one

station to another by stopping line

 It is of compact size which makes it easier to install

 It uses less wiring and is portable too!

 CLW have programming flexibility.

 Why do we need CLW?

 To ensure fool proofing of all manual Maru-A

tightening operations

 To help generate alarms through Main conveyor

stoppage

 Enhance elimination of assembly defects due to

improper / missed tightening
 How to use CLW
 Limit wrench is to be turned till it turns free

 It turns free only after the predetermined value of

torque has been applied

 When using it fastening should not be done with

impact loading, a steady increase of force should be
applied

 The bolts should not be crooked, should be put

straight
 CLW – Signal Miss

 Weak cells are the major issue for intermittent signal

miss
 Broken micro switch wire is the major issue for
permanent signal miss
 Performing torque very fast can lead to one or two count
miss by the receiver
 When micro switch does not get operated by wrench
lever
 Data mismatch from VTS end
 CLW – Handling Issues
 Incorrect handling of limit wrenches at station
 Using limit wrench for other purposes like hammering
or pushing
 Placing limit wrench inadvertently on hard base or
transmitter upside down
 Impact of Handling Issues
 Broken wires
 Electronics component damage, resulting in
replacement of transmitters.
 Transmitters cost around INR-5000/-
Last year 60 transmitter were procured which costed
around 3,50,000.
Best practices for Limit Wrench
handling
Problems encountered
 Some times due to technical failures CLW stops line
unnecessarily. In such cases, CLW server is turned off
and line is run in Bypass mode.
 Do’s and Don’ts for CLW System
 Do’s
 Torque wrench must be placed at proper location
 Transmitter should not come in contact with any
external object, while putting or picking
 Supervisor must ensure availability of two cells
always with him
 Supervisor must ensure all receiver box should be
closed
 Transmitter cell replacement record must be
available with supervisor
 Must return all used battery to store
 Do’s and Don’ts for CLW System
 Don'ts
 Should not open the transmitter other than the

battery chamber

 Should not open the receiver box

 Should not use wrench as hammer or other pushing

devices

 Should not throw used cell in dustbins

 Impact of CLW System
Safety : Many CLW are on MARU A components
if it does not work properly, human
safety is at risk
Quality : If any bolt is left without proper torque,
quality will suffer
Productivity : CLW breakdown by any cause, leads to
line stoppage
Cost : Spare part of these electronic products is
very costly and it can not be repaired
 Summary
 It is a radio frequency based torque fool-proofing
system to eliminate MARU-A tightening faults
resulting from manual operation

 CLW hardware consists of receiver and transmitter

in a limit wrench

 It prevents over tightening of parts, thus, preventing

stress on nut and bolt

 Purpose is to enhance elimination of assembly

defects due to improper / missed tightening
 Recap Quiz
Fill in the blanks:
Safety :
Quality :
Productivity :
Cost :
Recap Quiz
 Mention 3 do’s and 3 don’ts of CLW system
 Mention 2 impacts of bad handling of limit wrenches
 Draw a limit wrench and label parts