A new Intelligent Tool Control system (ITC) has been developed by Zeroshift specifically to solve many of the tool management problems faced by aerospace manufacturing companies. By automatically recording who removes tools from the cabinet and logging them back in, Zeroshift ITC will help to eliminate Foreign Object Debris (FOD - items that shouldn’t be in aircraft during flight), increase the availability of tools and provide useful productivity information.
The Zeroshift system sets new standards for ease of use and reliability. “Conventional solutions to tool control use either barcodes or radio frequency tags,” explains Zeroshift’s Managing Director Bill Martin.
Zeroshift ITC does not need anything to be attached to the tool and neither does it need the technician to take any positive action when removing or replacing tools. It is entirely automatic, totally non-intrusive and has no vulnerable small components or labels. It’s a significant step beyond today’s best.”
The US Federal Aviation Administration (FAA) has estimated the cost of FOD at more than $60 million per year. “It’s a very expensive problem,” explains MacGregor. “Whilst much of this is due to foreign objects inducted at airports, a lot is also due to items left in the ‘planes during build and maintenance. That’s the problem that ITC is designed to help solve.”
At high speeds and g-forces, anything left in an aeroplane can be extremely harmful to pilots and other occupants. It can also damage engines, jam control systems and impact other equipment, interfering with safe flight. “Tools are the second biggest contributor to engineering-related FOD, after fasteners,” says MacGregor. “The FAA suggests depanelling, non-destructive inspection and even x-rays to locate missing items. A single missing tool can cost hundreds of thousands of dollars to find and lead to significant delays.”
Electronic control and monitoring
ITC is supplied as an exceptionally strong tool cabinet available in a range of standard sizes. Tools are fitted into a precision cut, solvent resistant polyethylene foam available in a choice of colours. The electronic control system is a modular design to simplify maintenance and minimise downtime.
To access a tool, users must first enter their PIN via either a swipecard or a keypad. The system will compare the PIN with its internal or network database and allow (or disallow) access to the tool draws. An optical sensor mounted under the tool cavity notifies the control system when a tool is removed or replaced. Tools can be made of any material including wood and plastic and even very small items such as precision sockets can be accommodated. |
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Cabinets can operate as individual units or can be networked to provide an integrated tool monitoring system managed by remote PC. Management software allows tool usage to be tracked by user and by time and for missing tools to be quickly identified along with the last user. Calibration requirements can also be highlighted, helping to ensure safety and compliance with certification requirements, and tool deployment can be restricted, supporting lean manufacturing objectives.
The complete system is extremely durable and provides a wide range of data. “There is no vulnerable scanning,
Radio Frequency or other electronic subsystems on the cabinet. It can be part of a highly integrated tool management system or operate totally independently without any external connectivity,” concludes MacGregor. “It’s a very powerful system that is already generating a considerable amount of interest from manufacturing and maintenance companies across a range of high-technology engineering industries.”
Zeroshift ITC will be launched at the 28th National Aerospace FOD Conference in Texas, August 7-9. In the UK, ITC will be shown at the Aero Engine Expo, Olympia (London), September 12-13.
About Zeroshift
Zeroshift is a privately owned British innovation company, specialising in the development and application of power transmission and electronic control solutions across a wide range of transport industries.
Zeroshift’s main area of IP is an innovative system that replaces the conventional synchromesh in an Automated Manual Transmission (AMT) to provide an affordable, highly fuel-efficient, zero torque interruption fully automatic transmission. Zeroshift’s Intelligent Tool Control System (ITC) is a next-generation solution to the reduction of Foreign Object Debris (FOD) in aircraft.
All Zeroshift press releases and illustrations are available at:
www.autopresspoint.com
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