Case Studies
Industrial Bolting Success Stories
Customer success is our #1 priority. AcraDyne partners with you through the entire project lifecycle. Our custom engineered solutions ensure that each industrial bolting application meets productivity and accuracy requirements. Our superior tool design means AcraDyne bolting tools are not only powerful, but also durable and reliable, which is good for your budget. Our goal is to help our customers build a seamless assembly process so they can focus on their main goal — creating a quality product.
haliade-x wind turbine manufacturing
NEED
This GE Vernova project required many powerful high torque tools for assembling one of the world’s largest wind turbines, the Haliade-X.
CHALLENGE
Tools for this job needed to be powerful and accurate enough to assemble larger wind tower components than have ever been assembled, including longer blades and bigger rotors.
SOLUTION
AcraDyne provided multiple bolt tightening solutions for varying stages in the production line. AcraDyne’s custom engineered solutions provided reliable tools with the required data traceability for safety and torque measurement verification including our High Torque DC Nutrunner and the Gen IV iEC Controller.
RESULT
Acradyne’s custom engineered solutions met all the customer’s expectations and requirements. Continuing a decade long partnership, AcraDyne High Torque Tools remain the bolting tools of choice for GE Vernova’s Haliade-X offshore wind turbine assembly.
not pretty, but pretty impressive
NEED
Customer needed a high torque bolting tool for both scheduled and unscheduled wind tower maintenance. The tool needed to be durable enough to withstand repeated heavy duty use.
CHALLENGE
Severe, remote environments are tough on even the toughest tools. It is necessary for bolting tools to not only be durable, but consistently sustain long-term reliability and certification - all while keeping the budget in mind.
SOLUTION
AcraDyne supplied a 4,200 Nm electric torque tool that met all initial customer requirements, with a suggested calibration every 12 months.
RESULT
Acradyne’s AEP4B884200B1 high torque pistol tool has a proven 5 year track record of consistent performance and quality, incurring only minimal maintenance and repair costs. Despite heavy wear and constant use, it continues to pass certification, still going strong after more than 33,700 cycles. AcraDyne bolting tools have a total cost of ownership that is the lowest in the industry!
wind turbine tower hub construction
NEED
Customer needed high torque tools for bolt tightening during assembly and installation of wind turbine tower hubs.
CHALLENGE
A tool brand previously used by the customer proved incapable of tackling the job and the customer had burned through 7 tools in a 24-hour period. A sturdier, more rugged bolting tool was needed.
SOLUTION
AcraDyne supplied high torque tools: the High Torque Extreme Duty Series (Tool AEN4B998100B) to complete the application at 4,600Nm.
RESULT
Six months and 47,000 rundowns later, the tool is still providing outstanding reliability. In conjunction with the AcraDyne Gen IV iEC Controller, the results continue to be accurate and traceable.
tunnel construction
NEED
Customer needed high torque tools for bolt tightening during assembly and installation of tunnel components for a massive tunnel project with a construction budget of $2 million per day.
CHALLENGE
The Fehmarnbelt Tunnel is the world’s longest immersed tunnel. The project required fastening bolts both inside and outside of the “spine” of the tunnel. The height (13m above ground level) and the angle of the constrained space made the bolting application difficult to reach.
SOLUTION
AcraDyne supplied high torque tools: the High Torque Extreme Duty Series (tool AEP4W998100B) pistol grip nutrunner. The innovative solution to the tricky application included attaching the bolting tool to a long hoist with a balancer and a sling, which allowed easy access to the bolts.
RESULT
Customer was efficiently and safely able to tighten bolts to specifications of 6,515 Nm and 5,682 Nm. Coupled with the Gen IV iEC Controller, results were accurate, verifiable, & repeatable.
operator safety for lifting large bolting tools
NEED
Customer in Mexico needed an innovative tool-lifting solution that met their specific needs regarding weight, size, ease of disassembly/assembly, portability, and maneuverability for a wind turbine tower application.
CHALLENGE
The design needed to be simple and lightweight, yet robust enough to be transported and used in a challenging wind turbine tower environment.
SOLUTION
Working jointly with the customer, AcraDyne designed the portable, innovative XD Lift Assist, in direct response to the needs of the project - all on time and on budget.
RESULT
AcraDyne’s XD Lift Assist surpassed the customer’s expectations and is now used across multiple projects in Mexico and South America.
Wind turbine blade servicing with our right angle tool
NEED
Customer needed a high torque tool for bolt tightening around a pitch bearing in a wind turbine tower. This customer had been using hydraulic tools which were heavy, cumbersome, slow, and did not have the torque accuracy that the job required.
CHALLENGE
This application involved tightening more than 200 bolts in a confined space. Ergonomic tools and speed were imperative to complete the job quickly and safely.
SOLUTION
AcraDyne supplied high torque tools: DC Right Angle Tool (AEN4B773000B) with a single-ended offset reaction bar to complete the application at 2,800 Nm. When paired with the iEC Field Controller, we were able to provide our customer with everything they needed: speed, accuracy, traceable data, and repeatable results.
RESULT
AcraDyne’s High Torque Right Angle Tool is THE tool for Wind Turbine Maintenance and Blade Servicing. This powerhouse tool increased application speed by 500%! Customer was able to to tighten all 200 pitch-bearing bolts in just 1.25 hours, a vast improvement compared to the 6 hours it used to take using hydraulic tools.
torque multiplier for wind turbine manufacturing
NEED
This Siemens Gamesa project required an upgrade and repair of their torque multiplier tools.
CHALLENGE
One of the requirements for this torque multiplier job was to produce accurate and traceable torque and angle data.
SOLUTION
AcraDyne High Torque Tools: 2,500 Pistol Nutrunner was provided as a new torque multiplier tool for the job.
RESULT
Acradyne’s custom engineered solution solution for this job also combined the Gen IV iEC Controller for ultimate bolting tool control and traceable data collection. Our highly ergonomic and user friendly 3arm torque arm was an additional support for further operational safety and productivity.
