A Story of One Product’s Fighting Chance at Survival

Insight: “these things take a beating…”

Your typical construction jobsite is not a delicate environment and can really beat tools up quickly. While conducting jobsite research, it was quickly learned that air compressors used to power pneumatic nailers used for framing, roofing and trimming houses, are essential to ensure the job gets done. Compressors lead a hard life and experience everything from damage from falling debris, bouncing around in the back of pickup trucks, or even occasionally tumbling from a truck when not secured. Particularly vulnerable are the pressure gauges and drain plugs that protrude from the tank.

All of these occurrences can shorten the life of this expensive component and often lead to downtime on the jobsite. A compressor as tough as the environment it worked in was clearly needed to ensure longevity and reliable performance throughout the product’s lifetime.

The Innovation: Caging the Animal

Compressors need to drive a lot of air volume and run reliably at a high duty cycles. The challenge was to develop a compressor with a high output that can withstand the punishing conditions of the construction jobsite. Our approach was to develop the product from the outside-in, creating an exoskeleton frame similar to a roll cage, from which the critical components are mounted and can be protected. The roll cage of the new design provides a large framework to protect the pressure gages, which were frequently damaged due to the fact that they precariously protruded from the compressor. Smaller bars further protect the plastic bezels from being damaged by impact. The roll cage design created a great location to add rubber grips for easy lifting and transporting. The addition of a steel kick plate protects the other vulnerable items such as the drain plugs and tanks.

The Payoff: Supreme Air Power

The new design is as tough as it looks and can withstand anything the jobsite has to throw at it. With increased protection from direct impact of falling debris, or falling from the back of a truck, this compressor has a fighting chance to continue to function properly over a longer lifetime. The roll cage is a design equity that resonates strongly with contractors as a solution that provides clear benefits in increased protection. Increased protection = longer lifespan = less downtime.