Errors may occur at various points in a tightening process. The wrong fastener may be used, operations may be carried out in the wrong order or components may not be tightened in accordance with the defined parameters. All these errors have similar consequences; they cause additional cost for reworking or repairs. Industrial application Guidance (ILG) is an independent system from Atlas Copco’s tool location product portfolio designed to prevent such errors.
ILG combines tightening system with position and process monitoring
An ILG system consists of ILG software, positioning hardware, a nutrunner controller and, depending on the application, an industrial PC. The principle is as follows: the functions of tightening system, position and process monitoring are combined. What does this mean for the application of ILG in practice? As soon as the operator starts work on a tightening operation, the system monitors the precise position of the tool and compares it with the required tightening position. The tool or tools are installed on torque arms. Among other functions, these arms absorb reactive forces during the assembly of high-torque joints which expose the worker to considerable forces – this is a typical application of ILG.
Sensors identify incorrectly tightened joints
High-precision rotation or linear position sensors detect the actual position of the tool. These form part of the positioning hardware and are integrated in swivels, the linear guide system of a torque arm or similar components. The crucial point is as follows: if the sensors detect that the tool is not in the correct position for a tightening operation, the operator is not complying with the correct sequence or a joint will not be tightened in accordance with the specified program, the system automatically blocks the operation and tightening is not possible.
Operator is guided through the entire tightening process
The operator can follow all the operations via an industrial PC. The intuitive user interface visualizes the process and guides the worker through the entire process in combination with the SQS worker guidance system from Atlas Copco. ILG reduces the induction time required for new operators and ensures that the tightening procedure is completed correctly first time. The traceability of the torque results is also important if an error should occur during later use of the components which have been joined. This considerably facilitates reworking and minimizes the additional work required. One example is the tightening of the valve cover on an engine. Here it is important for the bolts to be tightened in the right order using the right tightening program.
Tool location with ILG offers high flexibility for integration and configuration
Another advantage is the high flexibility of ILG. It can not only be integrated in existing Atlas Copco tightening systems but also combined with other tool systems without any problems. The control platform offers several types of tightening processes including both free and forced process sequences. It can therefore not only be used for fasteners which are to be tightened in a specified sequence but also in applications where tightening may be carried out in any order. In short, tool location guidance with ILG from Atlas Copco ensures a high degree of process security for critical tightening operations and improves both quality and productivity in tightening work.