Atlas Copco ACTA 4000 Torque Analyzer Operation and Calibration Guide

6.2 Automatic Calibration (Fixture Application)

For fixed axis tools controlled by Power Focus or PowerMACS, ACTA can automatically control the tightening process through RS232 or Ethernet:

Complete synchronization settings, select target Pset and batch size

Enter Conf → Communication → Start Batch, ACTA automatically executes multi-stage measurements

After calibration is completed, adjust the tool coefficients in the same way as manual calibration

6.3 Sensor Calibration (Dead Weight Method)

ACTA supports the use of weights and force arms for sensor calibration:

Place the sensor in the dead weight device and connect it to ACTA

Enter Conf → Calibration → Deadweight

Record the mV/V output values of unloaded and loaded with known torque in sequence (at least 3 times)

Perform linearity check (at least 2 times)

ACTA calculates new calibration values. If using Atlas Copco sensors with storage chips, the new values can be directly written into the sensor memory

Print calibration report and mark the new calibration date on the sensor

Attention: ACTA body calibration needs to be conducted in a certified laboratory, and it is recommended to do it once a year.

Curve analysis and data output

7.1 Curve Display and Scaling (AA Version)

Select View → Trace to enter the curve analysis mode, which displays:

Torque over angle curve

Torque over time curve

Angle over time curve

Torque&angle over time curve

By using A. lyse → Zoom in, you can zoom in up to 5 times continuously to observe the curve features of specific areas in detail. Adjust position allows for manual adjustment of the measurement point position (marked as manual input after adjustment). Save trace can save curves in low/medium/high resolution to the database.

7.2 Printing and Data Export

The printing of ACTA 4000 is implemented through ACTA 4000 Printer Service software (installed on PC), supporting report types:

Continuous: Print the tightening results continuously each time

Rundown: Print all tightening records of the selected tool

Tool Setup: Print the complete parameter configuration of the current tool

Tool Statistics: A statistical report of printing tools

Tool calibration: Print calibration report

ISO 5393: Printing ISO 5393 Performance Test Reports

Trace: Only ACTA 3000 supports direct printing of curves; ACTA 4000 needs to be printed through ToolsTalk QAT

The data can be transmitted to ToolsTalk QAT software via USB/RS232/Ethernet, achieving unified management of the tool database, measurement database, and supplier database, and can be accompanied by maintenance instructions and service records.

Principles and Applications of Statistical Process Control (SPC)

The built-in statistical function of ACTA is based on normal distribution and control chart theory, helping engineers monitor process stability in real time.

8.1 Core statistical parameters

X-bar: subgroup mean

R: Subgroup range (maximum minimum)

σ (standard deviation): measures the degree of data dispersion

CM (Equipment Capability Index)=Tolerance Zone/6 σ, typically required to be ≥ 1.33

CMK (Modified Equipment Capability Index)=min [(upper limit mean)/3 σ, (mean lower limit)/3 σ], typically ≥ 1.33

CAM: Improved Capability Index, based on subgroup range calculation

8.2 Control Chart (X-bar&R)

ACTA can generate X-bar control charts (monitoring process levels) and R control charts (monitoring process variations). The control limit (UCL/LCL) is calculated based on historical data:

UCL_X = X-bar-bar + A₂ × R-bar

LCL_X = X-bar-bar - A₂ × R-bar

UCL_R = D₄ × R-bar

LCL_R = D₃ × R-bar

The coefficients A ₂, D ∝, and D ₄ depend on the size of the subgroup (obtained from the table). When 7 consecutive points are on the same side or exceed the control limit, a statistical alarm is triggered, indicating possible tool wear or material changes.

Torque Supervisor Integration (ACTA 4000)

ACTA 4000 supports cooperation with Torque Supervisor software to execute preset testing routes:

Create a test route in Torque Supervisor and transfer it to ACTA 4000

Set communication parameters: Conf → Interface → Communication → TTQAT, select RS232/USB/Ethernet, client port 7502, server port 7503

Execute each test item in the route and switch through Datab → Select tool

Torque Supervisor automatically retrieves test results

Note: Importing the Torque Supervisor route will clear all existing tightening programs from ACTA memory, so be sure to back them up in advance.

Common troubleshooting

Possible causes and measures for handling the phenomenon

When starting up, the Microtorque sensor reported an error and initialization abnormality. The sensor was disconnected and reconnected

The sensor calibration values cannot be written to non Atlas Copco storage sensors, and new values cannot be manually recorded and automatically written to memory

Check the baud rate and protocol (RS232/Ethernet) for communication settings errors or wiring issues without a controller in synchronous mode, and ensure that Flow control is set to Hardware

Frequent occurrence of statistical alarms, insufficient process capability or tool wear inspection of CM/CMK values. If it is lower than the requirements, the tool or process needs to be adjusted