Atlas Copco Power MACS 4000 Automated Tightening System Performance

The Power MACS 4000 has built-in Reject Management function, which can automatically define subsequent strategies based on tightening results. Whether using basic or advanced strategies, the system can handle non-conforming tightening in the most effective way, avoiding the waste of valuable time and resources. For example, the OK/NOK result can automatically determine whether to allow further tightening, whether manual intervention is required, or automatically initiate remedial steps.

4.2 Data processing capability

The powerful capabilities and sufficient memory of the processor ensure the processing and transmission of large amounts of data for analysis, continuous improvement, and full traceability without affecting the tightening process. The system supports the combined connection with Atlas Copco ToolsNet software to realize the centralized management of the data of the whole production line and maximize the boot rate.

Detailed explanation of hardware architecture and interfaces

5.1 Controller front panel

Indicator lights: ALL OK, OK/NOK, ALARM, E-stop;

Text display screen: displays TC node address, IP address, error message, software version, and loop data;

Button: Switch display information, set IP address, reset emergency stop button (TC-4000-P type).

5.2 Main Controller (TC-P)

Internal redundant E-stop relay: Class 3, upgradable to Class 4;

Digital input/output: 4 inputs, 4 outputs, optically isolated (TC-P only);

Anybus slot: Supports fieldbus cards (TC-P only);

Dual Ethernet ports (TC-P only): only 1 factory IP address is required;

TC communication LAN: isolated from the factory WAN to eliminate multicast interference.

5.3 Secondary Controller (TC-S)

TC-S is a simplified version without fieldbus or Ethernet switch, suitable for slave applications that do not require complex communication. The TC-4000-S-ES is equipped with a 6-port Ethernet switch.

5.4 Main Switch Box (MSB) and Distribution Box (DB)

MSB and DB are used for 400-480VAC 3-phase power distribution, and one MSB can power up to 6 controllers for easy power management. The emergency stop function can be upgraded from Class 3 to Class 4.

5.5 Attachments

Stacked lights: provide continuous workstation feedback;

I/O extender: provides an additional 8 digital inputs/outputs;

Indicator box: direct operation feedback, with buttons and integrated lights, supporting manual selection of programs through selection switches;

Com Node 2 touch screen: used for program selection, configuration input, viewing loop data, and tightening curves;

I/O bus cable: available in various lengths ranging from 0.5m to 15m.

Service Ecology - From Calibration to Comprehensive Maintenance

Atlas Copco provides complete life cycle services for the Power MACS 4000:

ToolScan RCM (Reliability Centered Maintenance): Analyze existing maintenance procedures and optimize them based on applications;

Full Coverage Agreement: A customized maintenance plan with fixed costs, covering planned maintenance and non abusive emergency repairs;

Preventive Maintenance Protocol: A standard recommended maintenance plan that can be conducted on-site or at a service center;

Calibration service: Regularly calibrate shaft and torque measuring equipment to ensure optimal performance;

Training: Provide operation and maintenance training at customer sites or training centers;

ToolStart: Fixed price startup service, including programming, trial operation, and operator training.

Customer Case: ZF Friedrichshafen

ZF, a global leader in transmission and chassis technology, has achieved significant results after using the Power MACS 4000

Eliminating the need for torque wrench inspection and reducing cycle time by up to 50%;

The assembly process of a single component saves thousands of euros annually;

Process engineer Thomas Weissenrieder commented, 'The assembly of this component is faster and safer than ever before. The Power MACS 4000 is the first system to meet our quality requirements.'. ”

Quick reference for selection

Component model/description Order number

Main controller (without fieldbus) TC-4000-P-ES 8435 6511 00

Main controller (ProfiNet) TC-4000-P-PN-ES 8435 6511 50

Secondary controller (without switch) TC-4000-S 8435 6500 00

Secondary Controller (with Switch) TC-4000-S-ES 8435 6501 00

Main switch box (up to 6 channels) MSB 8435 5660 00

Distribution box DB 8435 6560 50

Com Node 2 Touchscreen -8433 2711 10

I/O Expander -8433 0564 45