Atlas Copco PowerMACS 4000 Tightening Control System

The PowerMACS 4000 (TC2) fully automatic tightening system sample data is a multi axis fixed tightening shaft control system for automated production lines such as automobiles. It consists of a TC-4000 controller, QST series tightening shafts, cables and accessories, and ToolTalk software. It focuses on high-precision, high-speed, modular multi axis expansion. Different from the previous Power Focus600 handheld tightening system, this system is used for fixing nut runners at automated workstations.

System Overview and Core Advantages

PowerMACS 4000 is a new generation of upgradable automated tightening controller designed for lean production automation assembly.

QST tightening shaft performance: Compared to the old QMX tightening shaft, the maximum speed has been increased by 67%, maintaining high precision of ± 2.5%; Preventive maintenance cycle>1 million cycles, reducing downtime and maintenance costs.

DynaTork ™ Patent torque recovery strategy: Optimize bolt clamping force and improve residual preload force.

Intelligent Chip: Integrated inside the QST tightening shaft, storing shaft body parameters and calibration parameters to achieve error free configuration; Support digital communication, cables can be used for longer distances.

Modular plug and play: no need for control cabinet, saving space; Standardize components to reduce spare parts costs.

Programming software ToolTalk PowerMACS: Menu based simple programming, supports drag and drop editing; Basic/Advanced modes, only display required functions.

Multi axis expansion capability: A single system can support up to 18 tightening axes; The main controller TC-P is paired with the slave controller TC-S to achieve multi axis expansion.

QST Nutrunner tightening shaft product series

The QST tightening shaft is available in various structural versions, covering a torque range of 2-1750 Nm.

Version classification

CT/COT: Single torque sensor; CT straight out type; COT bias offset output.

CTT/COTT: Dual torque sensor redundancy, two torque readings are mutually verified to enhance safety level.

CATT: Dual torque+dual angle encoder dual feedback, simultaneously verifying torque and angle, high safety critical connection.

CTV: Bend angle head version, suitable for narrow installation spaces, some models come with spring compensation stroke.

Spring travel options: Standard 50   mm; optional 76   mm, 100   mm long spring compensation travel, used to absorb assembly tolerances.

Model Naming Rules (e.g. QST50-150CATT-T50-L134-H13)

QST: Product series; 50 motor specifications; 150 maximum torque;

CATT: dual torque+dual angle feedback; T50 represents 50mm spring stroke; L134 structural length; Specification of H13 socket seat.

The manual provides complete parameters for each model, including stroke, torque range, speed, minimum center distance, weight, gear ratio, sleeve seat size, key external dimensions, and order number. The torque range covers from a small torque of 2-8Nm to a large torque of 350-1750Nm.

Hardware features of QST tightening shaft

Built in electronic chip stores serial numbers, calibration, and maintenance intervals;

Hot Swap quick plug cable connector, power off can be plugged in and out; Bidirectional foolproof joint;

Inertial braking, preventing overshoot when tightened to stop;

The new generation of motors has significantly increased their rotational speed;

Sandwich style installation base, flexible installation layout.

Controller hardware TC-4000

Divided into primary controller TC-P and secondary controller TC-S

TC-P main controller

Supports multiple industrial fieldbuses, with order numbers distinguishing between bus types:

TC-4000-P-ES: No fieldbus

TC‑4000‑P‑PB‑ES：Profibus

TC‑4000‑P‑DN‑ES：DeviceNet

TC‑4000‑P‑EIP‑ES：EtherNet/IP

TC‑4000‑P‑MTCP‑ES：Modbus TCP

TC‑4000‑P‑PN‑ES：Profinet

TC‑4000‑P‑CC‑ES：CC‑Link

TC-S from Controller TC-4000-S

Without fieldbus and built-in Ethernet switch, used for expanding the number of axes.

Supporting system components

MSB Main Switch Box: Maximum drive for 6 axes, system main power input, with overall emergency stop. Order number 8435 5660 00.

DB distribution box: up to 6 axes, power and signal distribution. Order number 8435 6560 50.

Backplane: There are two options: one with a 6-port Ethernet switch backplane and one without a switch backplane.

Full range selection of cables

Tighten the communication cable of the shaft motor (single cable integrated power supply+digital communication bus) with a 12mm thin cable, durable and flexible; Support long-distance travel; Equipped with positioning markers for easy blind insertion. Length 2~40m, corresponding to the complete order number.

Power cable between MSB and TC: 0.5-15m in multiple specifications

Emergency stop E-Stop cable, terminal resistor

I/O bus cable: 0.5-25m, used for stack lights, operation panels, and I/O expansion modules.

System complete cable kit: The manual provides a complete system selection table for 1-18 axes, and the order number for the complete kit can be directly selected based on the number of tightened axes.

Software and peripheral accessories

ToolTalk PowerMACS Release 10 software

Authorization rating: 1 user/5 users/10 users/factory full license; Support English, German, and French.

Function: Drag and drop programming, Quick set variables for quick fine-tuning of processes; Support viewing tightening curves and cyclic data.

External supporting accessories

MiniDisplay 2 small local display screen;

Stacklight;

Indicator box;

HLTQ series touch screen (HLT15Q/HLT19Q, including WiFi version), can be used as a local workstation operation terminal;

I/O extender; Advanced/Basic Operation Panel;

The I/O accessory bus interface is compatible with the Power Focus600 accessory.

Customer Case: ZF AG, Germany

ZF is used for the assembly line of transmission chassis components:

After using PowerMACS4000, there is no longer a need for post torque wrench re inspection, and the cycle time can be shortened by up to 50%; Single assembly stations save thousands of euros in costs annually.

Customer review: Faster assembly, improved safety, and reduced risk of human error.

Complete service package

ToolScan RCM focuses on reliability centered maintenance: analyzing production line conditions, optimizing maintenance plans, and evaluating production line losses caused by failures.

Full Coverage Agreement: Fixed annual fee all inclusive, including unplanned repairs not caused by misoperation.

Preventive Maintenance Agreement: Regular on-site/factory preventive maintenance.

Calibration service: Torque calibration recognized by ISO system.

Training services: on-site or central training courses.

ToolStart startup service: engineer on-site installation, programming and debugging, trial production, operator training.