Atlas Copco Tensor ES electric tightening tool paired with Power Focus 600 controller

Product Overview

Tensor ES tool+Power Focus 600 controller is a set of error proof electric tightening solutions for quality critical assembly.

Accuracy of torque sensor: ± 7.5% under 6 σ conditions;

Replacing pneumatic tools can reduce energy consumption by up to 85%; Cooperate with TurboTight strategy to save 10% of energy consumption for motors;

Advantage dimensions: quality, environmental protection, ergonomics, production efficiency, usability;

Design features: Modular adhesive free welding, all screws assembled for easy disassembly, maintenance, and recycling; Compliant with RoHS II, REACH, and WEEE; The enterprise system has passed the triple certification of ISO9001, ISO14001, and OHSAS18001.

Hardware Features of Power Focus 600 Controller

High definition color display screen, displaying tightening results and operation instructions; Keypad, one click return to home page and results page;

Optional accessories can achieve IP54 protection, resisting oil, dust, and water;

Heat dissipation vent, suitable for high-intensity continuous operation;

Rich IO: configurable input and output, compatible with PLC, remote start; Support stack lights, operation panel, and socket selector I/O bus for assembly error prevention;

Communication interface: High speed USB (external printer, barcode scanner, local upgrade/export data); DHCP Ethernet, web remote access configuration controller.

Characteristics of Tensor ES Tool Ontology

Torque sensor with an accuracy of 6 σ ± 7.5%; Body LED visual feedback tightening OK/NOK;

There are two types of triggers: lever start and press start;

Precision cast aluminum shell, strong rigidity and good heat dissipation performance; Durable specialized tool cables;

Efficient motor, aluminum bearing seat, lightweight, good heat dissipation;

Ergonomic anti slip rubber handle reduces operator fatigue.

II TurboTight ®  Revolutionary Tightening Strategy

TurboTight is the core tightening algorithm of this system.

Principle: The tool itself absorbs most of the reaction force and transmits significantly less reaction force to the operator’s hands;

benefit

Shorten the pace, improve production line throughput, eliminate workstation bottlenecks, and balance the production line;

Reduce reaction force, minimize operator fatigue and work-related injury risks, and enhance comfort;

Easy to set up, most scenarios only require setting the target torque for direct use, reducing setup time and training costs.

Note: IAM Joint Control does not support TurboTight, and IAM Station Control must be selected for this feature.

IAM (Intelligent Application Module)

IAM is a portable intelligent module that stores software, tightening configurations, tightening results, and event logs for easy backup and upgrade. It is divided into two versions: IAM Joint Control and IAM Station Control.

Comparison of functionalities between two versions of IAM

Function IAM Joint Control IAM Station Control

Psets tightening program quantity 1 16

Batch sequence 1 16

Lock on reject support

TurboTight strategy is not supported

Tightening strategy: torque control, torque+angle monitoring, two-step/three-step/Quick Step, forward and reverse rotation, heavy hit detection, self tapping screw support

Tightening result storage (torque, status, fault cause) 30 records 1000 records

Torque time curve and event log support (1000 logs)

Web page configuration support

Ethernet remote read-write configuration is not supported

USB export tightening data support

Ethernet remote export of tightening data is not supported

USB upgrade controller firmware support

Ethernet remote firmware upgrade is not supported

1D/2D barcode scanner is not supported

Remote start, configurable IO, stack light, socket selector, operation panel support

Software upgrade mechanism: Dual software partitioning allows for downloading new versions to IAM, activating new versions, retaining old versions, and facilitating secure downgrade rollback. Simultaneously supports direct access to the controller through the Web HMI web browser, without the need for additional client software installation.

4 real customer application cases

Case 1: Wuxi Lihu LIHU (Production of Compressor Shell and Turbocharger)

Pain point: Daily production of 600 units, each unit is tightened 3 times; The problem of loose bolt clamping; The controller needs to display and store the tightening results.

Solution: 4 sets of PF600+Tensor-ES ETD ES61-30-10-T25, IAM Station Control, calibration and maintenance service package.

Benefit: Significant improvement in clamping relaxation issues; Reduce rework from a large quantity to 0-6 units per day; Production capacity increased by 8%; Dual feedback of tool LED and controller reduces dependence on operator experience.

Operator evaluation: One tool can achieve multiple tasks, and low vibration and low noise are the biggest advantages.

Case 2: Nanjing Skyworth (complete washing machine)

Pain point: Short rhythm requires high tightening speed; Key connection point torque accuracy; Improve the operator experience.

Plan: 4 sets of PF600; Three ETV ES61-25-10 and one ETV ES61-70-13, with TurboTight enabled.

Benefit: shortened tempo; The reaction force is significantly reduced under high torque conditions; High operator satisfaction.

Operator evaluation: Low vibration and noise, operating instructions exceed expectations.

Case 3: Czech Alco Controls (Emerson, air conditioning refrigeration expansion valve)

Pain point: Replace multiple pneumatic tools; Shorten assembly time; Reduce human errors; Simple configuration, capable of storing tightening data.

Solution: Two sets of PF600+ETD ES61-18-10, paired with two SML T-50 reaction arms.

Benefit: Replace multiple pneumatic tools with a single set of PF600/ES; Increase daily production from 50 units to 90 units (+80% capacity); Tool LED+screen guidance reduces human dependence; No external software is required, it can be configured on the webpage, and dual partition upgrades are convenient.

Case 4: Mexican BRP (leisure vehicles, engines)

Pain point: Old LTV tool overheating during continuous operation; Critical safety connection points require zero rework.

Plan: 3 sets of PF600+ETV ES61-25-10, IAM Station Control.

Revenue: 1 set of PF600 replaces 3 sets of old LTVs; Rework 15-20 units per day → 0 rework; Noise and reaction force improvement, ergonomic enhancement, and balanced production capacity and pneumatic tools.

Supporting accessories (error prevention solution)

Equalizer&Torque Reaction Arm: Offset the weight of the tool, absorb tightening reaction force, protect the operator, and ensure tightening accuracy.

Assemble error prevention accessories

Sleeve/batch head selector: automatically calls the corresponding tightening program based on the selected sleeve to prevent mixed and incorrect tightening;

Stacklight alarm light: sound and light prompts OK/NOK status;

I/O extender, advanced/basic operation panel.

Accessory ordering number

Stack light ESL-04 standard 8433 0570 13

4-digit selector Selector4 8433 0610 04

8-bit selector Selector8 8433 0610 08

Open I/O expansion module 8433 0564 39

Sealed I/O expansion module 8433 0564 45

Advanced operation panel 8433 0565 00

Basic Remote Startup Operation Panel 8433 0565 10

Hardware ordering number and tool selection

Controller&IAM ordering

Material ordering number

Power Focus 600 (with remote start) 8436 3700 01

IAM Joint Control 8436 0900 01

IAM Station Control 8436 0900 05

Tensor ES Tool Series

Divided into four major tool forms:

ETV ES elbow angle type: ETV ES21 low torque, ETV ES61 medium high torque; Some models support quick change clamps and ball retention. The torque range is 2.8Nm to 200Nm.

ETD ES straight handle type: ETD ES21 low torque, ETD ES61 medium high torque; T25 represents support for reaction block interface. Torque 0.8-180Nm, including lever start version.

ETF ES fixed installation type: equipment integrated fixed tightening shaft.

ETP ES pistol grip: pistol type, suitable for handheld use, with a low torque range of 0.8-12Nm.

The parameter table includes: square drive specifications, torque (Nm/ft lb), no-load speed (r/min), weight (kg/lb), total length, CS distance, and order number.

Tool extension cable

Optional 3m/5m/10m/15m/25m, unified order number prefix 4220 4393 XX.