2 TCS.2000 Controller

Instruction Manual

1 Safety instructions 6 1.1 Declaration 6 1.2 General instructions 6

2 Preface 7 2.1 TCS.2000 7 2.2 Controller 7 2.3 Communication 7 2.4 Tools 7

3 Specifications 8 3.1 Scope of delivery 8 3.2 Dimensions 8 3.3 Characteristics 8 3.4 Panel 9 3.5 Backplane 9

4 Initial power-on 10 4.1 Installation 10 4.1.1 "Stop" signal jumper wire 10 4.1.2 Wall mounting 10 4.1.3 Connecting tool cable 11 4.1.4 Connecting 250 VAC cable 11 4.1.5 Power-on 12 4.1.6 Power-off status 12 4.2 Startup 12 4.3 TCS 2000 controller interface operation 13 4.4 Interface language & time setting 13

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5 Monitoring 14 5.1 Monitoring (status bar) 14 5.1.1 Login 14 5.1.2 Clicking "Fault History" 15 5.1.3 Fault reset prompt 15 5.2 Monitoring (status display area) 16 5.3 Monitoring (information display area) 16 5.4 Monitoring (curve monitoring area) 17

7 Pset management 19 7.1 Pset settings 19 7.2 JOB settings 20 7.3 MAP settings 21

8 Process editing 22 8.1 Expert mode 22 8.1.1 Search sequence 23 8.1.2 Run-down 24 8.1.3 Tightening 25 8.1.4 Waiting 26 8.1.5 Socket release 27 8.1.6 Output 27 8.1.7 Seating detection 28 8.2 Fast mode 28

9 Settings 29 9.1 Basic 29 9.2 Control 30 9.3 Communication settiing 31 9.3.1 IO 31 9.3.2 Field bus 32 9.3.3 Network settings 33 9.3.4 COM 33 9.3.5 Barcode rules 34 9.4 User management 35 9.4.1 User 35 9.4.2 User group 35

10 Debugging 36 10.1 Basic 36 10.2 IO 36 10.3 Fieldbus 37 10.4 Calibration 37

11 Device maintenance 38 11.1 Maint setting 38 11.2 Replacing storage battery 38

12 Tightening strategy instruction 39 12.1 Torque control strategy 39 1 2.2 Angle monitoring strategy for torque mode 39 12.3 Torque monitoring strategy for angle mode 39 12.4 Socket release strategy 39

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1 Operation instructions of I/O Interface and expansion I/O module 41 1.1 Description of controller I/O 41 1.2 Expansion I/O 45

2 Bus configuration and operation instruction 47 2.1 Function overview 47 2.2 Description of parameters 47

3 Description of OP protocol 51 3.1 Supported functions 51 3.2 OP protocol instructions 52

4 WebAPI operation instructions and sample code 56 4.1 Tightening result uploading parameter setting 56 4.2 Uploading tightening results to data server 57 4.3 Querying tightening results 60 4.4 Querying tightening result details 61 4.5 Setting barcode 62 4.6 Setting Pest 63

5 Description of serial port printing formats 65

6 MAP function operation instructions 66 6.1 Function overview 66 6.2 Description of parameters 66

7 JOB function description 70 7.1 Function overview 70 7.2 Description of parameters 70

8 Common fault codes 72 8.1 Application faults 72 8.2 Controller faults 74 8.3 Drive faults 75 8.4 Tool faults 77

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1.1 Declaration

This product should be applied to drive and monitor EHS/EHA/EFS NRS/NRA series tools only. It is not allowed to be used for other purposes. It can be used for special purposes only. Electromagnetic compatibility (EMC) limitations: limited to industrial applications. In the working environment where the tightening tool controller is used, there may be various factors that affect the results of the tightening process. To ensure product quality and safety, users must comply with relevant standards and/or regulations, and when situations that may affect the tightening results occur, they should promptly check the installed torque and the direction of rotation. For the situations that may affect the tightening results, the following situations require special attention (including but not limited to): ▪ The first installation of the tool system; ▪ Replacement of component batches, bolts, screw batches, or tools; ▪ Changes in software, configuration, or environmental conditions; ▪ Adjustment of the ventilation system or electrical connections; ▪ Changes in ergonomic characteristics, processes, quality procedures, or operation methods; ▪ Change of the operator; ▪ Any other changes that may affect the results of the tightening process. Inspection requirements 1. Verification of the joint condition: Ensure that the above-mentioned changes have not led to any non-compliant changes in the condition of the joint. 2. Inspection after maintenance: Conduct a comprehensive inspection after the initial installation, maintenance, or repair of the equipment. 3. Regular Inspection: Conduct an inspection at least once after each shift change, or set a reasonable inspection frequency according to the actual requirements.

1.2 General Instructions

All individuals who use, install, repair, or maintain this tool, as well as those who replace its accessories or operate in its vicinity, must read and comprehend the safety instructions prior to undertaking any of the aforementioned tasks to minimize the risk of personal injury. Failure to follow these instructions may lead to electric shock, fire, and severe personal injury.

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TCS.2000 and TCS.2000A both belong to the TCS.2000 series and are compatible with the functions outlined in the manual. However, TCS.2000 is designed for screwdriver products with a torque capacity of up to 22 Nm, whereas TCS.2000B is intended for use with nutrunner and spindle products. The controller automatically controls the electric tightening system by measuring the tool power consumption and monitoring the tool angle. It features a built-in high-precision torque/angle sensor for accurate monitoring of tightening torque and angle. Electric tools are categorized into two series: handheld (EHS/EHA/NRS/NRA) and fixed (EFS).

TCS.2000 Series Tool Adaptation Relationship Table

Controller models

Applicable tightening tools

Electric screwdriver EHS.003 EHS.008 EHS.015 EHA.003 EHA.012 EHA.022

TCS.2000

TSC.2000A Electric wrench and spindle (excluding electric screwdriver)

2.2 Controller

The TCS 2000 series supports up to 200 tightening job cycles. It drives both low and high torque tools, including EHS, EHA, and EFS.

2.3 Communication

The TCS 2000 controller is equipped with the following communication devices:

▪One Ethernet interface for communication with PC devices;

▪Two RS232 serial ports, of which COM 1 is used for manufacturers maintenance and COM 2 is used for connecting bar code scanner; ▪Eight logical input ports and eight logical output ports.

▪Optional field bus module.

2.4 Tools

Every tool is equipped with a controller. Once connected to the tool, the controller automatically recognizes the tool and sets all characteristic parameters. The selection of tools should be based on the operating conditions specified by the users and within the operational limits set forth by the manufacturer at that time. The controller is designed to quickly detect when the tool motor's internal temperature exceeds 120° C and will subsequently shut down the tool. The tool may only be restarted after it has cooled to below 80° C.

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3.1 Scope of delivery

① TCS.2000 series controller ② Operation Manual of TCS.2000 series controller ③ I/O connector

3.2 Dimensions 3.3 Characteristics

▪Weight: 6 kg

▪IP rating: IP40

▪Operating temperature: 0/+45° C

▪Voltage: single-phase 180-250 VAC

▪Frequency: 50 Hz

▪Output power: 1000 W

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3.4 Panel

3.5 Backplane

COM

① USB interface ② CAN ③ COM 1: manufacturers maintenance ④ COM 2: bar code scanner ⑤ I/O: connector of 8 input/output terminals, used for connecting PLC, indicator box or extension socket, including "Stop" signal jumper wire ⑥ OP protocol, network interface ⑦ Field bus module: Ether CAT, Profinet, Ethernet/IP, Modbus TCP ⑧ Tool interface ⑨ Switch, overcurrent protector, earth fault protector ⑩ Main power interface

NC

STOP

COM

OVE

OVE

+24V

+24V

GND

GND

INPUT OUTPUT

115Vrms

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4.1 Installation

Before turning on the controller, make sure it has been installed according to the installation and safety instructions in this manual, as detailed in the "Safety instructions" section in Chapter 1.

4.1.1 "Stop" signal jumper wire

Check that the "Stop" signal jumper wire is correctly connected to the input connector of the controller. The "Stop" signal jumper wire may be connected to the PLC or the button near the tightening workstation. If it is not connected, verify that it is installed correctly.

4.1.2 Wall mounting

6.5

100 ==

292.75 7.25

All dimensions are in millimeters (mm)

Ensure the mounting plate is compatible with both the bracket and the device.

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4.1.3 Connecting tool cable

D

d D>10x d

Although the cable of this tool is designed to adapt to harsh operating conditions, we still recommend that you perform the following inspections to ensure a longer cable life:

▪ Avoid direct tension on the cable.

▪ Minimize friction on the outer sheath.

▪ The bending radius of the cable should not be less than 10 times the cable diameter.

4.1.4 Connecting 250 VAC cable

220 VAC

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4.1.5 Power-on 4.1.6 Power-off status

open

250 VAC

close

4.2 Startup

Upon power-on, the controller automatically performs a self-test and verifies the tool's proper functioning.

① Green flashing status: the controller is operating normally. Otherwise, the controller is malfunctioning. ② Click on the avatar to switch accounts. The default username is "guest", while the administrator account is named "admin".

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4.3 TCS 2000 controller interface operation

The TCS.2000 controller interface is designed with six sections: monitoring, recording, process management (including process management and process editing), setting, and debugging, which can be navigated through the menu bar.

① Menu bar - Monitoring ② Menu bar - Record ③ Menu bar - Pset management ④ Menu bar - Pset Editing ⑤ Menu bar - Setting ⑥ Menu bar - Maintenance

4.4 Interface language & time setting

Menu bar - Setting:

① Language setting ② Date & time setting

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Menu bar - Monitoring: Monitor the ongoing tightening process, and display real-time results and curves

① Login, logout, switch account, change password

② Machine running status display

③ Time & date display

④ Running status bar: including Ready, Running,Pset

OK, Pset NOK, and Fault Reset

⑤ Batch No.: the Pest run count, which is reset to zero

each time the power is turned on

⑥ Tightening ID: recorded tool run count, which

increases by one each time the pest starts

⑦ Bar code SN

⑧ Value range: the torque and angle value ranges

configured for OK pest during pset management

⑨ Process step differentiation identifier

⑩ Curve view switching

⑪ Curve auto range: coordinate adaptive

5.1 Monitoring (status bar)

5.1.1 Login

Login:

① Enter the default account name; the

username and password are both

"admin"

② The avatar outline turns green,

indicating successful login

③ Click on the avatar to switch user

accounts, log out and change password

④ Switch Accounts interface

⑤ Logout interface

⑥ Change Password interface

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5.1.2 Clicking "Error logs"

① Click the "Error logs" icon: to display

the fault history interface

② View and clear error logs

5.1.3 Reset Error

① Reset error:When the screwdriver

"system" delete detects a fault, a error

will appear. Click "Fault Reset" to

clear the error.

② Click "Reset Error" to clear the error

Some error can be cleared. When encountering error that cannot be cleared, you can restart the system.

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5.2 Monitoring (status display area)

① Ready status display (the system is ready and can

be run at any time)

② OK status display (indicating that the ongoing

process is OK, meeting the angle and torque

settings in the process setting)

③ NOK status display (indicating that the ongoing

process is NOK, and including relevant NOK codes

and their explanations)

④ Running status display

⑤ System fault status

⑥ Fault clearing success prompt

5.3 Monitoring (information display area)

① Tightening ID: cumulative tool startup count

② Bar code SN: when using a bar code scanner, the bar code SN will be displayed

③ Batch No.: the batch number of the ongoing process, where the last digit represents the expected number of pset

runs, and the previous digit represents the number of completed pset runs

④ Final angle value

⑤ Final torque value

⑥ Overall angle value: all angles during the process

⑦ Maximum angle value: parameter set in Pset Management - Tightening Step

⑧ Minimum angle value: parameter set in Pset Management - Tightening Step

⑨ Maximum torque value: parameter set in Pset Management - Tightening Step

⑩ Minimum torque value: parameter set in Pset Management - Tightening Step

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5.4 Monitoring (curve monitoring area)

① Curve type switching: view different

tightening curves

② Curve auto range

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Menu bar - Recording: Record the historical tightening results and curves

① Export history: insert a USB flash drive to export data files, including tightening results and curves

② Filter condition display

③ Filter condition setting: filter by time, number, and OK/NOK

④ Refresh: update historical data for sorting by recent time

⑤ Historical curve result display

⑥ Pset description: details of the process from the currently selected history

⑦ Pset curve: details of the process from the currently selected history

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7.1 Pset settings

Pset: a complete tightening strategy; a general manual tightening pset includes run-down and tightening steps, while an auto tightening process includes search sequence, waiting, run-down and tightening steps.

Menu bar - Pset Management: Create, activate, edit, and delete processes

① Pset management

② Create Pset: directly proceed to add pset step

③ Pset file: including pset number and pset name

④ Activate Pset: a new or selected pset needs to be activated before running

⑤ Edit Pset: edit pset to add pset step

⑥ Delete pset

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7.2 JOB settings

JOB settings: a pset strategy for continuous, automatic tightening formed by adding configured Pset in parallel or series

Menu bar - Pset management:

① JOB settings

② Create JOB

③ Activate JOB

④ Edit JOB

⑤ Delete JOB

① Add Pset in series: pset will be implemented in the

order they are added

② Add Pset in parallel: Pset may be selected for

prioritized implementation at runtime

③ Delete Pset

④ JOB editing configuration

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7.3 MAP settings

MAP: multi assembly Pset. The setup files in a multi-spindle process. When the tool is set as the master spindle, the pset previously established in single-spindle mode will be transitioned to a multi-spindle process, and a new map can also be created synchronously.

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Pset editing features both an expert mode and a fast mode. The expert mode features a configuration of seven process steps: alignment, fast spin-down, tightening, socket release, waiting, output, and seating test. This mode is advised for operations that demand more stringent process standards. The fast mode features a simple process setting to achieve tightening effect.

8.1 Expert mode

Menu bar -Pset Editing:

Advanced settings for Pset:

① Current process number

① Angle display range on the curve

② Add Pset step: add the steps required for

② Sampling frequency of points on the curve

tightening strategy

③ Number of sampled points on the curve

③ Pset name: editable

④ Ergonomic enable switch: ergonomics: a smooth

④ Enter Advanced Settings for Pset

feel when releasing after tightening

⑤ Ergonomic release time setting

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8.1.1 Search sequence

When Search sequence is necessary in the pset, this pset step will be implemented prior to tightening. This tightening strategy is generally applied in auto tightening to connect the bit or socket to the screw.

Menu bar - Pset Editing: Search sequence step

① Search sequence parameter setting

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8.1.2 Run-down

The rapid downward rotation function is a process that can enhance the efficiency of tightening operations. When the screw enters the threaded hole, the tool quickly completes the long-stroke screwing action at a relatively high speed (usually the no-load speed), enabling the screw to rapidly reach the per-tightening torque point. Subsequently, it can switch to a low-speed, high-precision tightening mode. This function can achieve the goal of ensuring the final tightening quality. The rapid downward rotation function of the Leetx TCS.2000 series supports the angle mode and the torque mode. In the torque mode, the torque is the control target, and the angle is used for monitoring and limitation. In the angle mode, the angle is the control target, and the torque is used for monitoring and limitation. In either the torque or the angle mode, the condition for determination is based on which of torque or angle is reached first. Simultaneously, it also offers the following advanced function settings: self-adjusting speed, flexible step-by-step combination and jump, and diversified data monitoring.

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Menu bar - Pset Editing: Run-down step

Basic settings:

①Speed: The target operating speed of the tool ②Acceleration time: The time it takes for the tool to accelerate to the set rotation speed. ③Target T:

Advanced settings:

④Max time (executable time for each process step) ⑤Delay after step (delay time after the completion of the current process step) ⑥Limit Exceed Jump (implementation of the process step when the safety torque is reached: proceed with this process step, stop, or proceed to another process step) ⑦Reset angle (reset the angle prior to this process step) ⑧Self regulation (auto speed reduction after reaching the torque adjustment threshold) ⑨Speed Control ratio: When setting auto adjustment, it refers to the speed adjustment ratio when rotation begins to decelerate. For example, if the rotation speed is 1000 rpm and the rotation speed adjustment ratio is 0.5, it means that the rotation speed when starting to adjust the speed is 500 rpm. ⑩Self-adjusting Sensitivity (torque value for starting auto adjustment): For example (for target torque of 5 Nm, speed of 360 rpm, self-adjustment sensitivity of 100 (half of the upper limit of 200), speed adjustment ratio of 0.5; when the torque reaches (5 * 100 / 200 = 2.5) Nm, the speed will start to decrease and run at 180 rpm). ⑪T braking ratio: It is the setting for the torque point at which the tool starts to decelerate. For example, if the target torque is 10 Nm and the setting value is 1, the tool will start to brake when it reaches 10 Nm. If the setting value is 0.99, the tool will start to stop when the torque reaches 9.9 Nm.

Menu bar - Pset Editing: Run-down step

Basic settings:

①Speed: The target operating speed of the too ②Acceleration time: The time it takes for the tool to accelerate to the set rotation speed. ③Safety T: The safety torque set for each process step. When the tool reaches this torque value during operation, the tool will stop. ④Threshold: The torque value at which the angle recording begins. ⑤Target A: Advanced settings for the target angle of the process step operation.

Advanced settings:

⑥Max time (executable time for each process step) ⑦Delay after step (delay time after the completion of the current process step) ⑧Limit Exceed Jump (implementation of the process step when the safety torque is reached: proceed with this process step, stop, or proceed to another process step) ⑨Reset angle (reset the angle prior to this process step) ⑩Self regulation (auto speed reduction after reaching the torque adjustment threshold) ⑪Speed Control ratio: The speed adjustment ratio when initiating deceleration in auto adjustment mode. ⑫Self-adjusting sensitivity (the torque value at which auto adjustment starts)

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8.1.3 Tightening

Menu bar - Pset Editing: Tightening step

① Basic settings

② Two modes (torque mode and angle mode)

③ Parameter setting for torque mode

④ Parameter setting for angle mode

Advanced settings:

① Reset angle: reset the angle prior to this pset step

② Reset torque: reset the torque prior to this pset step

③ Delay after step: time elapsed after completion of the current

pset step

④ Limit Exceed Jump: implementation of the pset step when the

safety torque is reached: proceed with this pset step, stop, or

proceed to another pset step

⑤ Action on NOK: implementation of the pset step when the

current pset step is NOK: proceed with this pset step, stop, or

proceed to another pset step

⑥ Self regulation: auto speed reduction after reaching the torque

adjustment threshold

⑦ Speed control ratio: ratio of speed reduction

⑧ T adjustment threshold: the torque value that triggers auto

adjustment

⑨ T braking ratio: start of speed reduction and braking after

reaching the set ratio of the target torque

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8.1.4 Waiting

The waiting configuration includes waiting time and waiting signal. Waiting time refers to the delay of the tool before working. Waiting signal refers to the mechanism by which a tool pauses its operation, awaiting a signal to resume work. This is typically a sync signal used for simultaneous operation of multiple tightening tools.

Menu bar - Pset Editing:

① Waiting time

② Multi-spindle synchronization

③ I/O signal synchronization

• Waiting signal source (high/low level)

• Max time (leaving this blank indicates no

timeout limit)

Advanced settings:

① Delay after step: time elapsed after completion of

the current process step

② Limit Exceed Jump: implementation of the pset

step when the safety torque is reached: proceed

with this pset step, stop, or proceed to another

pset step

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8.1.5 Socket release

A socket is used to tighten screws. After the tightening process, a reaction force is generated. To release the socket, a socket release step is added to turn the screw in the reverse direction.

Menu bar - Pset Editing:

① Socket release step

② Basic settings

③ Socket release parameter setting

④ Advanced settings

8.1.6 Output

A signal is output, configurable to I/O or bus.

Menu bar - Pset Editing:

① Output step

② Output parameter setting

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8.1.7 Seating detection

This feature tests the slope of the torque curve when the screw just fits the workpiece during tightening.

Menu bar - Pset Editing:

① Seating detection

② Basic settings

③ Seating detection parameter setting

④ Advanced settings

8.2 Simple mode

Menu bar - Pset Editing:

① Current pset number

② Max time setting

③ Pset name (editable)

④ Pset parameter setting

⑤ Save current pset

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9.1 Basic

Menu bar - Setting:

① Basic: basic settings and display of tool details and software version information.

② Basic settings include the units of time, language, torque, etc.

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9.2 Control

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Menu bar - Setting:

① Control: Configure the operation of the tool (including setting the enable source, the pset selection source, etc.)

② Enable source :The method to enable the tool to be logically allowed to enter the working state and accept the

start signal (options: Default Enable, I/O, Field Bus, OP Protocol, Web Api)

③ Pset selection source : Select Pset Method (options: Touch Screen, I/O, Field Bus, OP Protocol, Bar Code, Web Api)

④ Tool start source : The method to make the tool actually start running (options: Touch Screen, I/O, Field Bus,

Trigger, Push Start).

⑤ Barcode source: The method of barcode input (options: Disable, Field Bus, OP Protocol, Web Api, Bar Code Scanner).

⑥ JOB source : the method of job initiation (options: Touch Screen, I/O, Field Bus, OP Protocol, Bar Code, Web Api).

⑦ Fault reset: The method to reset the tool when the fault occurs (options: I/O, Field Bus)

⑧ Result confirmation source : Method for confirming pset qualification. Determines the next step based on pset

result compliance (options: I/O, Field Bus)

⑨ Max time (temporary result signal disappearance time)

⑩ Mode (Single-spindle, M-S: Master, Multi-spindle - Slave)

⑪ Synchronize the slave spindle process when Multi-spindle - Master mode is selected

⑫ Temperature protection: Set the motor protection temperature to a maximum of 120℃ and a minimum of 80℃

⑬ NG Lock: After turning on, run the result NOK, the tool will be automatically locked, you need to manually perform

the unlocking operation, and the unlocking operation is in the maintenance - NG unlock

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9.3 Communication settiing

9.3.1 IO

Menu bar - Setting:

① Communication settiing

② Communication settiing - I/O (see the Appendix on page 36 for details)

③ I/O - Input configuration setting

④ I/O - Output configuration setting

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9.3.2 Field bus

Menu bar - Setting:

⑥ Add input bus

① Communication setting

⑦ Add output bus

② Communication setting - Field bus

⑧ Input bus editing

③ Basic information settings of field bus

⑨ Output bus editing

④ Input bus

⑤ Output bus

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9.3.3 Network settings

Menu bar - Setting:

① Communication setting

② Communication setting - Network settings (set the IP address and port number for software upgrade of the tool

and communications such as OP, WebAPI)

9.3.4 Serial port

Menu bar - Setting:

① Communication setting

② Communication setting - COM (see the Appendix for

details)

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9.3.5 Bar code rules

36 TCS.2000 Controller

ule, and click on to enter the barcode rule editing interface.

• Length check: Select whether to enable the length check. If it is not enabled, any length may enter this rule for matching. • S/N code length: The length for length check. For example, for Sn: "Leetx", the length of the S/N code can be set to 5. • Character source: The source from which the barcode SN is obtained. The TCS.2000 series offers multiple options such as fieldbus, OP protocol, barcode scanner, and WebApi. 

▪ Disabled: No source ▪ Fieldbus: The barcode is derived from bus data (needs to be mapped in the bus configuration). ▪ Barcode scanner: The barcode is sourced from a serial port barcode scanner (both USB and RS232 are acceptable. It is necessary to know the end character of the barcode from the scanner. When using RS232, attention should be paid to the serial port baud rate. The specific configuration is made in Settings - Communication Settings - Serial Port - SCANER). ▪ WebApi: The barcode is entered via the WebApi.

• Character verification: After setting the length verification rule and character source in the barcode, further matching is carried out by setting character verification. 

Character verification settings

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◦ Character function

• Save bar: When the rule matching is successful, only save the barcode into the result. • Call Pset: When the rule matching is successful, switch the Pset (in Settings - Control - Process Selection Source, it needs to be set to barcode). • Call Job: When the rule matching is successful, switch the Job (in Settings - Control - Process Chain Selection Source, it needs to be set to barcode).

◦ Bit address: Select one or several positions in the barcode, concatenate them to form a string, which is used to invoke Pset or Job, or just for saving purposes. ◦ Char Direction: Set the matching direction of the composed string. For example, if the string in positions 4, 5, 6 of the sn is "ABC" and "Start from the right" is selected, then the string will be "CBA". ◦ Character && process: Character: The string that needs to be matched. Pest: The corresponding serial number of the Pset or Job. Example:

When the barcode Sn1 is "LeetxPset1" Sn2："LeetxPset2" If Sn1 is entered, the process Pset will be switched to Process No. 1; If Sn2 is entered, the process Pset will be switched to Process No. 2. (in Settings - Control - Pset selection source, it needs to be set to barcode) The same applies to Job (in Settings - Control – JOB source, it needs to be set to barcode).

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• Multi-barcode matching rules

Leetx controllers support multi-barcode multi-rule settings, supporting up to four barcodes, supporting up to 10 rules, and the same barcode source under the same code.

When the barcode source under one of the barcode rules changes, the barcode source under the associated barcode rule is automatically matched. Multiple barcodes: The concept of multiple barcodes comes from the different functions of barcodes, usually corresponding to the call of Pset or JOB; Or just to save barcodes Rules: Rules that represent specific barcode verifications

• Rule matching under multiple barcodes

39 TCS.2000 Controller

9.4 User management

You can set different user permissions for user management.

9.4.1 User

Menu bar - Setting:

① User management: for editing users and user groups

② User: for adding, modifying, editing and deleting users

③ User editing

9.4.2 User group

Menu bar - Setting:

① User management

② User group: for adding,

modifying, editing, and

deleting user groups

③ Edit user group

④ Add user group

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9.4.3 NG 模式

In factory operations, due to strict quality control, when frontline operators encounter nonconformities while tightening workpieces, the quality department needs to step in to determine the NG (nonconforming) causes. This requires the tools to be locked in a certain state, awaiting investigation of the nonconforming reasons. The Leetx TCS.2000 series realizes this application scenario through the management of higher-level permission settings. The NG lock switch button can be turned on in the Settings - Control Interface. Once turned on, if an NG situation occurs during the operation of the tool, the tool will be in a locked state and an account with higher permission needs to be logged in to perform the unlocking operation.

The tool unlocking operation can be set in Maintenance - Basic - NG Unlock. The required permission is the editable permission for maintenance.

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10.1 Basic

Menu bar - Maintenance:

① Basic: for basic maintenance: screen control tool

startup, system diagnosis, interface restart, backup

and recovery of configuration parameters, backup

and restore of process files

② Screen control tool startup: for configuring rotation

speed, protective torque and rotation direction

independently of pset parameters

③ Pset start: start pset through screen, run pset

cyclically

④ System diagnosis: monitor system status, including

internal and external network port addresses, CPU

usage, total capacity, used capacity and usage of

the disk

⑤ HMI refresh: restart interface without affecting tool

running and data transmission

10.2 IO

Menu bar - Maintenance:

① I/O display: when the I/O is used for control, the

current status of I/O point will be displayed

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10.3 Field bus

Menu bar - Maintenance:

① Fieldbus: he bus refers to the shared data channel

used for transmitting information between computer

devices.

② Fieldbus input

③ Fieldbus output

43 TCS.2000 Controller

10.4 Calibration

Calibration is a commonly used method for compensating for offset and linear errors. Leetx tools undergo internal calibration during the factory stage to ensure tool accuracy. Meanwhile, at the user site, to adapt to different on- site conditions, multi-point calibration is supported. The controller can select calibration torque points according to actual usage. Regarding the use of calibration coefficients, the tool will automatically match within ±10% of the existing calibration torque points. If there is no match within the range, the tool will select the default calibration coefficient.

Menu bar - Debugging: ① Calibration

② Pset selection: Select the Pset file for calibration.

③ Target torque: Manually fill in the target torque point for calibration. The upper and lower limits correspond to

the range of the tool's measuring capacity.

④ Start, Stop, Reverse: Start or stop the process file of "Pset Selection" on the screen or external WEB interface.

When the Backward Loosening button is turned on and Start is clicked, the tool will run backward loosening.

The backward loosening settings here are the reverse rotation speed and reverse torque settings in "Settings" -

"Control" of the tool.

⑤ Display: Displays the torque value recorded by the internal sensor of the tool controller.

⑥ Refer: The torque value of the tool output head measured by the external calibration instrument measuring

device, to be filled in manually.

⑦ Add, Delete: Click to add the current record as auto calibration calculation data. Select any piece of calculation

data and click to clear that data.

⑧ Auto calibration: Click "Auto calibration", and the controller will automatically calculate the calibration

coefficient based on the added calculation data. The range of the calibration coefficient is (0.7, 1.3). If it exceeds

this range, the calibration coefficient cannot be saved, and a prompt will be given to re-calibrate to avoid torque

abnormalities caused by abnormal calibration coefficients due to input errors.

44 TCS.2000 Controller

11.1 Maint 11.2 Replacing storage battery

The storage battery enables the controller to save parameters and operation results even when the main power is interrupted.

① Control panel

② Battery

① Maintenance:Maintenance button, if turned on, will

prompt a maintenance alarm when the number

of times it has been used reaches the required

number of maintenance times.(Total work: Record

the total number of tool runs)

② Reset:Maintenance count clear button, opens to

clear the current run count of the tool(This time

worked:Record the current number of runs of the

tool)

③ Intervals:Maintenance cycle setting in 10,000

① Control panel

cycles

② Battery

The controller must be disassembled and operated by certified technicians only. Do not replace the battery during the warranty and service contract period, as doing so will void the warranty and contract. Leetx's Customer Service Centers boast qualified and well- trained engineers ready to fulfill all your tightening system service requirements. Please consult your nearest Leetx Customer Service Center.

45 TCS.2000 Controller

12.1 Torque control strategy

Torque control is a widely used strategy for tightening. This strategy ensures that torque is accurately applied to the assembled connector; however, it cannot guarantee the connector's final tightening outcome. For example, when there are problems like "thread misalignment", missing washers, bolt breakage, oversized bolts, or substandard bolts, even if the tool does apply torque, the connector may not be fully tightened or not tightened at all.

One criterion for choosing torque control as a tightening strategy is significant angle deviation, which prevents the system from detecting issues with the connector.

12.2 Angle monitoring strategy for torque mode

For most connectors in assembly, a torque control strategy combined with torque and angle monitoring is an appropriate option. This strategy offers several benefits: it guarantees the successful implementation of the tightening process and the consistent, high-quality connection.

To achieve the above two points, the system monitors the angle during the operation process, effectively detecting problems like "thread misalignment", missing washers, bolt breakage, oversized bolts, or substandard bolts. During batch continuous operations, this strategy also enables the system to identify all repeatedly tightened bolts.

To calculate the torque threshold, the starting point should be determined in the linear torque increase phase. Given the torsion/reverse torsion of the operating spindle, the angle measurement should be conducted during the torque reduction phase, until the calculation starting point beyond the torque threshold. The system records two measurements: peak torque and final angle.

12.3 Torque monitoring strategy for angle mode

With this strategy, TCS 2000 can accurately control the tool angle within the range once the torque threshold is exceeded. This pset control strategy can generally be referred to as torque plus angle control strategy. It refers to the control strategy of first tightening to a certain torque and then causing the connecting piece to rotate at a fixed angle. On the basis of implementing these, ultimately monitor the output changes of the overall torque.

12.4 Socket release strategy

If it is necessary to maintain a small amount of constraint force during the assembly of connectors, the loosening operation based on the torque control strategy can be applied. In this case, the socket will not be released fully. During the loosening process, the system monitors the loosening action of the tool head, as well as the angle achieved, while maintaining the residual torque of the tool head.

Socket release based on angle control strategy is mainly used to fully remove the constraint force in the connectors.

46 TCS.2000 Controller

12.5 Tool search sequence strategy

Tool search sequence test is used for tightening the tool head until it touches the surface, regardless of the required high-speed torque. At this point, the speed can be reduced and the final torque or angle can be applied, whichever is more suitable for the application.

The benefits of this strategy include:

Accelerating the buffering process until the tool head is tightened, allowing pre-tightening with a safety distance to avoid over-adjustment, thus expediting assembly and saving time.

Monitoring is carried out throughout the buffering process, therefore all torques are visible until the tool head is tightened, and the curve is under surveillance constantly. An angle can be added later (which is known to be much better for tightening on wood), providing greater flexibility in addressing assembly problems.

The loosening operation based on angle control strategy is mainly used to fully remove the constraint force in the connectors. The measurements recorded by the system are the final torque and final angle.

Only by employing this strategy can the difficulties in various tightening operations during buffering (due to self- tapping) be addressed, making it suitable for a broader range of applications. This strategy is structured in two phases:

Tool search sequence test and After tool search sequence test

47 TCS.2000 Controller

12.5 Seating detection Strategy

Seating detection is suitable for applications such as self-tapping screws. Before application, as many samples as possible must be collected, including the tightening curve. On this basis, set a reasonable torque slope and superimposed torque or angle when the bolt is seated. The final torque using this tightening strategy will be relatively scattered, which is caused by the different torques during tapping. Therefore, for calculation of process capability, the final torque cannot be used for calculation. Instead, the process capability index should be calculated using the superimposed torque or angle and the torque slope during seating.

Related concepts: ( 一) Fitting torque The fitting torque refers to the torque when the connector and the connected part are tightened and fitted, which is the starting position of effective tightening (generating clamping force). On the tightening curve, it is represented by the lowest point of the straight-line segment where the torque changes with the angle. Before this point, the torque of the screw is consumed in tapping the thread upwards or overcoming the clearance, and effective clamping force cannot be generated. On the tightening curve, it is also represented as the lowest point of the straight section where torque changes with angle. Before this point, the torque of the screw is consumed in threading or overcoming clearance, and it cannot effectively generate clamping force. The fitting torque varies greatly. Generally, 20% - 25% of the target torque is selected as the fitting torque. ( 二) Threshold torque When the threshold torque is reached, the clearances between the threads and between the workpieces have been completely eliminated, and the screw has entered the linear region. The elongation of the bolt changes proportionally with the torque. This point serves as the starting point for angle monitoring. The determination of the set value of its torque theoretically requires analysis and calculation based on the attribute parameters such as the material and specifications of the bolt. In actual situations, it is very difficult to measure accurate parameter values. Therefore, the current processes mostly rely on experiments or empirical values for setting. Its torque value is generally 30% of the target torque, or 1.1 times the fitting torque plus 3 times the standard deviation. It should be particularly noted that the starting torque must be greater than the fitting torque to ensure that the threshold position is on the linear segment.

48 TCS.2000 Controller

Explanation of process step parameters:

Process step parameters Description

Offset mode None: The next process step is to perform normal tightening according to the set target torque. If the target torque of the next process step is 5 Nm, the tightening result will be 5 Nm.

Add: The setting will add an offset to the tightening result of the next process step. If the target torque of the next process step is 5 Nm and the seating torque is 0.2 Nm, the tightening result will be 5.2 Nm, and 5.2 Nm will be highlighted.

Deduct: This setting will subtract an offset from the tightening result of the next process step. If the target torque of the next process step is 5 Nm and the seating torque is 0.2 Nm, the tightening result will be 4.8 Nm, and 5 Nm will be highlighted.

Thresh.T Record the angle starting from this torque point, which is used to determine when to start measuring the angle change.

Thresh.T Start the judgment from this torque point, and then run the specified delayed angle, which is used to determine when to start the angle-related judgment.

Trate.Thr Start calculating the slope (torque/angle) from this torque point, which is used to determine when to start calculating the slope of torque versus angle.

Delay.A Run the specified angle after reaching the angle threshold.

Samp.Ang Calculate the torque slope based on this angular width.

T rate The point corresponding to the real-time slope reaching this value is the seating point.

The torque that must not be exceeded during operation Safety T

Safty angle The angle that is not allowed to be exceeded during the movement (calculated from the starting torque)

Max T and Min T Evaluate the torque range of the seating point.

Max A and Min A Evaluate the angular range of the seating point.

49 TCS.2000 Controller

1 Operation instructions of I/O Interface and expansion I/O module

1.1 Description of controller I/O

1.1.1 Description of input signal (IO_in)

• sys_status

No. Signal name Function description Signal type Remarks

1 fault_reset Reset system fault bool The fault is cleared on rising edge when

the system reports a fault

2 sync_signal Sync signal bool If the signal is configured for controlling

synchronization

To configure the signal, if "Enable Source"

is set to Default, the tool start source can be directly controlled, which is equivalent

3 tool_enable Tool enable bool

to the protection lock of the tool start

source

4 end_hat End alignment bool Alignment can be ended actively by configuring this signal during the search

search sequence phase

• action

No. Signal name Function description Signal type Remarks 1 tool_reverse Tool reverse enable bool

After the result acknowledgment function is configured, the rising edge can be sent to clear the result upon implementation of the process, for example, result_ok = false, result_nok = true. After sending the rising edge, the result is reset to result_ok = false, result_nok = false.

2 result_ack Result acknowledgment bool

• pset

No. Signal name Function description Signal type Remarks 1 pset_start Tool start/stop bool

2 pset_bit0 Program feedback 1 bool 3 pset_bit1 Program feedback 2 bool 4 pset_bit2 Program feedback 4 bool 5 pset_bit3 Program feedback 8 bool 6 pset_bit4 Program feedback 16 bool 7 pset_bit5 Program feedback 32 bool 8 pset_bit6 Program feedback 64 bool 9 pset_bit7 Program feedback 128 bool 10 next_pset Select the next process bool

Start on rising edge and stop on falling edge. pset_bit0-pset_bit7 allows creation of 255 processes, eg: pset_bit0+pset_bit1 represents process number 3

11 previous_pset Select the previous process bool

50 TCS.2000 Controller

• job

No. Signal name Function description Signal type Remarks

1 endjob Force the end of the current job when the controller is working in job mode bool Rising edge

2 job_bit0 Program feedback 1 bool

3 job_bit1 Program feedback 2 bool 4 job_bit2 Program feedback 4 bool 5 job_bit3 Program feedback 8 bool 6 job_bit4 Program feedback 16 bool 7 job_bit5 Program feedback 32 bool 8 job_bit6 Program feedback 64 bool 9 job_bit7 Program feedback 128 bool

job_bit0-job_bit7 allows creation of 255 processes, eg: job_bit0+job_bit1 represents process number 3

1.1.2 Description of output signal (IO_out)

• status

No. Signal name Function description Signal type Remarks 1 system_ready System ready or not bool 2 pset_running Process running bool

3 job_runing Job running bool Active when the controller is working in job mode 4 system_fault System fault bool 5 tool_reverse Tool reversing bool

6 summary_result_ok Overall spindle result OK in multi-spindle mode bool Taking a five-spindle system for example, "True" will be output when the results of five spindles are all OK

7 summary_result_nok Overall spindle result NOK in multi-spindle mode bool Taking a five-spindle system for example, "True" will be output when the result of any spindle is NOK

• result

No. Signal name Function description Signal type Remarks

1 result_ok Result OK bool "True" will be output when the pset implementation is OK

2 result_nok Result NOK bool "True" will be output when the pset implementation is NOK 3 angle_ok Angle OK bool 4 global_angle_ok Global angle OK bool 5 torque_ok Resulting torque OK bool

6 jobresult_ok Result OK; "True" will be output when the job result is OK bool Active when the controller is working in job mode

7 jobresult_nok Result NOK; "True" will be output when the job result is NOK bool Active when the controller is working in job mode

Result OK, Temp_result_ok = result_ torque_ok; the difference is that this signal can be automatically reset through configuration of a specified time period

bool For example, Temp_result_ok = true, a 5 s time period is set for reset, and 5 s after the tightening result is determined, Temp_result_ok = false

8 temp_result_ok

Result NOK, Temp_result_nok = result_torque_nok; the difference is that this signal can be automatically reset through configuration of a specified time period

bool For example, Temp_result_nok = true, a 5 s time period is set for reset, and 5 s after the tightening result is determined, Temp_result_nok = false

9 temp_result_nok

51 TCS.2000 Controller

• system

No. Signal name Function description Signal type Remarks 1 sync_signal Sync signal bool

2 step_out An output signal, allowing you to add and set the desired output position bool For example, monitoring the implementation of pset step to the desired position

• pset

No. Signal name Function description Signal type Remarks 1 pset_bit0 Program feedback 1 bool

2 pset_bit1 Program feedback 2 bool 3 pset_bit2 Program feedback 4 bool 4 pset_bit3 Program feedback 8 bool 5 pset_bit4 Program feedback 16 bool 6 pset_bit5 Program feedback 32 bool 7 pset_bit6 Program feedback 64 bool 8 pset_bit7 Program feedback 128 bool

pset_bit0-pset_bit7 allows creation of 255 processes, eg: pset_bit0+pset_bit1 represents process number 3

• job

No. Signal name Function description Signal type Remarks 1 job_bit0 Program feedback 1 bool

2 job_bit1 Program feedback 2 bool 3 job_bit2 Program feedback 4 bool 4 job_bit3 Program feedback 8 bool 5 job_bit4 Program feedback 16 bool 6 job_bit5 Program feedback 32 bool 7 job_bit6 Program feedback 64 bool 8 job_bit7 Program feedback 128 bool

job_bit0-job_bit7 allows creation of 255 processes, eg: job_bit0+job_bit1 represents process number 3

• multi-axis

No. Signal name Function description Signal type Remarks

1 aN_system_ready Ready #N spindle of multi- spindle system bool Taking #2 spindle for example, a2_system_ready

2 aN_result_angle_ok OK angle of #N spindle of multi- spindle system bool Taking #2 spindle for example, a2_result_angle_ ok

3 aN_result_torque_ok Torque result of #N spindle of multi-spindle system bool Taking #2 spindle for example, a2_result_ torque_ok

4 aN_result_ok OK Result of #N spindle of multi-spindle system bool Taking #2 spindle for example, a2_result_ok

5 aN_result_nok NOK Result of #N spindle of multi-spindle system bool Taking #2 spindle for example, a2_result_nok

6 aN_pset_running #N spindle of multi-spindle system running the process bool Taking #2 spindle for example, a2_pset_running

7 aN_system_fault System fault of #N spindle of multi-spindle system bool Taking #2 spindle for example, a2_system_fault

(Active in multi-spindle mode. Each bit from bit0 to bit19 represents a spindle. For example, in a five-spindle system, when five spindles are configured in process 1, if #2 and #3 spindles need to be disabled, bit0 = true, bit1 = false, bit2 = false, bit3 = true, bit4 = true). As the input of I/O is limited to 8 bits, up to 8 spindles can be masked off simultaneously for I/O.

8 mask_off_code_bitN Mask off code bool

52 TCS.2000 Controller

• When using tool_enable, be sure to set "source" to Fieldbus.

• When using request_profile_index (map_pset in map mode), be sure to set "Pset selection source" to Fieldbus.

• When using pset_start, be sure to set "Tool start source" to Fieldbus.

• When using product_sn, be sure to set "Barcode source" to Fieldbus.

• When using tool_reverse, be sure to set "Reverse mode" to Fieldbus.

• When using fault_reset, be sure to set "Fault reset" to Fieldbus.

• When using result_ack, be sure to set "Result confirmation source" to Fieldbus.

• Temp_result_ok and Temp_result_nok will be automatically reset after a timeout period of n seconds since tightening is completed, and will not be reset when n=0.

1.1.4 Wiring diagram

53 TCS.2000 Controller

1.2 Expansion I/O

1.2.1 Function description

The expansion I/O module increases the number of I/O ports, enabling additional I/O mappings.

1.2.2 Operation steps

1. The expansion I/O is differentiated by the node ID set by the users. Prior to use, the I/O expansion module needs to be configured with the node ID. For configuration instructions, please refer to the "Expansion I/O node ID setting" section. 2. Connect the expansion I/O board to the chassis and other expansion I/O modules according to the "Wiring method". 3. Set the number of expansion I/O modules on the user interface (ensure the number of I/O modules set does not exceed the number of physically connected expansion I/O modules).

1. Map the expansion I/O variables. After configuration, the words "Expansion Box" will appear on the I/O interface, where you can select the desired expansion I/O module for mapping from the right side.

1. Expend Select the corresponding ID in the Expansion Box.

54 TCS.2000 Controller

1.2.3 Wiring method

The I/O expansion board operates using the CAN bus mode, with the network topology illustrated as follows:

During use, connect the I/O expansion board interfaces to the CAN ports of the screwdriver. Connect the external interfaces as shown using harnesses. The terminal resistors must be turned on using the DIP switch on the bus board, and this is only necessary at both ends of the network (failure to turn on the terminal resistors can lead to impedance mismatch issues on the bus, which may impact data transmission).

1.2.4 Light contrast information

Running STAR PWR Meaning

Power-off OFF OFF The equipment is not powered on

Power-on The green indicator lamp is always on The green indicator lamp is always on The host is not connected or the IO expansion module is not enabled by the host

Power-on The green indicator lamp flashes quickly twice every 2 seconds

The green indicator lamp is always on The communication with the host has been established and is normal

Power-on The red indicator lamp flashes once per second The green indicator lamp is always on The communication with the host has been established but is abnormal

55 TCS.2000 Controller

2 Bus configuration and operation instruction

2.1 Function overview

Fieldbus is an industrial network technology used for communication between devices in automation systems, primarily in the fields of process control and manufacturing automation. The development of fieldbus technology is aimed at replacing traditional point-to-point hard wired signal transmission methods, achieving more efficient, flexible, and economical device interconnection and information exchange. Supports bus type: EtherCAT PROFINET EtherNet/IP Modbus/TCP

2.2 Description of parameters

2.2.1 Description of input signal

No. Signal name Function description Signal type Remarks

1 pset_start Tool start/stop bool Start on rising edge and stop on falling edge

When it is set to "True", the tool enters the reversing mode, rotating in the direction reverse to the process direction. For example, if the process is configured for clockwise rotation, the tool will rotate counterclockwise in reversing mode.

2 tool_backward Tool reverse enable bool

3 fault_reset Reset system fault bool The fault is cleared on rising edge when the system reports a fault

4 request_Profile_ index Set process number u8 Set the process number to be selected

5 tool_enable Tool enable bool Control whether the tool is enabled. When tool_enable = true, the tool is allowed to start and can be locked by this.

After the result acknowledgment function is configured, the rising edge can be sent to clear the result upon implementation of the process, for example, result_ok = false, result_nok = true. After sending the rising edge, the result is reset to result_ok = false, result_nok = false. 7 sync_signal Sync signal bool If the signal is configured for controlling synchronization

6 result_ack Result acknowledgment bool

8 request_job_ index Set job No. u8 Set the job number to be selected if the controller is working in job mode

Force the end of the current job when the controller is working in job mode

9 end_job

bool Trigger on rising edge

10 product_sn Add product code to process result string 128 byte Maximum 128 bytes, character string ending with “\0”

Active in multi-spindle mode. Each bit from bit0 to bit31 represents a spindle. For example, in a five-spindle system, when five spindles are configured in process 1, if #2 spindle needs to be disabled, bit0 = true, bit1 = false, bit2 = true, bit3 = true, and bit4 = true, which means setting mask_off_code = 0x1D.

11 mask_off_code Mask off code u32

12 map_pset Set process file in multi-spindle mode u8

13 end_hat End alignment bool Alignment can be ended actively by configuring this signal during the alignment phase

56 TCS.2000 Controller

2.2.2 Description of output signal

No. Signal name Function description Signal type Remarks

1 system_ready System ready or not bool

2 pset_running Process running bool

3 system_fault System fault bool

4 result_ok Result OK bool "True" will be output when the process implementation is OK

5 result_nok Result NOK bool "True" will be output when the process implementation is OK

6 system_fault_code System fault code u16 Read this code for details when the system reports a fault

7 active_Profile_index Currently active process u8 Current process used for setting

8 result_torque Resulting torque float

9 result_angle Resulting angle float

10 tool_reverse Tool reversing bool

11 sync_signal Sync signal bool

12 result_torque_ok Resulting torque OK bool

13 result_angle_ok Resulting angle OK bool

14 active_job_index Currently active job No. U8 Active when the controller is working in job mode

15 job_runnung Job running bool Active when the controller is working in job mode

16 jobresult_ok Job result OK bool "True" when the job result is OK, and active when the controller is working in job mode

17 jobresult_nok Job result NOK bool "True" when the job result is NOK, and active when the controller is working in job mode 18 global_angle_ok Global angle OK bool

19 active_map_index Currently active multi- spindle process number u8 Active in multi-spindle mode

20 summary_result_ok Overall spindle result OK in multi-spindle mode bool Taking a five-spindle system for example, "True" will be output when the results of five spindles are all OK

21 summary_result_nok Overall spindle result NOK in multi-spindle mode bool Taking a five-spindle system for example, "True" will be output when the result of any spindle is NOK

22 fail_code Result code: If the result indicates failure, read this code for further details. u32 The failed process step and the reason for failure can be analyzed.

23 step_out An output signal, allowing you to add and set the desired output position bool For example, monitoring the implementation of process step to the desired position

24 result_global_angle Global angle float

Temp_result_ok = result_torque_ok. The difference is that this signal can be automatically reset after a specified period of time through configuration (for example, Temp_result_ok = true, 5 s time period is set for reset, and 5 s after the tightening result is determined, Temp_result_ok = false).

25 temp_result_ok Result OK bool

Temp_result_nok = result_torque_nok. The difference is that this signal can be automatically reset after a specified period of time through configuration (For example, Temp_result_ nok = true, 5 s time period is set for reset, and 5 s after the tightening result is determined, Temp_result_nok = false).

26 temp_result_nok Result NOK bool

27 aN_system_ready Ready #N spindle of multi- spindle system bool Taking #2 spindle for example, a2_system_ready

28 aN_result_torque Torque result of #N spindle of multi-spindle system float Taking #2 spindle for example, a2_result_torque

57 TCS.2000 Controller

29 aN_result_angle Angle result of #N spindle of multi-spindle system float Taking #2 spindle for example, a2_result_angle

30 aN_result_angle_ok OK angle of #N spindle of multi-spindle system bool Taking #2 spindle for example, a2_result_angle_ok)

31 aN_result_torque_ok Torque result of #N spindle of multi-spindle system bool Taking #2 spindle for example, a2_result_torque_ok

32 aN_result_ok OK Result of #N spindle of multi-spindle system bool Taking #2 spindle for example, a2_result_ok

33 aN_result_nok NOK Result of #N spindle of multi-spindle system bool Taking #2 spindle for example, a2_result_nok

34 aN_pset_running #N spindle of multi-spindle system running the process bool Taking #2 spindle for example, a2_pset_running

35 aN_system_fault System fault of #N spindle of multi-spindle system bool Taking #2 spindle for example, a2_system_fault

36 product_sn Bar code currently set in the system string Maximum 128 bytes, character string ending with "\0"

2.2.3 Bus configuration

▪When using tool_enable, be sure to set "Enable source" to Field Bus.

▪When using request_profile_index (map_pset in map mode), be sure to set "Pset selection source" to Field Bus.

▪When using pset_start, be sure to set "Tool start source" to Field Bus.

▪When using product_sn, be sure to set "Barcode Source" to Field Bus.

▪When using tool_reverse, be sure to set "Reverse mode" to Field Bus.

▪When using fault_reset, be sure to set "Fault reset" to Field Bus.

▪When using result_ack, be sure to set "Result confirmation source" to Field Bus.

▪Temp_result_ok and Temp_result_nok will be automatically reset after a timeout period of n seconds since tightening is completed, and will not be reset when n=0.

58 TCS.2000 Controller

2.2.4 Control sequence chart

▪Rising edge and falling edge are shown in the following figure:

The rising edge is the signal generated at the moment when the signal jumps from 0 to 1 The falling edge is the signal generated at the moment when the signal jumps from 1 to 0

Rising edge Falling edge

▪pset_star: When a rising edge is generated, the tool will be started, and a high level shall be maintained during operation. ▪pset_star: When a falling edge is generated during operation, the tool will be stopped.

59 TCS.2000 Controller

3 Description of OP protocol

3.1 Supported functions

By default, version 1 is used when the version is set to 0

MID Function Version 001 Connection request 1-5 002 Connection response 1-5 003 Disconnection 002 and 003 004 Incorrect command return 002 and 003 005 Correct command return 002 and 003 010 Acquisition of pset list command 011 Return of pset list 001 012 Acquisition of specified pset content 002 013 Return of specified pset content 002 014 Subscription of pset 002 and 001

015 Pushing of pset information in case of any change in the active pset, supporting version 2 at most 002 and 001

016 Positive feedback of Mid0015 002 and 001 017 Unsubscription of pset 002 and 003 018 Switching of pset command 001 , 002 and 003 030 Acquisition of Job list 001 and 002 031 Return of Job list 001 and 002 039 Restart of job 001 032 Acquisition of job information 001 034 Subscription of job information 001,002 035 Pushing of job information 001,002 038 Switching of job command 001 and 002 050 Issuing of VIN 001 051 Subscription of VIN 002 052 Pushing of VIN 002 150 Issuing of VIN 001 042 Tool stop enabling 001 和002 043 Tool enable 001 , 002 and 003 060 Result subscription 001 , 002 and 003 061 Result subscription, supporting version 6 001 , 002 and 003 063 Result unsubscription 001 064 Query of results based on tid 001 065 Return of result information 001 070 Alarm subscription 001 071 Pushing of alarm information 001 073 Alarm unsubscription 001 074 Sending upon alarm clearing 001 076 Alarm event pushing 001 080 Acquisition of time 001 081 Return of time 001 127 Job stop request 001 7402 Subscription of job cycle and stage data report 001 7403 Unsubscription of job cycle and stage data report 001 7404 Stage data report 001

60 TCS.2000 Controller

7405 Stage data report confirmation 001 7406 Job cycle data report 001 7407 Job cycle data report confirmation 001 7408 Final torque curve data subscription 001,002 7409 Final torque curve data unsubscription 001 7410 Final torque curve data report 001 7411 Final torque curve data report confirmation 001 9997 Communication confirmation 001 9999 Heartbeat

3.2 Op protocol command

1. Op start command Command (ASCII): 00200001001 NUL Command (hexadecimal): 30 30 32 30 30 30 30 31 30 30 31 20 20 20 20 20 20 20 20 20 00 Return: 00570002001 0100010202031leetx

1. Disconnection Command (ASCII): 00200003001 NUL Command (hexadecimal): 30 30 32 30 30 30 30 33 30 30 31 20 20 20 20 20 20 20 20 20 00 Return: 00240005001 0003

1. Result subscription command Command (ASCII): 00200060001 NUL Command (hexadecimal): 30 30 32 30 30 30 36 30 30 30 31 20 20 20 20 20 20 20 20 20 00 Return: 00240005001 0060 02310061001 0100010202031leetx 04 050006001070000080000090100110120003751300112514000000150000031601 8001703 60018000001900000202023-07-03:13:08:41210000-0000:00:00:00220230000000130

1. Tool enabling Command (ASCII): 00200043001 NUL Command (hexadecimal): 30 30 32 30 30 30 34 33 30 30 31 20 20 20 20 20 20 20 20 20 00 Return: 00240005001 0043

1. Tool disabling Command (ASCII): 00300042001 0100010200\0 Command (hexadecimal): 30 30 33 30 30 30 34 32 30 30 31 20 20 20 20 20 20 20 20 20 30 31 30 30 30 31 30 32 30 30 00 Return: 00240005001 0042

1. Setting of pset (the last 002 means setting to pset 2) Command (ASCII): 00230018001 002NUL Command (hexadecimal): 30 30 32 33 30 30 31 38 30 30 31 20 20 20 20 20 20 20 20 20 30 30 32 00 Return: 00240005001 001803

1. Query of pset list (the return value is parsed into 002001002; the first three digits represent the number of psets and each subsequent three digits represent a pset) Command (ASCII): 00200010001 NUL Command (hexadecimal): 30 30 32 30 30 30 31 30 30 30 31 20 20 20 20 20 20 20 20 20 00 Return: 00290011001 002001002

61 TCS.2000 Controller

1. Setting of bar code (the first four digits 0030 represent a total of 30 bytes (*excluding the last flag bit 00), which can be modified as needed) Command (ASCII): 00300050001 helloworldNUL Command (hexadecimal): 30 30 33 30 30 30 35 30 30 30 31 20 20 20 20 20 20 20 20 20 68 65 6C 6C 6F 77 6F 72 6C 64 00 Return: 00240005001 0050

1. Acquisition of specified pset content Command (ASCII): 00230012 001NUL Command (hexadecimal): 30 30 32 33 30 30 31 32 20 20 20 20 20 20 20 20 20 20 20 20 30 30 31 00 Return: 01040013001 0100102 pset10310402050000000600010007000100080000009036001000000

1. Subscription of set pset Command (ASCII): 00200014001 NUL Command (hexadecimal): 30 30 32 30 30 30 31 34 30 30 31 20 20 20 20 20 20 20 20 20 00 Return: 00240005001 0014

1. Pushing of pset information in case of any change in the active pset, supporting version 2 at most

Return: 00200016 NUL

1. Unsubscription of pset Command (ASCII): 00200017001 NUL Command (hexadecimal): 30 30 32 30 30 30 31 37 30 30 31 20 20 20 20 20 20 20 20 20 00 Return: 00240005001 0017

1. Acquisition of Job list command (ASCII): 00200030001 NUL Command (hexadecimal): 30 30 32 30 30 30 33 30 30 30 31 20 20 20 20 20 20 20 20 20 00 Return: 00240031001 0101

1. Result unsubscription Command (ASCII): 00200063001 NUL Command (hexadecimal): 30 30 32 30 30 30 36 33 30 30 31 20 20 20 20 20 20 20 20 20 00 Return: 00240005001 0063

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1. Result subscription, supporting version 6 MID: 0061

Return: 00200062001 NUL

1. Subscription of job cycle and stage data report Command (ASCII): 00207402001 NUL Command (hexadecimal): 30 30 32 30 37 34 30 32 30 30 31 20 20 20 20 20 20 20 20 20 00 Return: 00240005001 7402

1. Unsubscription of job cycle and stage data report Command (ASCII): 00207403001 NUL Command (hex): 30 30 32 30 37 34 30 33 30 30 31 20 20 20 20 20 20 20 20 20 00 Return: 00240005001 7403

1. Stage data report MID: 7404 (multi-step result)

Return: 00207405001 NUL Return upon completion of the multi-step process:

63 TCS.2000 Controller

Return: 00207407001 NUL

1. Final torque curve data subscription Command (ASCII): 00207408001 NUL Command (hexadecimal): 30 30 32 30 37 34 30 38 30 30 31 20 20 20 20 20 20 20 20 20 00 Return: 00240005001 7408

1. Final torque curve data unsubscription Command (ASCII): 00207409001 NUL Command (hexadecimal): 30 30 32 30 37 34 30 39 30 30 31 20 20 20 20 20 20 20 20 20 00 Return: 00240005001 7409

1. Final torque curve data report Return:

Return: 00207411001 NUL

1. Heartbeat Command (ASCII): 00209999 NUL Command (hexadecimal): 30 30 32 30 39 39 39 39 20 20 20 20 20 20 20 20 20 20 20 20 00 Return: 00209999 NUL

64 TCS.2000 Controller

4 WebAPI operation instructions and sample code

4.1 Tightening result uploading parameter setting

▪Function description: Subscribe or unsubscribe the tightening result and curve. Set the subscription parameters. After successful subscription, receive the result through the result pushing interface. ▪URL: http://192.168.20.145:9001/v2/webApi/result/subscribe

▪Request method: Post

▪Request direction: Mes----->Tightening controller Request Param is defined below:

Parameter Type Required item Description

version string Interface version number, v1.0.0

subscribe bool Subscription or unsubscription, true: subscription, false: unsubscription

Indicating whether the subscription result includes a curve. If the parameter is not included, the result will be the same as that of the previous subscription. The curve is not subscribed by default upon delivery.

curve bool

dataServerIp string Data server IP. If the parameter is not included, the result will be the same as that of the previous subscription. The default IP is 192.168.20.100 upon delivery.

dataServerPort int Data server port. If the parameter is not included, the result will be the same as that of the previous subscription. The default port is 8082 upon delivery.

dataServerPath string Data server path. If the parameter is not included, the result will be the same as that of the previous subscription. The default path is "/leetx/result" upon delivery.

Response body json description:

Parameter Type Description status int Response code, 0: OK, others: NOK description string Prompt data string ""

Request:Post http://192.168.20.145:9001/v2/webApi/result/subscribe { "version": "v1.0.0", "subscribe": true, "curve": false, "dataServerIp": "192.168.20.100", "dataServerPort": 8082, "dataServerPath": "/leetx/result" } Response: { "status": 0, "data": "", "description": "Subscription parameter set successfully" }

65 TCS.2000 Controller

4.2 Uploading tightening results to data server

▪Function description: After successful subscription through the subscription interface, when a new tightening result is generated, it will be actively pushed to the data server. ▪URL: http://192.168.20.100:8082/leetx/result

▪Request method: Post

▪Request direction: Tightening controller----->Data server Description of uploaded data:

Parameter Type Description

tighteningId int Tightening ID, which is the unique identifier for tightening

userName string Username for login during tightening

deviceId int Device ID, which is configured through the panel on the device

deviceName string Device name, which is configured through the panel on the device

toolSn string Tightening gun SN

controllerSn string Tightening controller chassis SN

pset int Tightening program No.

stage int Tightening strategy, 1: angle mode, 2: torque mode, 3: slope mode

In pset mode, the batch "1/1" is displayed no matter whether the result is OK or NOK. In job mode, the batch is displayed according to the configured current pset counting method and total tightening frequency. For example, "1/3" represents a total tightening frequency of 3 and the current first tightening.

batch string

mode int Tightening mode, 0: pset, 1: job

psetName string Tightening program name

maxAngle float Maximum angle for tightening process, in ° , which is applicable to the process step at the time of ending.

minAngle float Minimum angle for tightening process, in ° , which is applicable to the process step at the time of ending.

*targetAngle float Target angle for tightening process, in ° , which exists in angle mode and is applicable to the process step at the time of ending.

*targetTorque float Target torque for tightening process, in N.m, which exists in torque mode and is applicable to the process step at the time of ending.

*targetSlope float Target slope for tightening process, in N.m/° , which exists in slope mode. and is applicable to the step at the time of ending

maxTorque float Maximum torque for tightening process, in N.m, which is applicable to the process step at the time of ending.

minTorque float Minimum torque for tightening process, in N.m, which is applicable to the process step at the time of ending.

resultAngle float Resulting angle, in °

resultTorque float Resulting torque, in N.m

*resultSlope float Resulting slope, in N.m/° , which only exists in slope mode

resultIsOk int Tightening result, 0: NOK, 1: OK

66 TCS.2000 Controller

Failure code, a result code u32 in hexadecimal character string format, b0 - b7 pset step stop index. b8 - b15 u8 1. Receive the pset stop signal 2. Servo fault 3. Pset step displacement out of limit 4. Pset step force out of limit 5. Pset step implementation timeout b16 - b23 b16 low torque b17 high torque b18 small angle b19 large angle b20 small overall angle b21 large overall angle b22 reserved b23 reserved desc string Result description

failCode string

createdTime string Tightening time

sn string Bar code

stepCount int Stepwise tightening frequency

steps list[dict] List of stepwise tightening results which are generated in tightening and seating torque pset steps

steps[0].index int Stepwise tightening result--result index, showing the nth result, which is consistent with the index of steps

steps[0].step int Stepwise tightening result--step index, showing the result in the nth pset step; the result is only generated in the tightening pset step currently steps[0].is_ok int Stepwise tightening result--0: NOK, 1: OK

steps[0].fail_code string Stepwise tightening result--failure code

steps[0].pos float Stepwise tightening result--angle, in °

steps[0].sensor float Stepwise tightening result--torque, in N*m

*steps[0].slope float Stepwise tightening result--slope, in N*m/° , which exists in slope mode

steps[0].max_pos float Stepwise tightening result--maximum angle, in °

steps[0].min_pos float Stepwise tightening result--minimum angle, in °

steps[0].stage int Tightening strategy, 1: angle mode, 2: torque mode, 3: slope mode

*steps[0].target_pos float Stepwise tightening result--target angle, in ° , which exists in angle mode

*steps[0].target_sensor float Stepwise tightening result--target torque, in N*m, which exists in torque mode

*steps[0].target_slope float Stepwise tightening result--target slope, in N*m/° , which exists in slope mode

steps[0].max_sensor float Stepwise tightening result--maximum torque, in N*m

steps[0].min_sensor float Stepwise tightening result--minimum torque, in N*m

*curves dict Tightening curve, which is judged based on the subscription or query parameters

*curves.samples int Number of points on the tightening curve

*curves.torques list[string] Tightening curve--torque, which is represented by a base64 character string. For each segment of the tightening curve, a base64 character string is used. After parsing into a binary data, every four bytes represent a floating-point data *curves.angles list[string] Tightening curve--angle, in ° , which is the same as above

*curves.times list[string] Tightening curve--time, which is the same as above

*curves.speeds list[string] Tightening curve--speed, which is the same as above

67 TCS.2000 Controller

{

"curves": {

"tighteningId": 894686,

"torques": [

"pset": 2,

"NZM7vJzxK7w="

"maxAngle": 540.0,

],//[[-0.011448671109974384,-0.010494615882635117]]

"minAngle": 180.0,

"angles": [

"maxTorque": 6.0,

"AAAAAAAAAAA="

"minTorque": 5.5,

],

"resultAngle": 0.0,

"times": [

"resultTorque": 0.009486,

"AAAAAG8Sgzo=" ], "speeds": [ "AAAAAAAAAAA=" ], "samples": 2 } }

"resultIsOk": 0,

"failCode": "50501", "desc": "Step 1: Process step implementation timeout, low torque, small angle", "createdTime": "2023-11-02 17:52:43.350",

"sn": "helloworldhello",

"userName": "guest",

"deviceId": 1,

"deviceName": "Line0-0.0",

"toolSn": "SN4613213",

"controllerSn": "LX202109290010",

"psetName": "pset2",

"stage": 1,

"batch": "1/1",

"mode": 0,

"targetAngle": 360.0,

"steps": [

{

"index": 1,

"step": 1,

"is_ok": 0,

"fail_code": "50501",

"pos": 0.0,

"sensor": 0.009486,

"max_pos": 540.0,

"min_pos": 180.0,

"max_sensor": 6.0,

"min_sensor": 5.5,

"stage": 1,

"target_pos": 360.0

}

],

"stepCount": 1,

68 TCS.2000 Controller

4.3 Querying tightening results

▪Function description: Query the historical results based on diversified conditions.

▪URL: http://192.168.20.145:9001/v2/webApi/results

▪Request method: Post

▪Request direction: Mes----->Tightening controller Request Param is defined below:

Parameter Type Required item Description

numCurve int Limit of the number of results queried.

code string Result code queried in hexadecimal character string

resultIsOk int Indicating whether the result is OK. 0: NOK, 1: OK.

pset int Tightening program No.

timeStart string Tightening result query time, which can be left blank or recorded as "" to indicate the start time

timeEnd string Tightening result query time, which can be left blank or recorded as "" to indicate the end time

sn string Result traceability code, or bar code set through the bus\mes\bar code scanner\op protocol, etc.

Response body json description:

Parameter Type Description

status int Response code, 0: OK, others: NOK

description string Prompt

data list A list of tightening ID for the tightening result

Request: Post http://192.168.20.145:9001/v2/webApi/ results {

734893,

734892,

734891,

"numCurve": 10,

734890,

"code": "0101",

734889,

"resultIsOk": 0,

734888,

"pset": 1,

"timeStart": "1970-01-01 00:00:00",

], "description": "Return the tightening ID for the queried result" }

"timeEnd": "2023-01-01 00:00:00",

"sn": "1234"

}

Response:

{

"status": 0,

"data": [

734896,

734895,

734894,

69 TCS.2000 Controller

4.4 Querying tightening result details

▪Function description: Query the detailed single tightening result which is basically the same as the tightening result generated through active subscription ▪URL: http://192.168.20.145:9001/v2/webApi/result/details?tighteningId=-1

▪Request method: Get

▪Request direction: Mes----->Tightening controller Request Param is defined below:

Parameter Type Required item Description

tighteningId int √ Tightening ID to be queried. If the value is less than or equal to 0, it means that the latest data is queried.

curve int Indicating whether the curve is included. 0: not included, 1: included. The curve is not included by default.

Response body json description:

Parameter Type Description

status int Response code, 0: OK, others: NOK

description string Prompt

data dict The detailed tightening result is the same as the data obtained at the upper interface

Request: Get http://192.168.20.145:9001/v2/webApi/ result/details?tighteningId=734895

"controllerSn": "LX202109290010",

"psetName": "pset4",

"stage": 0,

Response:

"batch": "1/1",

{

"mode": 0,

"status": 0,

"steps": [

"data": {

{

"tighteningId": 894678,

"index": 1,

"pset": 4,

"step": 1,

"maxAngle": 3600.0,

"is_ok": 0,

"minAngle": 1800.0,

"fail_code": "50101",

"maxTorque": 16.5,

"pos": 0.0,

"minTorque": 5.5,

"sensor": 0.011448,

"resultAngle": 0.0,

"max_pos": 3600.0,

"resultTorque": 0.011448,

"min_pos": 1800.0,

"resultIsOk": 0,

"max_sensor": 16.5,

"failCode": "0101",

"min_sensor": 5.5

"desc": "Step 1: Receive the process stop signal",

}

"createdTime": "2023-11-01 15:33:49.132",

],

"sn": "",

"userName": "guest",

},

"deviceId": 1,

"description": "Return tightening details"

"deviceName": "Line0-0.0",

}

"toolSn": "SN4613213",

70 TCS.2000 Controller

4.5 Setting bar code

▪Function description: Set or clear the bar code through an external interface. Be sure to select the correct bar code source on the controller ▪URL: http://192.168.20.145:9001/v2/webApi/control/sn

▪Request method: Put

▪Request direction: Mes----->Tightening controller Request Param is defined below:

Parameter Type Required item Description

code string √ Bar code to be set, "" means clearing a bar code.

Response body json description:

Parameter Type Description

status int Response code, 0: OK, others: NOK

description string Prompt

data dict The detailed tightening result is the same as the data obtained at the upper interface

Request: Put http://192.168.20.145:9001/v2/webApi/control/sn

{

"code": "123456"

}

Response:

{

"status": 0,

"data": [],

"description": "Bar code set successfully"

}

71 TCS.2000 Controller

4.6 Setting pset

▪Function description: Set pset through an external interface. Be sure to select the correct pset source on the controller ▪URL: http://192.168.20.145:9001/v2/webApi/control/pset

▪Request method: Put

▪Request direction: Mes----->Tightening controller Request Param is defined below:

Parameter Type Required item Description

pset int √ Pset to be set

Response body json description:

Parameter Type Description

status int Response code, 0: OK, others: NOK

description string Prompt

data [] None

Request: Put http://192.168.20.145:9001/v2/webApi/control/pset

{

}

Response:

{

"status": 0,

"data": [],

"description": "Pset set successfully"

}

72 TCS.2000 Controller

4.7 Querying pset list

▪Function description: Query the pset list through an external interface

▪URL: http://192.168.20.145:9001/v2/webApi/psetlist

▪Request method: Get

▪Request direction: Mes----->Tightening controller Response body json description:

Parameter Type Description

status int Response code, 0: OK, others: NOK

description string Prompt

data list[dict] Pset list

data[0].pset int Pset No.

data[0].name string Pset name

data[0].mode int Process type 1: fast mode, 2: expert mode

Request: Get http://192.168.20.145:9001/v2/webApi/psetlist

Response:

{

"status": 0,

"data": [

{

"name": "pset1"

"pset": 1,

},

{

"name": "pset2",

"pset": 2,

},

{

"name": "pset4",

"pset": 4,

}

],

"description": "Return pset list"

}

73 TCS.2000 Controller

5 Description of serial port printing formats

1. The serial port needs to set the baud rate and termination symbol in advance to be consistent with the upper computer. 2. Receive the tightening result of the serial port (the serial port connection cable needs to be connected to the controller's serial port 1 position) Result: * 3; False;0.038;0.000;2023-7-3 15:28:34# The result of one tightening is pushed out through the serial port above (starting with * and ending with #, followed by tightening ID, success, torque, angle, and tightening time)

Start symbol

Tightening frequency

Result NOK

Torque

Angle

Time

End symbol

74 TCS.2000 Controller

6 MAP function operation instructions

6.1 Function overview

As a highly automatic tightening device, the multi-spindle tightening machine adopts the integrated multi-spindle (two or more independent spindles) design to accurately tighten the bolts or nuts at the same time. Each spindle is equipped with an electric servo system, which can independently control the tightening torque and angle to ensure that all tightening points meet the specified tightening requirements.

6.2 Description of parameters

6.2.1 MAP setting

1. Mode Selection: For the master spindle, select "M-S:Master"; for the slave spindle, select "M-S:Slave".

1. Number of Spindles = number of master spindle + number of slave spindle: With respect to the configuration of the master spindle, for a 3-spindle system (master spindle + 2 slave spindles), set the number to 3.

1. ID: For the master spindle, set the node number to 1. For the slave spindle, set the node numbers in sequence (e.g. for a 5-spindle system, set the node numbers of master spindle to 1 and slave spindles to 2, 3, 4 or 5).

1. Map ID: A multi-spindle system shall be set with the same multi-spindle identifier.

1. Mask source: When it is enabled, the spindle can be dynamically disabled through the bus or I/O.

1. Map emergency stop: When this mode is enabled, if any spindle fails during implementation of the process, all spindles will stop. (Take the 5-spindle system for example, if #3 spindle fails in a process step, the remaining 4 spindles will stop actively and the process will not be implemented.) When this mode is disabled, if a spindle cannot be tightened during implementation of the process, the remaining spindles will be tightened normally according to the process.

Description of map file:

1. Currently only the configuration of the same pset for all spindles is supported.

1. To disable a spindle, set "Spindle Pset" to "Disable".

1. When implementing the master spindle loading pset, select the map file.

1. When configuring the slave spindle, just set the slave spindle mode and node number.

75 TCS.2000 Controller

6.2.2 MAP synchronization configuration

When the controller is set to "M-S:Master", click "Sync" to view the online state of the master and slave spindles. A gray dot indicates that the device is offline, and a green dot indicates that the device is online.

1. Pset synchronization: Click "Sync" to enter the multi-spindle synchronization configuration interface;

1. Click "Synchronous all". If the synchronization is successful, a " √ " will be shown in the "Successful Setting" box, otherwise a "×" will be shown. After successful synchronization, the same pset will be adopted for the master and slave spindles.

76 TCS.2000 Controller

6.2.3 Configuration of 3-spindle system

The actual tightening pset configuration is simulated. Different from the single-spindle pset, the multi-spindle pset involves addition of "Wait" in the segmented tightening pset due to the difference in the tightening time of spindles during implementation of the multi-spindle pset. The pset taken as an example is set with three steps: "Tightening" - "Wait" - "Tightening".

6.2.3.1 MAP settings

Add "Wait" between two tightening

Edit the map file under "MAP settings"

pset steps.

After selecting "Wait", select "MAP sync".

After setting, click "Save" to save the map file.

At this point, the 3-spindle pset editing is completed.

77 TCS.2000 Controller

6.2.3.2 Implementation of 3-spindle pset

After the master station is connected to the slave station, synchronize the edited pset files in the master station.

Click "Sync" on the "Control" page.

Click "Synchronous all".

Wait for the pset to be synchronized.

The pset are synchronized

successfully

It is allowed to run the map program (Step 1: Pre-tightening -> Step 2: Wait for map synchronization -> Final tightening) to achieve synchronized multi-spindle tightening.

78 TCS.2000 Controller

7 Job function description

7.1 Function overview

The tightening pset chain (JOB) is designed to achieve highly automatic and intelligent tightening to ensure that each connection point meets the designed mechanical performance requirements and to improve the production efficiency, reduce the manufacturing cost and ultimately ensure the overall quality and long-term safety of the product.

7.2 Description of parameters

7.2.1 Basic parameter configuration

1. JOB name: Set the name. 2. Pset auto select (when it is enabled, the program activates the pset in order, and only one pset is valid on each line when JOB is added in series). 3. MRT (the value indicates the number of failures allowed for the entire JOB. For example, when the value is set to 0, it means that no failure is allowed, and the JOB ends when the pset fails once. When the value is set to 1, it means that one failure is allowed, and the JOB ends when the pset fails twice). 4. JOB circulation: (When it is enabled,) JOB is reactivated after being implemented. 5. Pset: Select the pset number to be implemented. 6. Run: Set the number of times for implementation of the current pset. 7. Count mode: a) OK result (the number is increased by one only when the process result is OK); b) All result (the number is increased by one each time after the process is implemented, without any need to determine the result). 8. Reverse angle (used together with "9"). 9. Deduct mode: a) Disable (the number of times for implementation of the process is not decreased after reverse loosening); b) Reverse result (the number of times is decreased by one each time after reverse loosening); c) Reverse angle OK result (the reverse loosening angle is greater than the value set in "8"). 10. Reverse mode: a) Disable reverse (reverse loosening is prohibited); b) Reverse on NOK (reverse loosening is allowed when the process result is NOK, but not allowed when the result is OK). c) Enable reverse (reverse loosening is allowed).

79 TCS.2000 Controller

7.2.2 JOB function setting

1. JOB implementation: JOB is implemented line by line. 2. With respect to the pset selection, only the current and configured pset can be selected (for example, if two pset are configured on the first line, only pset 1 or 2 can be selected. If pset 1 is selected and implemented, only pset 2 can be selected. After pset 2 is implemented, go to the second line). 3. With respect to JOB, when the JOB selection source is set to I/O or bus, the signal shall be changed to activate JOB. a. JOB is not activated currently. To activate JOB1, JOB=0 will be sent, and after 5 s, JOB=1 will be sent; b. If JOB1 is currently activated and JOB is not implemented, select the target JOB2, and JOB=2 will be sent directly; c. If JOB1 is currently activated and needs to be reactivated after JOB is implemented, JOB=0 will be sent, and after 5 s, JOB=1 will be sent; d. If JOB1 is currently activated and JOB is being implemented, it is necessary to send the JOB ending command (rising edge). After ending of implementation, JOB=0 will be sent, and after 5 s, JOB=1 will be sent to reactivate JOB=1. 4. To enable "Pset auto select", JOB must be configured without horizontal addition as shown below.

1. After JOB is implemented, only when all process implementation results are OK, the OK signal will be generated; otherwise, the NOK signal will be generated.

80 TCS.2000 Controller

8 Common fault codes

8.1 Application faults

Fault code (hexadecimal) Fault description Fault cause Solution

110 No loading of process configuration file, resulting in Sequence start failure Internal software problem Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

111 No activation of Sequence running lock, resulting in Sequence start failure Internal software problem Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

System not in SystemReady state, resulting in Sequence start failure

Internal software problem Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

113 No activation of servo, resulting in Sequence start failure Internal software problem Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

1. Check if the external emergency stop switch input of the controller is active; 2. If the external emergency stop switch input is not activated, check if the cable or power supply of the internal emergency stop switch of the controller is normal.

120 External emergency stop The emergency stop function of the controller is activated

0712 Missing process content There is no normal process step setting content in the process setting file Check the pset setting to ensure that one pset setting is activated.

0713 Missing Sequence content Internal software problem Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

0714 No process file An attempt is made to activate the file that is not in the process file format Delete the incorrect file and create a normal pset file.

0723 Missing executable process step No executable process step is set in the process setting Check the pset setting to ensure that at least one pset step is set.

0724 Missing tightening process step No tightening process step is set in the process setting Check the pset setting to ensure that the tightening pset step is set.

0725 Incorrect setting of jump process step The jump process step is set incorrectly in the process setting Check the pset setting to modify the jump pset step setting.

0726 Set process speed exceeding the maximum system speed

A too large speed value is set in the process setting, exceeding the allowable maximum value

Set the speed value in the pset setting according to the maximum speed parameter of the tool.

0727 Set process torque exceeding the maximum system torque

A too large torque value is set in the process setting, exceeding the allowable maximum value

Set the torque value in the pset setting according to the maximum torque parameter of the tool.

The total number of results stored by the controller at one time exceeds the maximum storage capacity of the system

0728 Number of results exceeding the maximum storage capacity

Export the locally stored data to the offline storage device and clear the stored data.

The number of process steps implemented at one time exceeds the allowable maximum value of the controller

0729 Number of executable process steps exceeding the maximum value

Check the setting of pset step number and jump, and adjust it to the allowable range of the system.

81 TCS.2000 Controller

0802 No power-on, resulting in Sequence start failure Internal software problem Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

0803 Sequence implementation error Internal software problem Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

2012 No process calibration file The process calibration is activated, but the calibration data are not available Perform the pset calibration again to generate the pset calibration file.

4086 No process file An attempt is made to activate a non- existent process file Create the pset file to be activated.

4088 No Job file An attempt is made to activate a non- existent Job file Create the Job file to be activated.

4090 Unconfigured process file The process is not configured in the Job file Check if the pset is configured in the Job file

In the multi-spindle networking application, the spindle process group file configuration or shielding code is incorrect

Check if the configuration item for the multi-spindle networking application is normal

4094 All spindles disabled

40B1 Sequence configuration error Internal software problem Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

40B2 Seq Jump target line exceeding the maximum value

The target set value of process step jump is too large, exceeding the allowable maximum value

Check the pset step jump section in the process setting file

40B3 Seq implementation error Internal software problem Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

40BB Sequence timeout Internal software problem Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

40BC Sequence speed exceeding the maximum set value of the system Internal software problem Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

40BD Sequence torque exceeding the maximum set value of the system Internal software problem Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

Variable byte count of input bus set by the upper computer exceeding the maximum limit

The input byte count of bus communication exceeds the maximum mapping and processing capacity of the controller

Check if the bus mapping configuration of the upper controller exceeds the limit, and if so, modify the configuration.

40C3

Variable byte count of output bus set by the upper computer exceeding the maximum limit

The output byte count of bus communication exceeds the maximum mapping and processing capacity of the controller

Check if the bus mapping configuration of the upper controller exceeds the limit, and if so, modify the configuration.

40C4

When the system is subjected to bus or I/O control, the process start source is not configured Check the configuration of the pset start source.

5001 Process start not configured

Check if the network cable between the PLC and the controller is connected normally, and if the network connector is connected properly.

5003 Bus offline The communication between PLC and controller is interrupted

In the multi-spindle networking application, the inter-spindle synchronization is not achieved after modification of the process

After modifying the pset setting, perform pset synchronization on the master spindle interface and confirm that the synchronization is successful.

500B Process not synchronized

8003 Torque limit reached When the tool is reversed, the torque output exceeds the set torque limit Check the set reverse torque limit and modify it properly.

82 TCS.2000 Controller

8.2 Controller faults

Fault code (hexadecimal) Fault description Fault cause Solution

0800 Power-on failure The controller fails to start the tool 1. Check if the handle cable is loose, and disconnect and reconnect the tool cable;

0801 Power-off failure The controller fails to stop the tool 2. Check if the emergency stop input is triggered.

0804 Servo direction setting failure Internal software problem 1. Check if the handle cable is loose, and disconnect and reconnect the tool cable;

1. Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer for technical support.

2000 Server bus offline The drive bus communication is interrupted

3800 Self-test failure The controller power-on initialization self-test fails Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

4010 Basic configuration file opening failure The user file of the controller fails to be read or is corrupted 1. Check if the bus cable of the servo drive is connected normally.

The factory parameter file of the controller fails to be read or is corrupted

4011 Factory data loading failure

Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

4022 Profile file saving failure Fail to save the Profile file in the storage 1. Switch on the power supply again;

4085 Profile format error The Profile file format is inconsistent with the requirements 2. Delete the original Profile file, create a new one, and save it.

The auto process switching time of the controller exceeds the allowable limit Check if the saved file format is correct

4087 Process switching timeout

1. Clear the fault and perform process switching again. If the fault occurs frequently, contact the manufacturer for technical support.

4089 Job file loading failure The Job file of the controller fails to be read or is corrupted

4091 Process configuration file opening error Internal software problem 1. Switch on the power supply again;

4092 Process configuration file reading error Internal software problem 2. Delete the existing Job file, create a new one, and save it

4093 Process configuration file closing error Internal software problem Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

40A1 Incorrect Sequence data format in process file Internal software problem Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support.

1. Check if the chassis is installed with a bus module normally;2. Check if the status indicator lamp of the bus module is normal.

5002 No bus module The bus module is not detected during power-on of the controller

5008 Slave spindle failure The slave spindle fault occurs in the multi-spindle networking application

1. Check which slave spindle is faulty and perform troubleshooting accordingly.

The CAN communication of the slave spindle is abnormal in the multi-spindle networking application

1. Check if the cable at the CAN communication interface of each slave spindle is connected normally;2. Check if the 120 Ω terminal resistors are connected to the two terminals of the bus network normally.

5009 Slave spindle offline

1. Check if the cable at the CAN communication interface of the master spindle is connected normally;2. Replace the controller set in the master spindle mode, switch on the power supply again, and check if the controller found to be faulty is switched to the mode in which the slave spindle is offline.

The CAN communication of the master spindle is abnormal in the multi-spindle networking application

500A Master spindle offline

1. Reset the correct time information, save it, and switch on the power supply again;2. Open the side cover of the chassis and check if the button battery on the control panel is fully charged.

5010 Controller time exception The time information of the controller is abnormal

1. Check if a strong electromagnetic interference source (such as electric arc welder) works around, and if any, avoid it;2. Switch on the power supply again. If the fault occurs frequently, contact the manufacturer for technical support

818D EtherCAT packet loss The frame is lost during PDO communication of EtherCAT

83 TCS.2000 Controller

8.3 Drive faults

Fault code (hexadecimal) Fault description Fault cause Solution

For the output phase current from the drive to the tool, the current feedback value exceeding the test threshold is collected.

1. Check for poor contact at both ends of the tool cable; 2. Contact manufacturer for technical support.

2214 Software overcurrent

2250 IPM bridge short circuit Internal fault of drive Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer and return the drive to the manufacturer for troubleshooting.

1. Increase the tightening speed and reduce the continuous output time of the tightening segment; 2. Adjust the tightening cycle and reduce the average load; 3. Select the tool with a wider range.

2310 Motor overload The average load is too high during long-time operation of the motor

1. Increase the tightening speed and reduce the continuous output time of the tightening segment; 2. Adjust the tightening cycle and reduce the average load; 3. Select the tool with a wider range.

2311 Drive overload The average load is too high during long-time operation of the drive

2330 Abnormal current sensor upon enabling The motor speed is detected when the tool is started Ensure that the motor is stopped when the tool is started.

1. Check if the input power voltage is too high; 2. If the fault occurs frequently, contact the manufacturer and return the tool to the manufacturer for troubleshooting.

3110 DC bus overvoltage The internal DC bus voltage of the drive is too high

1. Check if the input power voltage is too low; 2. If the fault occurs frequently, contact the manufacturer and return the tool to the manufacturer for troubleshooting.

3120 DC bus undervoltage The internal DC bus voltage of the drive is too low

1. Check if the external emergency stop switch input of the controller is active; 2. If the external emergency stop switch input is not activated, check if the cable or power supply of the internal emergency stop switch of the controller is normal.

3181 Drive STO disabled The STO input of the drive is active

In the three-phase power supply application, one phase of the input three-phase power supply is disconnected

3183 AC power input phase loss

Check the input three-phase power supply for missing or improper connection.

3199 Abnormal brake circuit Internal fault of drive Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer and return the controller to the manufacturer for troubleshooting.

1. Perform shutdown or switch off the power supply, and clear the fault after the drive temperature drops; 2. If the fault occurs frequently, reduce the work cycle; 3. If the fault cannot be cleared, contact the manufacturer and return the drive to the manufacturer for troubleshooting.

4080 IPM overtemperature The internal temperature of the drive is too high

1. Perform shutdown or switch off the power supply, and clear the fault after the drive temperature drops; 2. If the fault occurs frequently, reduce the work cycle; 3. If the fault cannot be cleared, contact the manufacturer and return the drive to the manufacturer for troubleshooting.

4310 Drive overtemperature The power circuit module temperature of the drive is too high

1. Switch off the power supply and switch it on again; 2. Check the connection of the network cable between the control panel and the drive panel inside the controller power supply; 3. If the fault occurs frequently, contact the manufacturer and return the drive to the manufacturer for troubleshooting.

The network cable between the drive and the controller is connected abnormally

5005 Drive network cable not connected

84 TCS.2000 Controller

Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer and return the drive to the manufacturer for troubleshooting.

5006 Bus not in OP state The drive does not enter the OP state due to the abnormality of the EtherCAT state machine

5530 Power board EEPROM fault Internal fault of drive Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer and return the drive to the manufacturer for troubleshooting.

5581 Control panel EEPROM fault Internal fault of drive Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer and return the drive to the manufacturer for troubleshooting.

5585 EEPROM version information error Internal fault of drive Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer and return the drive to the manufacturer for troubleshooting.

5586 Fail to write EEPROM Internal fault of drive Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer and return the drive to the manufacturer for troubleshooting.

1. Electronic gear ratio out of range 2. Drive parameter initialization error 3. EEPROM motor parameter loading error 4. Main circuit power-on timeout

1. Switch off the power supply and switch it on again; 2. Check if the input power voltage is too low; 3. View the drive fault alarm information through the drive debugging software.

6320 Electronic gear ratio out of range

The critical parameters of the drive are modified, and will be validated after manual confirmation of the configuration

6381 Configuration to be performed

Send the configuration command to the drive through the drive debugging software.

6581 Abnormal FPGA parallel port communication Internal fault of drive Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer and return the drive to the manufacturer for troubleshooting.

1. Check if the motor is stalled or stuck; 2. Check if the angle feedback of the motor encoder is normal during operation of the motor; 3. Clear the fault and restart the motor.

7082 Fail to locate the initial phase angle Internal fault of drive

7090 FPGA version information mismatching Internal fault of drive Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer and return the drive to the manufacturer for troubleshooting.

7091 Emergency stop The drive enters the emergency stop mode Cancel the emergency stop input command and clear the fault.

1. Check if the tool is stuck; 2. Check if the bolt is stuck before being tightened to the specified torque; 3. Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer for technical support.

7121 Stalling The motor is stalled for a long time

Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer for technical support.

7198 Runaway The motor is out of control during operation

1. Check if the tool is connected to the controller power supply; 2. Check the cable between the drive and the motor for poor contact.

7380 Communication encoder timeout The communication between the motor and the drive is interrupted

1. Check if the cable between the drive and the motor is grounded properly; 2. Check if PE of the input outlet of the controller power supply is grounded properly; 3. Check if a strong electromagnetic interference source (such as electric arc welder) works around, and if any, avoid it.

738D Communication encoder CRC check error

The communication between the motor and the drive is interfered or the data transmission is abnormal

85 TCS.2000 Controller

1. Switch off the power supply and switch it on again; 2. Check the connection of the network cable between the control panel and the drive panel inside the controller power supply; 3. If the fault occurs frequently, contact the manufacturer and return the drive to the manufacturer for troubleshooting.

The network cable between the drive and the controller is connected abnormally

7580 EtherCAT network cable not connected

1. Check if the motor runs at a such a speed that the set overspeed protection limit is exceeded due to an external force; 2. After the motor stops, clear the fault and restart the motor.

8481 Overspeed The motor feedback speed is too high, exceeding the set overspeed protection limit

Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer for technical support.

The drive does not enter the OP state due to the abnormality of the EtherCAT state machine

F080 EtherCAT State Not Operational

After the factory settings of the drive are restored, they need to be validated through saving, power-off and power- on

Send the saving command to the drive through the drive debugging software, save the settings, and switch on the power supply again.

FF03 Saving, power-off and restart

FF04 CPU overload Internal fault of drive Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer and return the drive to the manufacturer for troubleshooting.

FF16 MCU version information mismatching Internal fault of drive Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer and return the drive to the manufacturer for troubleshooting.

8.4 Tool faults

Fault code (hexadecimal) Fault description Fault cause Solution

If failed to get the screwdriver data, please contact the manufacturer for assistance

Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer for technical support.

The information stored in the tool fails to be read or is read abnormally

The temperature test circuit in the tool or the temperature test result is abnormal

Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer and return the tool to the manufacturer for troubleshooting.

2009 Abnormal temperature sensor

1. Check if the surface temperature of the tool is truly too high. If so, it may be caused by overloading of the tool. In this case, reduce the work cycle of the tool or use a new tool with a wider torque range;2. If the surface temperature of the tool is not too high, it can be concluded that a false alarm is given. After clearing the fault, monitor whether it is reported again;3. If the tool gives a false alarm frequently, contact the manufacturer and return the tool to the manufacturer for troubleshooting.

2010 Temperature protection The internal temperature of the tool is too high (above 120℃)

Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer for technical support.

5004 Fail to get the handle data The information stored in the tool fails to be read or is read abnormally

Switch off the power supply and switch it on again. If the fault occurs frequently, contact the manufacturer and return the tool to the manufacturer for troubleshooting.

5007 Abnormal torque sensor The torque test circuit in the tool or the torque test result is abnormal

5011 Tool maintenance The set maintenance cycle of the tool is reached Contact the manufacturer for tool maintenance.

86 TCS.2000 Controller

8.5 The NOK code

8.5.1 Overview of the NOK code

The NOK code is a 32-bit unsigned integer that represents failure or abnormal information during process execution. The hexadecimal representation of this code is u32, consisting of different bit positions (b0 - b31), with each part identifying a different error type. Based on its content, problems that occur during process execution can be quickly located and analyzed.

8.5.2 Structure of the NOK code

The 32-bit structure of the NOK code is divided into several regions, with each region representing a specific error type or failure information. The following is a detailed description of each field:

8.5.2.1 b0-b7: stop index of the process step

Meaning: This field is used to identify the stop index of the current process step. The process step stop index indicates that a stop or abnormal situation has occurred in a specific process step during the process execution, and further investigation may be required.

8.5.2.2 b8-b15: error category identification

The u8 region is converted to the corresponding decimal number: 0: The tool is running normally. 1: Received process stop signal Meaning: The process was interrupted during execution. Possible causes and measures: (1) Misoperation: The operator accidentally triggered the stop signal. It is necessary to confirm the source of the stop signal. (2) Control signal jitter: The signal instability leads to a false stop. It is necessary to check the signal stability or the hardware connection. 2: Servo failure Meaning: There is an abnormality in the servo motor or the servo system. Possible causes and measures: (1) Stall problem: The screwdriver is obstructed or stuck during operation. Check if the screwdriver operates smoothly. (2) System failure: The servo system is abnormal and needs to be repaired. 3: The process step displacement exceeds the limit. Meaning: During the execution of a process step, the displacement exceeds the preset range. Possible causes and measures: (1) Positioning mismatch: The screw holes are not aligned. It is necessary to re-position the tool and the screw holes. (2) Screw thread stripping: The tool rotates idly, causing abnormal displacement. It is necessary to replace the screw or adjust the process parameters. 4: The process step force exceeds the limit Meaning: During the execution of the process step, the torque exceeds the preset range. Possible causes and measures: Overshoot caused by high-speed stop: After the tool runs at high speed and reaches the target torque, the torque continues to rise when stopping. It is necessary to optimize the deceleration strategy or debug the torque control logic. 5: The process step execution timeout Meaning: The execution time of the process step exceeds the set limit. Possible causes and measures: (1) Screw misalignment: The screw is not fully aligned with the screw hole; the alignment process needs to be checked. (2) Screw thread stripping: It causes the inability to reach the target torque. Check the tool status and retighten.

87 TCS.2000 Controller

8.5.2.3 b16 - b23: Torque and angle failure identifiers

b16: Torque low failure Meaning: This error is triggered when the torque falls below the set lower limit during the execution of a process step. Identifier: 1: Torque low failure, 0: Normal. Possible causes and measures: (1) The screw hole position is not aligned: This causes the screwdriver to idle without applying effective torque. It is necessary to reposition the screw hole. (2) Screw thread stripping: It fails to provide sufficient torque. It is necessary to replace the screw or adjust the process parameters.

b17: Torque high failure Meaning: This error is triggered when the torque exceeds the set upper limit during the execution of the process step. Identifier: 1: Torque high failure, 0: Normal. Possible causes and measures: (1) It gets stuck during operation. Please check the condition of the screw and the thread, or whether there is any foreign matter that causes the failure due to high torque. (2) If the rotation speed of the tightening section in the process is set relatively high, the screwdriver will operate at a higher rotation speed when running in the tightening section. During the deceleration process after the screwdriver detects that the target torque has been reached, the torque will continue to rise, resulting in a final high torque failure. Suggestion: According to the situation of torque overshoot, appropriately adjust the speed of the process step in the tightening section.

b18: Angle low failure Meaning: This error is triggered when the angle falls below the set lower limit during the execution of a process step. Identifier: 1: Angle low failure, 0: Normal. Possible causes and measures: (1) Check the condition of the screw thread or whether there is any foreign matter causing the torque to reach prematurely. (2) If the torque is conforming or quite close to the standard, please check the previous process step to see if any abnormal situation occurred in that step, which led to the torque being reached ahead of time.

b19: Angle high failure Meaning: This error is triggered when the angle exceeds the set upper limit during the execution of the process step. Identifier: 1: Angle high failure, 0: Normal. Possible causes and measures: Situations such as misaligned screw holes or stripped screw threads cause the screwdriver to idle without bearing force, resulting in the angle exceeding the limit.

b19: Angle high failure Meaning: This error is triggered when the angle exceeds the set upper limit during the execution of the process step. Identifier: 1: Angle high failure, 0: Normal. Possible causes and measures: Situations such as misaligned screw holes or stripped screw threads cause the screwdriver to idle without bearing force, resulting in the angle exceeding the limit.

88 TCS.2000 Controller

b20: Global angle low failure Meaning: This error is identified when the global angle in the process is below the set lower limit. Identifier: 1: Global low angle failure, 0: Normal. Possible causes and measures: Check the condition of the screw threads or whether there is any foreign matter that causes the torque to be reached ahead of time.

b21: Global angle high failure Meaning: This error is identified when the global angle in the process exceeds the set upper limit. Flag: 1: Global angle high failure, 0: Normal. Possible causes and measures: Screw hole positions not aligned, stripped screws, etc., causing the screwdriver to spin idle without load, resulting in angle exceeding the limit.

8.5.3 Illustration of example

It is observed from the results that the corresponding result code in hexadecimal is 0x00050501. Parsing steps: 1. Process step stop index (u8): 0x01: Indicates that this Pset stops at the first process step. 2. Error category identifier (u8): 0x05: In decimal, it is 5, which is parsed as "The process step execution times out". 3. Torque and angle failure identifier (u8): Data: 0x05 Convert it into binary: 101b b16 (Torque low failure): 1 = Trigger torque low failure b17 (Torque high failure): 0 = Normal b18 (Angle low failure): 1 = Trigger angle low failure Therefore, the result code 0x50501 is parsed as: Error index: Step 1 (process step stop index 0x01). Error category: process step execution timeout (error category identifier 0x05). Failure reasons: Torque low failure (b16 = 1) Angle low failure (b18 = 1) The Pset execution stops at Step 1. The process step execution times out, resulting in torque low failure and angle low failure.

89 TCS.2000 Controller

90 TCS.2000 Controller

Instruction Manual

91 TCS.2000 Controller