CONTROL UNIT TPU-A3 – 120V

The TPU-A3 – 120V control unit is capable of managing and controlling all the functions of the paired eTensil brushless electric screwdrivers with torque/angle control by integrated transducer. The torque is detected by the electronic transducer, while the angle is measured through dedicated Hall sensors, both integrated into the tool.

• Allows in-process torque adjustments during work by modifying the relevant parameter on the operating panel
• Displays, at the end of each tightening cycle, of the TORQUE VALUE detected by the transducer, the ANGLE VALUE measured during tightening, as well as the OK/NOK status and the TIGHTENING TIME.
• It detects process anomalies, by CHECK TIGHTENING TIME for example stripped threads or screws already tightened
• It communicates with the outside, the PLC or other devices, and can be controlled remotely
• Works as Poka Yoke system when tightening critical joints. Should you have elastic gaskets, rubber elements or other materials, the control unit verifies that these are present or not during the process
• Allow to communicate the phase and the system status and to remote control the tool

FUNCTIONS: here are some of them, essentials to monitoring a tightening process correctly and making it reliable.

• 8 programs to control tightening process
• 1 programmable sequence up to a max of 8 steps
• Retention function: programmable waiting interval between programs
• Automatic recognition of the connected tool and setting
• Screws counting: effective Poka Yoke device
• Min/Max tightening time control – Poka Yoke System
• Settable untightening speed
• 2 level password: to protect the set parameters or totally block the system
• Unit calibration
• Available measurements units: Nm/Lb/In./Kgf.cm
• Language selection (IT, EN, DE, FR, ES, TR)
• Serial communication (RS232)
• Storing the outcome of the last 99 tightening
• Interfacing with working stations and its devices
• Selection of programs from I/O (remotely)
• Min/Max tightening angle control – Poka Yoke system
• Program Source function: when external devices – such as automatic accessory selectors – are connected, it is possible to manage the program‑selection mode
• “SMART THREAD” function for processing of selfthreading, self-tapping, self-drilling screws, or else where the final torque value is lower than thread forming torque
• “SMART SPEED” function useful for speeding up the production process. It is possible to create a “two-phase” tightening strategy: screwdrivers start with a high-speed rotation until reaching the set angle, then rotate at a pre-defined speed that allows to maintain the accuracy of the result. This function optimizes the tool’s behavior in applications with very hard joints, where it is necessary to precisely manage the progressive reduction of the initial speed in order to reach the final torque in a controlled mode. Thanks to the integrated torque transducer and the parametrization of the threading angle, it is possible to: • control the approach to the target torque with greater accuracy • reduce speed progressively and repeatably, improving process control and tightening reliability.

PROGRAMMING SMART PRO EVO, other functions can be set on the unit:

TIGHTENING STRATEGIES

• Torque control
• Torque control and tightening time monitoring
• Torque control with tightening angle monitoring
• Torque control with time and tightening angle monitoring
• Angle control and torque and time monitoring
• Time control and torque and angle monitoring (Stop-by-time tightening)
• Prevailing Torque
• Average torque monitoring (rolling)

• PRE-AUTO UNTIGHTENING: it is possible to set the untightening angle and the pause between the untightening and the subsequent tightening. This strategy finds its application in the electrical / electronic field, for example when it is necessary to open and then close connectors to insert electrical wires (see video 1)
• POST-AUTO UNTIGHTENING: the untightening angle is settable as well as the time pause of left rotation start after the tightening end (see video 2)
• STOP-BY-TIME TIGHTENING: to tighten in depth and not to defined torque, by controlling the cycle with set tightening time. When it is necessary to tighten threaded fasteners to a certain height and not to a defined torque. This is made by checking the tightening time (see video 3)
• SMART TORQUE PROGRAMMING: allows setting a torque limit value beyond which the system automatically stops the tightening cycle. This function is useful to prevent abnormal and unsafe conditions for the operator, such as hand‑arm system kickbacks caused by high torque generated by damaged threads or non‑conforming components. It enhances process safety and reliability by enabling the immediate identification of component non‑conformities (defective threads, irregular materials, etc.).
• PREVAILING TORQUE: monitoring of the average torque detected over the entire threading angle, with configurable acceptance thresholds for minimum and maximum values. At the end of the threading angle, the screwdriver considers as target torque the set torque plus the detected average torque, in order to compensate for any torque losses due to friction. Possibility to choose whether to display only the Peak Torque of the final phase or the Peak Torque of the final phase + the Average Torque detected during the threading phase. Benefits: material quality control and rejection of parts with out-of-range values. For example, in tightening applications with self‑locking nuts, where it is necessary to overcome the high friction generated by the plastic insert to prevent possible loosening of the nut. The prevailing torque function therefore allows monitoring the quality of the self‑locking nuts used.
• AVERAGE TORQUE MONITORING (ROLLING): “test” function to display and verify the average torque on the component, by setting an angle-based strategy with: Threading angle = maximum angle = minimum angle. By setting the MIN and MAX Prevailing Torque according to the limits required by the customer, it is possible to verify the integrity of the component within the defined acceptability range. Typical application: integrity check of bearings.

FEATURES

• I/O Port : 8 inputs/8 outputs programmable (21+22 signal types)
• 7 LEDs for immediate display of the process status
• ESD certification
• Power cable
• 120 Vac ±10% 50-60 Hz
• EXTENDED WARRANTY: 2 years or 1 million cycles

APPLICATIONS

Thanks to their advanced technology, they guarantee maximum accuracy and precision in tightening, making them indispensable in industrial sectors where process control is essential for the quality of the finished product.
Moreover, by eliminating post-process checks used in traditional systems, they help reduce production time and costs.