■ Configure up to 32 DC spindles in varying configurations.
Consult your Apex representative for details.
■ Facility Cost Savings
? Installation Expenses: Save on Ethernet and
power drops, controller stands, cable
management, labor to install and support
? Production Expenses: One controller
means fewer backups, fewer repairs,
fewer headaches and one-time training
Control System
Customer
Control
System
Corded Hand Tool
DGD
Conventional
Spindles
DGD Intelligent Spindles
Unique Technology, Smallest Hardware Foot Print, Best TCO.
CPM3 system with
internal power
transformer
Data Server mPro Remote
Programming
Access
Point
5
Effective Systems Controller ... Ever
6
Cleco mPro400GC Global Controller
Universal connectivity begins with global autosensing
input voltage, 16 configurable inputs and
outputs, plus DeviceNet, Ethernet-IP, Profibus and
Profinet fieldbus standards. Userfriendly
software mapping of discrete
and fieldbus selections provides
ultimate error-proofing control. Dual
fieldbus ports allow redundant
I/O mapping or expansion. Utilize
two different fieldbus standards
simultaneously for maximum flexibility.
The Cleco mPro400GC Global
Controller comes standard with a
system bus to manage internal data
flow and avoid burdening outside networks. It can
be utilized for rapid “grab and go” connectivity
to accessories, such as adding error-proofing
from socket trays, stack lights, or operator boxes.
Configurable software menus allow quick integration
into any process. With up to 32 configurable nodes
on the system bus, endless errorproofing
combinations are possible.
The system bus can manage
multiple secondary controllers in
combination with single and multispindle
stations. Spindle sequencing,
data management, and diagnostics
are just a few of the many functions
performed. In addition, DGD?
Fixtured Intelligent Spindles can
utilize the system bus to drive up to 30% of cost out
of a traditional system through cable reduction,
maximizing acquisition and facility cost savings.
Universal Connectivity Ethernet
Connections (2)
USB Ports
(2 bottom, 1 front)
System Bus
Connection
Auto-Sensing
Voltage Input
GFCI
Serial Ports (2)
Digital
Input/Output
(16)
Redundant
Fieldbus
Interface
Tool Cable
Connector
Universal
Connectivity
■ Auto-Sensing Voltage
■ 16 Configurable I/O’s
■ Redundant Fieldbus
■ Redundant Serial
and Ethernet Ports
■ Isolated System Bus
7
Remote
Programming
Ethernet
TCP/IP
For Ultimate Flexibility
User
Friendly
GUI
Quick-
Start
Auto
Program
Option
Oscilloscope
Process
Management
In-Depth
Data
Management
Easy-To-
Read Run
Screen
Digital Image
Bolt
Sequencing
Rundown Data Storage
The mPro400GC supports TorqueNet, our data
collection and archiving software, as well as other
industry standard software packages. Protocols are
available for many of the standard products.
The Cleco mPro400GC Global Controller works
seamlessly with current protocols and offers
significant performance advantages over traditional
systems. Features include:
n A single software program that covers both
standard and fixtured applications
n Standard spindle sequencing and
reject management
n 19 advanced fastening
control sequences standard
at no additional cost
n Remote programming software
with no licensing restrictions
n Touch screen display with
integrated alpha-numeric keyboard
No Software
Licensing!
8
Cleco mPro400GC Global Controller
Superior Serviceability For Master/Primary Unit
Installation Flexibility
At only 10”w X 15”h X 15”d (254mm X 381mm X 381mm) and weighing
just 30 lbs. (13.6 kg.), the Cleco mPro400GC is smaller and lighter
than most traditional controllers. It can be lifted easily by a single
person and will mount just about anywhere.
10 ” x15 ” x15 ”
(254mm X 381mm X 381mm)
And Just
30 lbs. (13.6 kg.)
9
For Exceptional Ease-Of-Use
Secondary Unit
Quick Mount Bracket
No more templates and measuring mounting hole patterns...installation of the
mPro400GC is simple with a separate receiver bracket that makes locating
mounting holes easy. The unit then attaches directly to the bracket so the
installation is fast and foolproof.
Integrated Cable
Management
The mPro400GC mounting bracket
incorporates an integral cable management
channel, so installations stay orderly and easily
accessible. Clearly labeled connectors and top-down
cable routing means a clean installation with no
guesswork. Mounting was designed to be simple and
effective to get you up and running fast.
CompactFlash? Memory
For Production Uptime
A standard CompactFlash card
reliably stores:
n Operating system
n Drivers
n Network settings
n Application parameters
n Torque data
Positioned on the back of the unit for added security
and tamper resistance, the card is still easily accessible.
n Rapid controller swap with 50-second boot
n No licensing or proprietary hardware
n Card stores up to 10,000 rundowns
Secondary Controller Functionality
A secondary controller is controlled from a master or primary unit. It
has I/O for local error proofing and peripherals, plus a LCD for operator
feedback and troubleshooting.
50
Second
Boot!
10
Electric Nutrunners – Cordless Transducer Control
LiveWire? Wireless Communications
LiveWire? offers precision torque, angle
and speed control features for safety
critical fastening in an ergonomic,
wireless design.
With up to 1,700 rundowns per battery
charge or continuous power, your safety
critical applications are assured to never
run out of power.
LiveWire? has been
designed and tested to
provide wireless
connectivity across the
harshest of machine-tomachine
environments.
All The Brains. All The Power. Electronic
Intelligence
■ On-board controller with
power management
■ Integrated servo with I/O
signal handling
■ Auto sensing power
intelligence
■ 512 cycle memory buffer
Digital Process Control
■ Auto bolt sequencing
■ Auto image selection
■ Configurable reject management
11
Configurable
LED Illumination
Power. And It’s Wireless.
Integrated Bar Code Scanner (optional)
■ Enables real-time bar code data collection
■ Programmable bit for Auto Parameter Select
■ Tool enable and disable configurability
Operator Display
■ Real-time interface
■ Redundant feedback
? Green LCD = OK
? Yellow LCD = Running
? Red LCD = NOK / Errors
? Green LED = OK
? Red LED = NOK
■ Configurable application buttons
12
The Most Cost-Effective Safety Up To 50% Savings Over Traditional Systems!
Mobility is a major advantage with wireless communications. Cleco LiveWire? marries the
freedom and flexibility of cordless tools with real-time wireless error proofing. Utilizing an
industry standard 2.4/5GHz WLAN (Wireless Local Area Network) interface in conjunction
with the highest security encryption and authentification levels, plus a 512-cycle tool
memory buffer, LiveWire? ensures you will never
compromise safety critical
data transmissions.
Up To 16
LiveWire
Tools.*
1 Line
Controller.
*Contact Regional Application
Center for requirements
greater than 10.
Electric Nutrunners – Cordless Transducer Control
LiveWire? Wireless Communications
12
2.4 or
5GHz
WLAN
13
Safety Critical Solution Available
Wireless Security
■ WEP (Wired Equivalent Privacy)
? 64/128 Bit Encryption
■ WPA (Wireless Protected Access)/WPA2/802.1x
? 128 Bit TKIP/CCMP Encryption
? 802.1x
Authentification pre-shared
keymode (PSK) - LEAP, PEAP
Up To 83% More Productivity!
Cleco LiveWire? tools are now available with Vmax?, a solution that drives tool power and speed
increases up to 83% without losing accuracy or durability. This leading innovation utilizes the same
10 tools to one line controller hardware solution with up to 50% cost savings over traditional systems.
New Vmax? technology auto-senses the applied power source and adjusts the maximum tool
speed capability on the fly. LiveWire? with Vmax? combines the power you need with the most
versatile wireless system available today.
13
14
Durability. Speed. Cleco 18-48 series tools are driven by a maintenance-free brushless motor with up to 50%
more speed and productivity. This motor technology coupled with our high-resolution resolver
offers full range control for safety critical joints. The 18-48 series tools with industry proven gear
trains create outstanding durable production performance.
The Cleco 18-48 series electric tools provide a unique modular assembly design for ease of
repair. The on-board intelligent memory chip records tool set-up values and counts
cycles for maintenance scheduling to prevent costly production downtime.
Highly visible operator
feedback LEDs
Intelligent
memory
chip
Low
compression
switch
Ergonomic handle for
operator comfort
Resolver technology
for full range
speed control
Tools shown with Apex? u-Guard? protective covered industrial sockets. Cover spins independently of socket virtually eliminating damages Error free
connector
(in tool handle)
Air-LB
(Tools with Matrix connector
available upon request.)
Electric Nutrunners – Corded Transducer Control
15
Ergonomics.
Optimal tool weight
and balance
Reaction transducer for
consistent torque
repeatability
Standard tools
required
for service
Durable
industry proven
gear train
damages and risks associated with incidental contact between the tool and the workpiece or user. Not included with tool.
Adjustable
angle head allows
Low inertia brushless motor flexible orientation
for superior fastening control
16
Durability. Speed. Cost Effective Solution for Quality Critical Applications.
Cleco CurrentControl electric assembly tools provide an up-sell solution to quality critical
applications presently specifying a pneumatic clutch tool and verifier combination. Cleco
proprietary CurrentControl systems up-sell on superior productivity, error proofing
and process flexibility.
Our Cleco controller systems are recognized globally for “best in class” software
interface. This is accomplished through simple navigation, basic
programming screens, visual programming graphics and real-time process
feedback. Our latest innovation “Auto Program” takes the guesswork out
of programming. Simply enter the application torque target and the
software automatically compiles the program for production use.
Adjustable
angle head
allows
flexible
orientation
Unrestricted
Speed Control
Electric Nutrunners – Corded Current Control
17
Speed. Ergonomics.
Why CurrentControl vs. Pneumatic Clutch?
Superior Productivity
n Up to 2–3X faster
n Unrestricted speed control
n Up to 25% less noise
n Cleaner operating environment
n Auto torque sequencing
n Proven production durability
Superior Process Flexibility
n 255 programmable tightening strategies
n 6 configurable stages per strategy
n Angle process control/monitoring
n Counter-clockwise process
control/monitoring
n Less parts to maintain – no clutch
n 100M field cable lengths
Superior Error Proofing
n 96 position fastener count
n 9 tool LED operator feedback
n 8 configurable I/O
n Fieldbus ready
n 5,000 tightening cycle storage
n Advanced system diagnostics
n Barcode application select
Easy Setup 1-2-3-Go!
1. Select “Basic” from menu. 2. Enter final torque value.
3. Tool automatically programmed. Go! Production ready.
18
Productivity That Drives Intelligent Spindles
Introduced in 2005, DGD Intelligent Spindles were the
first fixtured nutrunners that offered onboard servo and
modular construction. Today, these third generation
nutrunners are based on over 50 years of proven
success of our conventional spindles.
DGD Intelligent Spindles combine high speed,
exceptional up time availability, and unprecedented
accuracy and durability in a compact design that
requires substantially less cabling than
traditional nutrunners. The result is
productivity gains at a lower cost,
with up to 30% savings on initial purchase price. DGD
Intelligent Spindles also offer easy integration with
Cleco electric tool products, including the new Cleco
Global Controller.
Up To 170% Faster
With sealed, long-life, maintenance-free 380
VDC motors, DGD Intelligent Spindles are
faster than a conventional spindle at most
every torque level.
Compact
On-Board Intelligence
The on-board servo module is
proven technology that has been tested to:
? Shock & Vibration: 3 dimension at 13G
? Temperature : 45° C
? MTBF of 7 million cycles
Durability &
Accuracy
The BTS and BTSE
nutrunners are certified
to the highest standard of
accuracy and durability.
? ISO certified to
± 2% accuracy
? 1 million duty cycles
maintenance free
? 3 million cycle guarantee
@ 80% of capability
Reduced Field Cables
DGD Intelligent Spindles provide a solution for the
number-one cause of shut-down … cable failure
… by substantially reducing the number of cables
needed. Where DGD conventional spindles each
need a separate cable, up to 16 Intelligent Spindles
can be run from a single field cable by cascading
cables between spindles.
Field Cable
CPM3
DGD Speed Comparison
Torque
(Nm)
DGD
Conventional
Spindle
DGD
Intelligent
Spindle
DGD
RPM
Advantage
10 1222 1921 57%
50 329 890 170%
100 329 890 170%
150 219 502 137%
200 220 502 48%
19
Drives Cost Savings
Acquisition & Installation Costs plus Floor Space Are All Reduced
System Simplicity
Cost effective
DGD Intelligent System
Older and more expensive
DGD Conventional System
Savings with a DGD 10 Spindle
Intelligent Spindle System
vs. DGD Conventional System
In The Following Areas
Festooning Hardware
(including installation)
Installation Labor
System Field Cables
Replacement Spare Parts & Cables
Trouble Shooting Time
System Availability
Incredible $avings!
DGD Conventional Spindle
System Solution
DGD Intelligent Spindle
System Solution
DGD 10 Spindle
Requirements
Conventional Intelligent
10 Controllers 1
10 Field Cables 1
10 Power Interface
Points 1
5 hrs. Cable Festooning
Time 1 hr.
5 hrs. Controller
Installation Time 1 hr.
5 hrs. Startup/Debug
Time
3
hrs.
6
sq.ft.
Required
Floor Space
3.5
sq.ft.
No
Ability to add
additional tools to
existing controller
Yes
$avings Time &
Material
Tools, Cables & Controller $
Installation $$$
Parts (cables & controllers) $
Total System $avings $$
?
?
?
?
?
?
20
Your Single Source For
Custom Automated Systems
Automated Systems provides custom solutions
for the automated fastening of threaded joints.
Our global customers span the entire vehicle
assembly market, including passenger cars and
trucks, power train assembly, off-road vehicles,
and agricultural machines. We support machine
tool builders in the vehicle and industrial markets
with custom fastening system designs based on
proven fastening product building modules.
Over many decades, Automated Systems has
been providing custom solutions for training,
service, and support. From single handheld
nutrunners to multiple spindle machines, our
custom designed systems are used around the
world in an interesting variety of applications.
We have a full support staff of Sales Engineers,
Mechanical Engineers, Controls Engineers,
Project Managers, Field Service Engineers and In
house Service Engineers waiting to serve you.
Custom Automated Solutions
The custom designed equipment Automated
Systems creates can be configured in either
vertical or horizontal orientations depending
on the application and customer requirements
Automated Systems
An automatic station on an engine assembly line uses two
opposing electric power heads, each having 8 spindles, and a
center power head of 6 spindles.
Shown are two semi-automatic DC electric systems
to secure camshaft cover fasteners and water pump
assembly mounting fasteners.
21
Automated Systems
The left
cylinder head of
a V12 engine is
being fastened using
a 26 spindle fixtured
electric multiple. The suspension
system has been designed to not
only support the weight of the
tool, but to rotate into fastening
alignment with the cylinder head
on the right side of the engine.
utilizing standard components. Designs may
incorporate operator input or be fully automated
dependent on the needs of the customer.
Automated Systems’ products use high-efficiency
electric motors manufactured specifically for
this application. Available motor torques range
from 2 Nm to 4,000 Nm. Motor spindles can
be mounted and arranged to match any pattern
using standard in-line, special offset, and 90°
angle electric motors.
In order to apply our powerhead designs, we also
design custom suspension systems along with
cable management systems to provide support
and movement. In addition to custom built
stations fitted with fixtured nutrunner powerheads,
Automated System designs, builds, installs and
provides service and support from the complete
fastening lines.
The above manually operated railroad wheel bearing multiple has the capability to tighten three (3) fasteners equally spaced on various
centers between 3.50” to 5.85” diameters up to 600 NM torque.
22
Wheelnut Fastening
