Transducer
(programmed) 1 542846-12P 1 542846-31P 1 542846-36P 1 542846-48P
Transducer Capacity 12 Nm 31 Nm 36 Nm 48 Nm
5
Page 16
PL12EN-48EP
03/16/2015
“G”
15
Cleco?
Single Stage Gearing
Models
48EP(E)12Q
“F1”, “F2”
23
22
13 14 4
3
10
12
1
7
16
2
6
3
3
1 4
1 3 4 See Service Notes
17
5
5
11
8
19
18
Loctite?
222
Dead Handle Assembly
(not to scale)
20
21
9
Off
Page 17
PL12EN-48EP
03/16/2015
EN
Descrtption
1 1011732 1 4 O-Ring
2 203749 3 6 Needle Bearing
3 833688 1 2 Retaining Ring
4 541893 3 6 Planet Gear (21T)
5 542089 2 4 Ball Bearing
6 541914 1 Spindle Washer
7 541904 1 Front Nut
8 536592 1 Sleeve
9 844265 1 3 Steel Ball (1/8")
10 540842 1 2 Spring
11 540800 1 2 Washer
12 503009 1 2 Retaining Ring
13 800116 1 2 Retaining Ring
14 541887 1 Retention Washer
15 542090 1 Ring Gear (52T)
16 542092 1 Output Spindle
17 1019356 1 Wave Washer
18 542091 1 Gear Case
19 542076 1 Retaining Ring
20 541802 1 Screw
21 542220 1 Dead Handle (Includes Ref. 20)
22 541044 1 2 Pinion Adapter
23 541898 1 2 Extension Pinion
(#) Quantity
(X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation)
(T) Teeth
Illustration "G"
Ref Number # X
Cleco?
Single Stage Gearing
Page 18
PL12EN-48EP
03/16/2015
“H”
5
Cleco?
Single Stage Gearing
Models
48EP(E)12D2(B)
1
19
22
7
6
7
8
4
9
13
8
21
23
Off
3
3
3
1 3 4 See Service Notes
20 1 4
18
18
17
Dead Handle Assembly
(not to scale)
25
24
2
3
“F1”, “F2”
16
15
14
48EP(E)12D2B
12
11
10
48EP(E)12D2
Loctite?
222
Page 19
PL12EN-48EP
03/16/2015 Cleco?
Single Stage Gearing
EN
Descrtption
1 541044 1 2 Pinion Adapter
2 541898 1 2 Extension Pinion
3 800116 1 2 Retaining Ring
4 541887 1 Retention Washer
5 542090 1 Ring Gear (52T)
6 1011732 1 4 O-Ring
7 541893 3 6 Planet Gear (21T)
8 203749 3 6 Needle Bearing
9 542093 1 Output Spindle - Pin (includes Ref. 10-12)
10 23569 1 3 Button
11 27722PT 1 3 Spring
12 26989PT 1 3 Plug
13 543423 1 Output Spindle - Ball (includes Ref. 14-16)
14 94010006 1 3 Steel Ball
15 WS-252 1 3 Spring
16 LB-252 1 3 Bushing
17 1019356 1 Wave Washer
18 542089 2 4 Ball Bearing
19 542091 1 Gear Case
20 541904 1 Front Nut
21 542076 1 Retaining Ring
22 541919 1 Spindle Washer
23 800216 1 2 Retaining Ring
24 542220 1 Dead Handle (Includes Ref. 21)
25 541802 1 Screw
(#) Quantity
(X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation)
(T) Teeth
Illustration "H"
Ref Number # X
Page 20
PL12EN-48EP
03/16/2015
“I”
Cleco?
Double Stage Gearing
Models
48EP(E)25D3(B)
48EP(E)36D3(B)
1 3 4 See Service Notes
8
1
23
25
12
5
12
13
4
14
13
26
27
Off
3
3
3
24 1 4
5
18
21
20
2
3
“F1”, “F2”
48EP(E)(__)D2B
17
16
15
48EP(E)(__)D2
Loctite?
222
26
1 28
29
30 31
19 Off
11
11
9
10
3
32
7 3
6 3
22
Page 21
PL12EN-48EP
03/16/2015
EN
Descrtption
1 541044 1 2 Pinion Adapter
2 541898 1 2 Extension Pinion
3 800116 1 2 Retaining Ring
4 541887 1 Washer
5 542724 2 4 O-Ring
6 542722 1 Ring Gear
7 541899 1 2 Slip-On Gear (17T)
8 Table "I" 1 Idler Plate
9 541894 3 6 Planet Gear (17T
10 203749 3 6 Needle Bearing
11 541888 3 6 Planet Pin
12 Table "I" 3 6 Planet Gear
13 203749 3 6 Needle Bearing
14 Table "I" 1 Output Spindle - Pin (includes Ref. 15-17)
15 24499 1 3 Button
16 9D6481 1 3 Spring
17 26989PT 1 3 Plug
18 Table "I" 1 Output Spindle - Ball (includes Ref. 19-21)
19 1091PT 1 3 Steel Ball
20 WS-371 1 3 Spring
21 LB-370 1 3 Plug
22 1019356 1 2 Wave Washer
23 542723 1 Gear Case
24 541904 1 Front Nut
25 542134 1 Spline Guard
26 542089 2 4 Ball Bearing
27 541775 1 Bearing Spacer
28 542097 1 Retaining Nut
29 542076 1 3 Retaining Ring
30 541919 1 Spindle Washer
31 800216 1 3 Retaining Ring
32 542127 1 Reaction Bar
(#) Quantity
(X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation)
(T) Teeth
Illustration "I"
Ref Number # X
Cleco?
Double Stage Gearing
Table "I"
Ref. Descrtption # 48EP(E)25D3 # 48EP(E)36D3
8 Idler Plate 1 542230 1 542233
12 Planet Gear 3 541894 (17T) 3 541897 (21T)
14 Output Spindle - Pin 1 541916 1 541917
18 Output Spindle - Ball 1 543424 1 543425
(T) Teeth
Page 22
PL12EN-48EP
03/16/2015
“J”
Cleco?
Double Stage Gearing
Models
48EP(E)48D3(B)
1 3 4 See Service Notes
7
1
22
24
11
5
11
12
4
13
12
25
26
Off
3
3
3
23 1 4
5
17
20
19
2
3
“F1”, “F2”
48EP(E)48D2B
16
15
14
48EP(E)48D2
Loctite?
222
25
1 27
28
29 30
18 Off
10
10
8
9
3
31
6 3
21
Page 23
PL12EN-48EP
03/16/2015
EN
Descrtption
1 541044 1 2 Pinion Adapter
2 541898 1 2 Extension Pinion
3 800116 1 2 Retaining Ring
4 541887 1 Washer
5 542724 2 4 O-Ring
6 542668 1 Ring Gear
7 542671 1 Idler Plate
8 541893 3 6 Planet Gear (21T
9 203749 3 6 Needle Bearing
10 542666 3 6 Planet Pin
11 542669 3 6 Planet Gear (17T)
12 203784PT 3 6 Needle Bearing
13 542670 1 Output Spindle - Pin (includes Ref. 14-16)
14 24499 1 3 Button
15 9D6481 1 3 Spring
16 26989PT 1 3 Plug
17 543426 1 Output Spindle - Ball (includes Ref. 18-20)
18 1091PT 1 3 Steel Ball
19 WS-371 1 3 Spring
20 LB-370 1 3 Plug
21 1019356 1 2 Wave Washer
22 542673 1 Gear Case
23 541904 1 Front Nut
24 542134 1 Spline Guard
25 542089 2 4 Ball Bearing
26 542672 1 Bearing Spacer
27 542097 1 Retaining Nut
28 542076 1 3 Retaining Ring
29 541919 1 Spindle Washer
30 800216 1 3 Retaining Ring
31 542127 1 Reaction Bar
(#) Quantity
(X) Recommended Spare Parts (quantity shown based on 1-5 tools in operation)
(T) Teeth
Illustration "J"
Ref Number # X
Cleco?
Double Stage Gearing
Page 24
PL12EN-48EP
03/16/2015 Cleco?
Service Notes
Ft-Lbs
(in-lbs) Nm
1 (10-14) 1,1-1,6
2 (10-14) 1,1-1,6
4 (10-14) 1,1-1,6
5 (50-55) 5,6-6,2
13 (Swivel) 15-18 20-25
1 (4-6) 0,45-0,68
6 (4-6) 0,45-0,68
G 7 35-40 47-54
H 12 35-40 47-54
28 30-35 41-47
24 35-40 47-54
27 30-35 41-47
J 23 35-40 47-54
E1, E2
I
Illustration Reference
Tightening torque
D1, D2
1 Tightening Torque
2 Transducer Identification
3 Gear Train Lubrication
5
Part Id Stamped
on this end
Transducers are not interchangeable, check part number.
541444 - 2 oz. (56 g)
541445 - 1 pound (0.45 kg)
Idler
Gears
Ring
Gears
Pinion
Gears
Grease Grease
4 Spanner Wrench
Pin - 3/16”
Spanner
Wrench
Off
Page 25
PL12EN-48EP
03/16/2015 Cleco?
Service Notes & Tool Memory Parameters
5 Retaining Ring Assembly
Model Number Max Speed
Introduction 2-3
Product Descrtptions 4-25
Building A Safety Critical DC Fastening System . 26
Cordless Transducer Control Tools 28
Right Angle Tools . 28
Pistol Tools . 29
Tube Nut Tools . 30
Crowfoot Tools . 31
Corded Transducer Control Tools . 32
Right Angle Tools 32
Inline Tools . 34
Pistol Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Push-to-Start Tools . 37
Inline Floating Spindle Tools . 38
Hold & Drive Tools . 40
Flush Socket Tools 41
Tube Nut Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Crowfoot Tools 43
Right Angle Floating Spindle Tools 44
Building A Quality Critical DC Fastening System 46
Corded Current Control Tools 48
Right Angle Tools 48
Inline Tools . 49
Pistol Tools . 50
Push-to-Start Tools 51
Inline Floating Spindle Tools 52
Hold & Drive Tools 53
Flush Socket Tools . 54
Tube Nut Tools . 55
Right Angle Floating Spindle Tools . 56
Crowfoot Tools . 58
Building A Safety Critical Fixtured DC Fastening System 60
Fixtured Transducer Control Tools . 62
Intelligent Spindles . 62
Intelligent Spindle Accessories 88
Conventonal Fixtured Spindles 90
Conventonal Fixtured Spindle Accessories . 112
Controllers 114
mPro400GC-M, -P, -S, -SG Panel Controllers . 114
mPro400GC-E, -I Controllers 115
mPro400SG Controllers . 116
Software 119
Accessories 121
Isolation Transformer 121
Tool Cables . 122
Cordless Tool Accessories 123
Corded Tool Accessories . 124
Balance Arms & Balancers 128
General Accessories & Information . 130
Apex Bits & Sockets 132
Conversion Charts . 134
Model Number Index . 137
Waranty & Lubrication 140
Safety
Critical
Quality
Critical
Accessories
Controllers
Fixtured
Safety
Critical
Cleco's fastening technology is used globally and
across all industries. This technology is used in
Aerospace, Motor Vehicle, Offroad, Wind Energy,
Agriculture, and a great multitude of applications
within general industry where “quality critical”
requirements are the rule. In motor vehicle
environments across the globe, Cleco and DGD's
complete line of transducerized electric tools are
used in “safety critical” applications where spot-on
precision and traceability are required. And finally, in
one of the most demanding environments, our line of
DC electric tools are used in aircraft assembly where
“good enough” will never be acceptable.
Because of our drive for perfection, you can excel
in your job. Indeed, due to our uncommon focus on
total fastening solutions instead of just products, our
customers look upon us not merely as vendors, but
as strategic allies. And at Apex, we welcome the
challenge of leadership this imposes.
The Systems
Cleco's state of the art Tightening System delivers
unprecedented performance, productivity and
accountability in both “quality critical” and “safety
critical” assembly applications.
Durability, speed, and ergonomics are achieved using
the corded Cleco DC electric tools with a complete
line of tool configurations and an assortment of
controller options to choose from.
2
The Total Solution For Safety & Quality Critical Fastening Operations
The Cleco LiveWire? system provides the most
cost-effective safety critical fastening solution available
in the world today. By marrying cordless tools and
WiFi communications, the operators gain the mobility
and flexibility they need to increase productivity and
reduce in-system damage costs. One line controller
managing up to 16 cordless tools while utilizing the
most up-to-date wireless encryption technology
provides
a cost savings unparalleled in industry today.
When considering the cumulative impact of all these
components – the tools, the controllers, the software,
the flexibility, the accessories and the support – it is
easy to see why the Cleco Tightening System is the
benchmark for all DC electric tool systems.
3
Label Printer
Ethernet TCP/IP
System Bus
Fieldbus
Tool
Serial – RS232
Serial – RS232
Discrete I/O – 24vdc
Serial – RS232
Serial – RS232
Socket Tray
Wireless
Torque Wrench
Operator
ID
Barcode
Scanner
4
Cleco mPro400GC Global Controller
The Most Flexible, Cost-Effective Introducing the Cleco mPro400GC Global Controller, the first controller for safety-critical applications that
offers unsurpassed levels of flexibility, connectivity, and serviceability while providing superb torque accuracy
and process control. This new controller incorporates the advanced technical features of the proven DGD
mPro system with the user-friendly software of the trusted Cleco TME controller, resulting in a powerful
control solution that offers impressive cost savings through unequalled flexibility.
Corded, Cordless, Or Fixtured ... All From One Controller
The Cleco mPro400GC Global Controller is compatible with all Cleco 18-48 Series DC electric corded
tools, LiveWire cordless tools, and all DGD and EMT fixtured spindles. That means fewer controllers and
cables are needed for your line. And that means savings…up to 50% over traditional systems.
Reduce System Costs Up To 50%
■ 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 $$$
Parts (cables & controllers) $
Total System $avings $$
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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
Automated Systems is the recognized leader in the
design and manufacture of multiple spindle wheelnut
assembly systems. We are known across the
globe for excellence of innovative engineering
design, support, and quality award winning service.
Decades of expertise in the design and manufacturing
of multiple spindle fixtured and portable
assembly systems have identified Automated
Systems as an experienced, innovative supplier
capable of creating custom solutions matched to
unique customer assembly requirements.
Automated Systems makes use of standard system
building block components which are used
to blend a custom system from a complete line of
DC electric spindles, fastening controllers and an
extensive listing of twenty-four different fastening
strategies which not only include the usual Torque
Control, Angle Control and Yield, but also includes
the unusual Pulse Torque Recovery makeup
torque fastening strategy awarded US Patent
number 5,094,301.
Medium Duty Wheelnut Tool
For Passenger Vehicles requiring
Medium Torque, High Volume
? 100 Nm to 500 Nm
Automated Systems supplies custom Wheelnut
multiple designs using standard major components
with proven track records for reliability,
lifetime performance, millions of cycles capability
and ergonomic solutions which support operator
safety, comfort and efficiency.
Heavy Duty Wheelnut Tool
For Trucks requiring High Torque,
Low Volume
? 700 Nm to 1200 Nm
Automated Systems Wheelnut multiples use highefficiency
electric motors manufactured specifically
for this application. Available motor torques range
from 700 Nm to 1200 Nm. Motor spindles can be
mounted and arranged to match any bolt circle
pattern, using standard in-line motors with or
without offset gearing.
Automated Systems
Wheelnut Fastening
23
Automated Systems
Wheelnut Fastening
Adjustable Wheel Stud Centers
When several similar wheels need to be assembled
and the economics of separate powerheads
dictates a single powerhead, Automated Systems
has the answer! Adjustable stud centers. The position
of the studs can be controlled by an operator
manual switch, or auto detection.
Budd Double Wheels
When it comes to fastening inner and outer wheel
lug nuts including Budd style stud/nut adapters,
a wheelnut powerhead requires long retractable
spindles which are designed to prevent side
loading. Automated Systems has the know-how,
and the products to supply wheelnut multiples for
double wheel truck applications. Our wheel equipment
is more rugged than the trucks it assembles.
Suspension
System
A properly designed
suspension system can
not only support the
tool and return it to a
home position, it can
also provide a zero gravity
lift and hold. The total
weight of the tool
is controlled by the
operator with very little
pressure required to
move the tool up or
down.
Local Operator Display
(Operator Interface)
Each powerhead
displays a red, green,
and yellow LED on a
per spindle basis. The
LED display indicates
the status of the last
tightening as NOK,
OK and Low Torque or
Angle. An optional local operator interface display
can be used to display output, and accept touch
screen switch inputs.
Some of the uses of a local operator display include:
? Application selection
? Tool home position jog
? Overall fastening status in green or red
? Part graphics
? Fastening values for torque and angle
? Functional push-button inputs & display outputs
24
Push-off and Return
On moving transfer lines, the overhead suspension system
can be mounted to an overhead track, supporting the
multiple. At the conclusion of the fastening rundown by all
spindles, the suspension pushes the tool away from the
wheel and returns the tool to the home position ready for
the next wheel. The vehicle on the assembly transfer line
continues to move while the lug nuts are being tightened.
Application Detection of
Aluminum and Steel Wheels
Wheel lug nut tools are distinguished from standard horizontally
aligned systems by their cylindrical shape. Rotation
of the tool is required for proper alignment with the wheel
lugs, and the ability to provide a clear line of sight for the
operator. In addition, a 6 spindle tool can be rotated 30
degrees, rundown a second time and tighten the alternate
6 lug nuts on a 12 lug nut wheel. This alternative design is
tightening dual truck wheels, and can automatically determine
if the wheel is aluminum or steel and change the
fastening parameters automatically.
Automated Systems
Wheelnut Fastening
Shown are two
manually operated
vertical multiples and
one semi-automatic
DC electric systems.
25
Automated Systems
Intelligent Spindle Field Cables
Shown above is a ten Intelligent spindle application with nine jumper cables and a single
field cable that terminates at the power distribution box.
Shown above is a seven Intelligent spindle application with six jumper cables and a single field cable that terminates at
the power distribution box.
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. We offer both
HighFlex for fixed or flexible routing
for heavy duty requirements and
SuperHighFlex for robotic and all
high mobility applications. See
