Conventional vs Smart Tensioning

The evolution of Bolt Tensioning

Until now, the bolt tensioning process has been dependent on equipment and operators efficiency and skills. STS - (Smart Tensioning System) is the first truly smart bolt tensioning system which enables production and service companies to trace the tensioning process completed on critical applications.

Atlas Copco's new Smart Tensioning System combines the power of conventional tensioners with smartness to obtain data of the process and final results. The system will completely guide the operator on how to complete the process with accuracy, ultimately reducing errors and rework, and can reduce the process time by upto 50%.

What is the main pain point in your tensioning process?

Training the operators correctly.
The length of time it takes to complete the process
The inability for full data traceability to confirm the job has been done correctly.

Current pain points for the bolt tensioning process

Bolt tensioning process: Standard vs Smart

Standard method

Pick up the equipment - Has it been calibrated?
Select the bolt to be tensioned - is it correct bolt and tensioner?
Set required pressure on pump -Is it in bar or PSI, can't see gauge
Mark bolts & position tensioner - Which bolt was I on before break?
Build pressure to set value - Have I achieved the correct pressure?
Hand tighten the nut - How much should I hand tighten?
Release pressure to move to next bolt - Hoping the bolt is tight

The Smart Method

Mount tensioner - Tensioner will be engaged correctly.
Set Parameters - Easy to do with Hand controller.
Seat Nut - Simple to activate.
Pressurize (tension) - Completed via hand controller.
Lock/Secure Nut - Easy to do with click wrench.
De-pressurize - Completed by hand controller.
Document - Data instantly saved and easy to access.