Atlas Copco Power Focus 8 (PF8) Series New Generation Tightening Controller Platform

Atlas Copco Power Focus 8 (PF8) Series New Generation Tightening Controller Platform

Product Background: Intelligent Factory and Intelligent Integrated Assembly

Pain points in the current situation of the factory: multiple product models and complex variants on the production line; Human machine collaboration is important and requires user-friendly systems; The requirements for carbon emissions, energy efficiency, and sustainable production have increased, and there are differentiated challenges for each production line.

Smart Factory: A highly automated digital production line that relies on the Internet of Things, big data, and AI to continuously collect production data, predict and solve production line problems.

Smart Integrated Assembly: Atlas overall solution covering the whole ecosystem of hardware, software and services; Includes intelligent interconnected assembly tools, turnkey production line solutions, and data-driven services that run through the entire customer product manufacturing cycle.

PF8 platform system composition

To build the PF8 tightening system, essential components include the Power Focus8 controller, IAM intelligent application module, Virtual Station virtual site authorization, tightening tool, and optional additional function authorization.

Power Focus 8 controller: hardware interface between MES system and tools on the production line; Provide power to tools and handle communication; A single machine can connect up to 20 tools simultaneously; Wi Fi access points expand wireless coverage, simplify on-site wiring, reduce infrastructure and spare parts inventory costs, and support remote program distribution.

IAM intelligent application module: dual partition storage unit, storing software, tightening data, and configuring parameters; Support upgrade, backup, and restore; Dual software partitioning, lower upgrade risk, can switch between two firmware versions, and quickly restore configuration in case of failure.

Virtual Station: Digital instance of the controller, PF8 platform core; Deciding to support tool types, feature sets, communication protocols, and reporting data formats; Different levels of authorization correspond to different tool families, program quantities, and tightening strategies.

Power Focus S (PFS): an independent drive unit that serves as the secondary slave controller for PF8; Suitable for fixed fixtures and multi spindle applications; Reduce energy consumption by 50% compared to standard controllers; Divided into single-phase standard version and three-phase high-voltage HV version.

ToolsTalk 2 (TT2) software: a comprehensive controller configuration management software that enables centralized control of tightening controllers, complete traceability, and visual management of tightening production lines.

Hardware family model

Model, power supply specifications, typical applications

Power Focus 8 single-phase main controller with 7-inch high-definition touch screen and dual antennas; Rich I/O, fieldbus, IAM slots; Can accommodate 20 tools

Power Focus 8 LV single-phase low voltage version compatible with Tensor SL series tools

Power Focus 8 HV three-phase 380-480V high voltage fixed fixture, multi axis high torque QST tool, replacing the old PowerMACS4000

Power Focus S single-phase independent drive secondary slave station, no display screen, LED status indicator light; Fixtures/Multi axis

Power Focus S HV three-phase high-voltage independent drive secondary slave station, high torque fixture multi axis

Hardware interface (PF8 host)

7-inch touch screen, physical Home/Result button, dual Wi Fi antennas, heat dissipation vents, portable handle

Interface: Remote start, 4x4 digital I/O, 24V auxiliary power supply, emergency stop circuit, accessory I/O bus, Anybus-CC fieldbus module, USB/Ethernet, IAM slot, safety switch, power socket.

PFS status LED indicator light

White: The power has been turned on

Blue constantly on: tool connected; Blue flashing: Software is being upgraded

Red constantly on: system malfunction; Red flashing: Emergency stop triggered

Virtual Station (Authorization Level)

There are a total of 7 levels, from basic to safety critical multi axis synchronization, with different levels corresponding to the number of programs, tightening strategies, and tool compatibility.

Example of Authorization Level, Key Level, Program/Sequence, Core Capability Adaptation, Scenario Compatibility Tool

Batch Control: Customer Key 1 Program, 1 Sequence OK/NOK Traceability; Support clutch closing tools, click torque wrenches for simple batch tightening, basic qualification judgment MWR-S, XCB

Joint Control Quality Key 1 Program, 1 Sequence Torque Control+Angle Monitoring; Support battery pulse tool TBP-S to replace pneumatic tools, with few variants, requiring torque control Tensor ES, TBP-S, Tensor SB

Station Control Station Control Quality Key 16 Programs, 16 Sequence Torque+Angle Monitoring; Single controller replaces multiple pneumatic tool workstations with multiple variants of MWR-TA, Tensor STR, ST, TBP, SRB products

Critical Control Critical Control Safety Critical 250 Program, 250 Sequence Torque/Angle Dual Control; Complete result curve storage and reporting; Support 4 VIN code association results for secure tightening, full data traceability Tensor SL, ST Revo, ITB-A, STR wrench QST

Process Control Safety Critical 250 Program, 250 Sequence Advanced Tightening Strategy; Built in TrueAngle and low reaction strategy; Complete curve traceability requires high safety critical assembly Tensor SR, SRB-HA

Sync Critical Control Sync Critical Control Safety Critical 250 program, up to 50 tools per station, multi spindle angle synchronous tightening, full traceability multi spindle fixture synchronous tightening multi spindle fixture system

Sync Process Control is a safety critical 250 program, with a maximum of 50 tools per station at the highest level; Advanced synchronous tightening and defect elimination management; High requirements for full traceability, multi axis safety critical assembly, large multi axis automated fixtures

Addendum: There is also Manual Tightening Control, specifically designed for mechanical torque wrenches.

Optional additional authorization function

Virtual site level functionality (applicable to a single virtual site)

Low Reaction Strategies: Reduce tightening reaction force, decrease dependence on reaction arms, improve human-machine efficiency, and enhance rhythm; Compatible with STR and SRB series tools.

TrueAngle True Angle: Only available with STR tool; Eliminate operator interference with tightening angle and improve angle control accuracy; Detect assembly abnormalities.

Open Protocol Extension: Supports the transmission of tightening curves through open protocols; External system reads, writes, and modifies controller tightening programs.

Yield Control: Control the rate of torque increase when entering the plastic zone, obtain stable clamping force, and allow the use of smaller size screws.

Industrial Location Guidance (ILG): Error prevention system; Track the relative position between the tool and the fastener to ensure the correct tightening sequence and point position, and reduce scrap parts.

Controller global functionality (applies to the entire IAM)

Automation Rules: Flexible linkage between controller signals and external devices (signal lights, torque arms) simplifies production line integration.

Zero Position function: The tool automatically rotates to the preset angle each time it is triggered; Ensure that the starting angle of each tightening is consistent; Critical is an option that comes with Process Control.

Multi spindle/fixture application solution

PF8 HV/PFS HV three-phase high voltage version, used for high torque fixed fixtures; Fully compatible with the old platform PowerMACS4000, enabling device replacement.

Power supply architecture: MSB main switch box inputs three-phase power; Controller daisy chain cascade; Shared power supply, emergency stop circuit, Ethernet; Compatible with all QST series tools (QST34~QST210).

Tool compatibility summary table

PF8 LV single-phase PF8/PFS single-phase PF8-HV/PFS-HV three-phase high voltage

Tensor SL  ✅  

Tensor ES/ST/STR/SR 

✅  

QST＜350Nm 

✅ （≥200V）  ✅

QST＞350Nm 

✅

Ordering Information

The document provides complete material ordering numbers, divided into:

Hardware body: PF8, PF8-LV, PF8-HV; PFS、PFS‑HV

IAM module: 32GB basic IAM, pre filled with authorized IAM for different virtual sites (Critical/Process/Sync series, supporting 1-50 channels)

ToolsTalk 2 software components: Line Manager, Line Configurator, Station Setup, FMS Portable

Fieldbus module Anybus-CC: Profinet, EtherNet/IP, Profibus DP, CC Link IE, etc

Workstation accessories: operation panel, CAN converter, stacking signal light, selection switch, ILS/ILG positioning error prevention system

Virtual Station virtual site authorization: electronic delivery (issued 24 hours a day), physical media delivery, supports batch ordering of 1-10 sites

Additional function authorization: low reaction force TrueAngle、Yield Control、ILG、Zero Position、Open Protocol Extension； Supports electronic/physical media, packaged in large quantities

Multi axis system materials: MSB main switch box, distribution box; Various length specifications for emergency stop cables and power cables; Sync Critical/Sync Process authorization (1-50 channels)

Service Solutions

Atlas provides services for PF8 complete system:

Programming for startup debugging, calibration, and tightening;

Customize maintenance plans to improve equipment utilization and save maintenance costs;

Operator product training;

Tightening process consulting services, optimizing tightening processes;

Global support, providing standard products and customized project solutions.