Introduction

• General Description
• Features
• Benefits
• General Data Protection Regulation (GDPR)
• Conventions
• Liabilities and Warnings
  • Liability
  • Safety Signal Words
• About the User Guide
• Revision History
• System Overview
  • Hardware Structure
    • Controller Connected To Positioning System
    • Industrial Personal Computer Connected over Network to Controller and Positioning System
  • Software Structure
    • ILG Toolbar
• Accessories
  • Stacklight
  • Barcode Reader

General Description

Industrial Location Guidance (ILG) is the perfect tool to ensure consistent production quality and throughput. ILG is an integrated, stand-alone error proofing system that offers high-level process security for applications ranging from simple to complex. It tracks the exact location of the tool relative to the desired fastening position, ensuring the correct fasteners are tightened to specification, in the proper sequence. Comprised of ILG software, positioning hardware and tightening controller, the system combines the functionality of a tightening system with position and process control.

Features

• Provides tightening data based on location

• Provides assembly traceability

• Configurable reject management

• Configurable user interface

• Tightening positions with start and finish

• Visual indicators for status and feedback

• Reject management – rework workpieces offline

Benefits

• Production quality through process security

• Less rework and scrapped parts

• Clear diagnostics

• Increased productivity

• Intuitive design for easy start-up

General Data Protection Regulation (GDPR)

This product offers the possibility to process personal identifiable information such as system user name, role and IP-address. The purpose of this processing capability could be to enhance quality control through traceability and proper access management.

If you decide to process personal data you need to be aware of and comply with relevant personal data protection rules, including, in the EU the GDPR as well as other applicable laws, directives and regulations. Atlas Copco can in no way be held liable for any use made by you of the product.

Conventions

To enhance user understanding, certain formatting conventions are used throughout this document. The formatting conventions used are listed below.

Liabilities and Warnings

• Liability
• Safety Signal Words

Liability

Many events in the operating environment may affect the tightening process and shall require a validation of results. In compliance with applicable standards and/or regulations, we hereby require you to check the installed torque and rotational direction after any event that can influence the tightening result. Examples of such events include but are not limited to:

• initial installation of the tooling system

• change of part batch, bolt, screw batch, tool, software, configuration or environment

• change of air- or electrical connections

• change in line ergonomics, process, quality procedures or practices

• changing of operator

• any other change that influences the result of the tightening process

The check should:

• Ensure that the joint conditions have not changed due to events of influence.

• Be done after initial installation, maintenance or repair of the equipment.

• Occur at least once per shift or at another suitable frequency.

Safety Signal Words

About the User Guide

The Industrial Location Guidance (ILG) User Guide gives all the operations of the Industrial Location Guidance (ILG) system: from initial system configuration to daily operations.

For a successful customer experience, execute the steps to procedures completion described in the ILG User Guide while working in the ILG software.

Industrial Location Guidance (ILG) is an integrated, stand-alone error proofing system that offers high-level process security for applications ranging from simple to complex.

ILG tracks the exact location of the tool depending on the fasteners position, making sure that the correct fasteners are tightened in the correct sequence. ILG system combines the functionality of a tightening system with position and process control.

The ILG system consists of:

• ILG software

• Positioning hardware

• Tightening controller

• Industrial PC (optional, depending on application)

The ILG service receives the data in real time from the positioning hardware sensors to calculate the tool location in three-dimensional space. Once the tool is located in the specified position, the ILG service selects the tightening program and enable the tool through Open Protocol.
Visual indicators - such as Stacklight, tool LED, or HMI process screen - tell the operator to initiate the tool start.

The positioning hardware includes high precision rotary or linear position sensors that are integrated into the pivot joints or linear guides of a torque arm or similar applications. The sensors connect with the tightening controller or the Industrial PC via a gateway module.
The gateway module communicates with the ILG service through Modbus TCP protocol.
Camera base ILS sensors are available too.
The ILG service communicates with the tightening controller through Open Protocol.
Multiple Atlas Copco tightening controller models are compatible with the system. Different positioning hardware configurations are available to suit the different arm types.

Revision History

System Overview

• Hardware Structure
  • Controller Connected To Positioning System
  • Industrial Personal Computer Connected over Network to Controller and Positioning System
• Software Structure
  • ILG Toolbar

Hardware Structure

It is possible to set up several possibilities of the ILG software because of the high modularity and flexibility of the ILG software. Different connection structures can be used, depending on the requirements.

Controller Connected To Positioning System

The controller and the positioning system are directly connected through TCP/IP. The controller and the positioning system use the normal Ethernet connector of the controller.
This setup uses the Embedded ILG software version running on the controller.

It is possible to have one or more positioning system connected to the same controller. Example setups:

• ILS Sensor connected to the controller.

• Arm Position System connected to the controller.

• ILS Sensor and Arm Position System connected to the controller.

1	Stacklight	6	ILS Sensor
2	Barcode Scanner	7	Sensor Gateway
3	Tool	8	Analog / IO Link
4	Controller	9	Arm Position System
5	TCP/IP over Ethernet

Industrial Personal Computer Connected over Network to Controller and Positioning System

The tightening controller, sensor gateway and Industrial Personal Computer (IPC) are connected (by Ethernet) to a network.
All devices must be in the same TCP/IP Subnet (for example 192.168.0.XXX).

It is possible to have one or more positioning system connected to the same controller. Example setups:

• ILS Sensor connected to the controller.

• Arm Position System connected to the controller.

• ILS Sensor and Arm Position System connected to the controller.

• Multiple ILS Sensors connect to the controller.
  This is called a Multi Sensor Solution

1	Stacklight	7	TCP/IP
2	Barcode Scanner	8	TCP/IP
3	Tool	9	Sensor Gateway
4	Tightening Controller	10	Analog / IO Link
5	Open Protocol TCP/IP	11	Arm Position System
6	IPC - ILG HMI	12	ILS Sensor

Software Structure

There are two versions of the ILG software; Embedded and HMI. The Embedded version runs on a controller and the HMI version runs on an external IPC.

For the configuration of the ILG software, and also for daily operations, a Graphical User Interface (GUI) is needed.
If using the HMI version, it is possible to use the screen of the IPC.
If using the Embedded version, connect a computer to the controller to make a TCP/IP connection.

In any case, it is possible to get to the GUI of the ILG software only through the web interface.

ILG Toolbar

ILG software toolbar is a grouping of commands which are optimized for efficient access.

On the left side of the ILG toolbar, the name of the software - Industrial Location Guidance - appears.

On the right side of the ILG toolbar, it is possible to see the connection status. Besides, it is possible to select the software language, the tool which the user can work with, the mode, and the user role.

Connection Status

On the right side of the ILG toolbar, the connection status shows 4 circles icons.
The first circle icon gives the connection between the User Interface (UI) and the ILG back-end through REST-API.
The second circle icon gives the connection between the User Interface (UI) and the ILG back-end through WebSocket.
The third circle icon gives the connection between the ILG back-end and the sensors.
The fourth circle icon gives the connection between the ILG back-end and the tightening controller.

The connection is up only if the circle icon is white. If the circle icon is blue, the connection is down.

On the left side of the ILG toolbar, hover over the 4 circle icons to see the connection status.

Language

On the right side of the ILG toolbar, open the Language drop-down menu and select the necessary language.

The start language is based on the browser language settings. Change the browser settings to the needed language for best user experience.

Tool

On the right side of the ILG toolbar, open the Tool drop-down menu and select the necessary tool.

Mode

On the right side of the ILG toolbar, open the Mode drop-down menu and select one of the available modes: Configuration, Setup, Diagnosis.

The Mode drop-down menu shows also the names of existing Workplaces.

User Role

On the right side of the ILG toolbar, the active User Role is shown: Worker, Configurator, or Service. Select the icon to change between user roles.

The user roles can be configured in Setup mode.

Accessories

Accessories are additional elements of the ILG setup that enrich the user experience and make sure the fulfillment of some specific use cases.
The proper usage of the accessories usually requires that all elements - the ILG software, the tightening controller, and the accessories - are correctly configured.

A standard ILG setup does not require any accessory.

Stacklight

The Stacklight, in combination with ILG software, can be used for different tasks.
The main task is to inform the user about the progress of the process through visual and audible indicators.
The Stacklight input options can also be used to control ILG processes.

Configuring Visual Indicators

If you use the Stacklight in combination with ILG software, we recommend the following visual indicators configuration:

• Operator information related to tightening enabled through the blue visual indicator: on the Home page of the controller, select Configurations > Stacklight > select Edit > select the blue lamp > set "Ready to start" as lamp signal.

• Operator information related to OK tightening results: on the Home page of the controller, select Configurations > Stacklight > select Edit > select the green lamp > set "Tightening OK" as lamp signal.

• Operator information related to NOK tightening results: on the Home page of the controller, select Configurations > Stacklight > select Edit > select the red lamp > set "Tightening NOK" as lamp signal.

Barcode Reader

The Industrial Location Guidance (ILG) software can be used in combination with a barcode reader for different tasks.

Installation and Upgrade

• System Requirements
• Web Browser Requirements
• Installing ILG Software
• Upgrading ILG Software
  • Transferring a License

System Requirements

To install the Industrial Location Guidance (ILG) software on an industrial PC the minimum system requirements are the following:

Processor: i3-6100

Memory: 8 GB

Operating System: Windows 10 or later

Web Browser Requirements

For optimal performance use a web browser that has good JavaScript performance and enable browser caching.

It is possible to run the software on the following web browsers:

• Google Chrome 70 or later

• Microsoft Edge 79 or later

• Firefox 63 or later

Installing ILG Software

To install ILG software on the Industrial Personal Computer, run the full installation procedure.

It is possible to connect to the Graphical User Interface (GUI) by browser on the Industrial Personal Computer - or any device connected to the same subnet.
Open a web browser and enter the IP of the Industrial Personal Computer followed by the port of the application (for instance, locally https://127.0.0.1:8181/, or remotely https://192.168.0.70:8181).
Wait a moment for the connection to become stable, and proceed with the further installation steps.

If ILG software runs on a controller, use the IP address of the controller.

If ILG software runs on the ILS Sensor, use the IP address of the ILS Sensor followed by the port of the application: https://192.168.0.80:8181. Replace the IP with your default setup IP of ILS Sensor.

Upgrading ILG Software

Before upgrading the ILG software, transfer the licenses.

To upgrade the ILG software on the Industrial Personal Computer, run the full uninstallation and installation procedure.

Transferring a License

Transferring a License Video

Configuration

• Working with Configuration Mode
  • Start Page
  • Tightening Positions Page
    • Programming the Tightening Processes
      • Creating a Process Structure
      • Creating a Workpiece
        • Compensation for Variable Workpiece Location: Referencing Strategy
        • Compensation for Variable Workpiece Location: Dynamic Part Tracking
      • Creating a Group or Level
        • Configuring a Group
      • Creating a Position
        • Volume Types
        • Configuring a Position
      • Teaching Process
        • Teaching New Workpieces
        • Teaching Existing Workpieces / Groups
        • Reteaching Existing Workpieces / Groups
        • Reteaching Single Positions
      • Copying and Pasting
  • Workpieces Page
    • Selecting Workpiece Model and Image
    • Rotating the Image
    • Referencing Images
    • Moving the Tightening Positions
  • Images Page
    • Uploading Images
    • Deleting Images
  • Message Mapper Page
    • Message Mapper Assistant
    • Input Message
    • Output Message
    • Message Mapping
  • Help Page
• Working with Setup Mode
  • Workplaces Page
    • Creating a Workplace
    • ILG and Source Batch Behavior
    • Configuring a Workplace
      • Position Selection Method
  • Licenses Page
    • Generating a License
    • Uploading a License
  • Tools Page
    • Tool Tab
      • Connection Type Setting
      • Advanced Section Configuration
      • Creating a Tool for ILS
      • Creating a Tool for Arm Systems
      • Creating a Tool for ILP
    • Tags Tab
      • Adding a Tool Tag
      • Editing a Tool Tag
      • Deleting a Tool Tag
    • Geometry Tab
      • Creating the Geometry Model
    • Model Tab
  • ILS Sensor Page
    • Controller Tab
      • Configuring an ILS Sensor
    • Tool Targets Tab
    • Part Target Tab
      • Adding a Part Target
      • Adding a Multi-tag Target
    • Workspace Tab
      • Dual Sensor Teaching
  • Barcode Reader Page
    • Configuring a Barcode Reader
    • Configuring the BarcodeExaminer
  • Security Page
    • Setting a Password
    • User Role Access
    • Downloading a Certificate
  • Backup Page
    • Creating a Backup
    • Restoring from a Backup
  • Help Page
• Working with Diagnosis Mode
  • Modules Page
    • Tightening Tracker
    • Process Safety
  • Messages Page
    • Downloading the Messages

Working with Configuration Mode

• Start Page
• Tightening Positions Page
  • Programming the Tightening Processes
    • Creating a Process Structure
    • Creating a Workpiece
      • Compensation for Variable Workpiece Location: Referencing Strategy
      • Compensation for Variable Workpiece Location: Dynamic Part Tracking
    • Creating a Group or Level
      • Configuring a Group
    • Creating a Position
      • Volume Types
      • Configuring a Position
    • Teaching Process
      • Teaching New Workpieces
      • Teaching Existing Workpieces / Groups
      • Reteaching Existing Workpieces / Groups
      • Reteaching Single Positions
    • Copying and Pasting
• Workpieces Page
  • Selecting Workpiece Model and Image
  • Rotating the Image
  • Referencing Images
  • Moving the Tightening Positions
• Images Page
  • Uploading Images
  • Deleting Images
• Message Mapper Page
  • Message Mapper Assistant
  • Input Message
  • Output Message
  • Message Mapping
• Help Page

Start Page

Station

The Station section shows the ID, Name, Description, and Location of the station.

Tool

The Tool section shows the details of the selected tool. Details shown are:

• Tool ID

• Status

• Direction

• Last Result

• Job Result

• P-Set

Positions

The Positions section shows the X, Y, and Z coordinates of the selected tool.

Target

The Target section show the ID and coordinates of the target.

Tightening Positions Page

The process configuration of the ILG software gives the tightening parameters of the individual components and the necessary fastener sequences. The process configuration is necessary to define the working methods and tightening tasks. During operations, the working instructions control the individual component tightening connections.

In the ILG standard configuration, the processing is performed in a workflow relying on defined workpiece models. The ILG software starts processing a workpiece when it receives an identifier string corresponding to an identification number configured for a workpiece model. The process ends usually when all the tightening positions configured for the workpiece are completed. Then, put the tool to the home position.

All other actions of the process configuration are performed through the Tightening Positions page.
The buttons at the top of the Tightening Positions page can be used to add new elements or make changes.

• Add Group: adds a new group above the currently selected position. To add a group at the bottom, clear the check box related to a selected line in the table.

• Add Position: adds a new position.

• Edit: opens the editing menu for the selected group or position.

• Delete: deletes the selected element.

• Teaching: starts the teaching mode where a series of new positions can be re-taught or created through the deactivated tool, and pulling the tool trigger.

• Reteach: sets the XYZ values of the selected position depending on the tool physical position.

• Reteach Relative: uses the relative position for teaching - for example, with part target.

• Cond. Geo. ON: activates the conditional geometry of this element.

• Copy: lets the user to copy/duplicate the selected positions into a specified Group.

• Paste: lets the user to paste the copied positions into a specified Group.

• Up arrow key: moves the item around accordingly.

• Down arrow key: moves the item around accordingly.

• Left arrow key: moves the item around accordingly.

• Right arrow key: moves the item around accordingly.

Programming the Tightening Processes

To create tightening processes, ILG software has no fixed programming sequence which must be followed.
Since very different process sequences and structures may be necessary, ILG software offers different methods to support the setup of processes. These methods are not exclusive and can be combined according to requirements.

In general, to set up a complete tightening process, the user must:

Creating a Process Structure

ILG software uses a tree structure - shown through the Tightening Positions page - to build tightening processes. This structure has three classes that can have different types, features, and characteristics.

• Home class: defines the home position of the tool that in the ILG setting is used for process finish. It exists only 1 Home class for 1 station.

• Groups class: always describes several positions and possibly other groups. Their task is to define a sequence for the subordinate positions and groups, and to set higher-level tightening parameters.

• Positions class: defines a single tightening position with all parameters for that single position.

The Groups class is responsible for building the structure of the process flows.
The groups can be additionally divided into two different types:

• Group Workpiece: the workpiece is the main group and represents one component variant of the user or one tightening process. The workpiece is the start point for each tightening sequence. Only one workpiece is used per process.

• Group Level: a level is an extension of a normal group. It can run its own images for the process visualization.
  A level is used when the Process / Workpiece has several tightening layers that cannot be visualized in one main picture or require different tightening sequences of the same part.

The construction of a tightening process must always start with the workpiece.
The workpiece can then be structured by making different groups, levels and positions. The user can make as many groups / positions into an existing workpiece group as it is needed. The elements can be put freely, depending on the application.

Properties of the Classes

It is important to know the different properties of the individual classes to design the optimal process structure.

The properties assigned to the Groups class are:

• Group ID - only the ID of the Workpiece is also the process ID

• Order

• Loosening strategy

• Reject management

• Referencing

• Images

The properties assigned to the Positions class are:

• Position ID

• Tightening programs

• Coordinates

• Enabling / Disabling volume

• Geometry condition

ILG software visualizes the hierarchical structure - and thus the work sequence of a process - by moving the individual elements in the process list.

Creating a Workpiece

Compensation for Variable Workpiece Location: Referencing Strategy

In many situations, the workpiece to be processed is located in a location which is not the one that the model - created, for example, after teaching the tightening positions - assumes. Those situations can occur because of the setup of the assembly line, or because of the operation made on a movable table. It is possible to configure ILG software to compensate the variable workpiece location compared to the ILG system, depending on the application.
The compensation functionality is called Referencing.

ILG software gives different options to set up the Referencing:

• Static: the workpiece is introduced in the same location every cycle.
  All the Reference Positions boxes on the Advanced tab of the Workpiece Properties dialog box must be empty.

• 1-Point Referencing: the part is introduced in different linear locations. 1-Point Referencing let the part translate linearly across any axes: X, Y, or Z.
  A typical example is the assembly line, where the workpiece stops on the station in slightly different positions.
  To use 1-Point Referencing for the given workpiece model, enter the ID of 1 tightening position defined for the workpiece as the Reference Position 1 on the Advanced tab of the Workpiece Properties dialog box.
  Thus, before any other operation on the workpiece, the operator must pull the tool trigger on this particular position.

• 2-Point Referencing: the part is introduced in different linear locations and rotated around one axis.
  A typical example is when the workpiece gets at the ILG station on a movable table.

  To use 2-Point Referencing for the given workpiece model, give the axis around which the rotation is expected. Then, enter the IDs of the 2 tightening positions defined for the workpiece as the Reference Position 1 and Reference Position 2 on the Advanced tab of the Workpiece Properties dialog box.
  Thus, before any other operation on the workpiece, the operator must pull the tool trigger on these particular positions in the specified order.

• 3-Point Referencing: the part is introduced in different locations along all axis. 3-Point Referencing let the part translate linearly and rotationally across any axes: X, Y, or Z - all 6 degrees of freedom.

  To use 3-Point Referencing for the given workpiece model, enter the IDs of 3 tightening positions defined for the workpiece as the Reference Position 1, Reference Position 2, and Reference Position 3 on the Advanced tab of the Workpiece Properties dialog box.
  Thus, before any other operation on the workpiece, the operator must pull the tool trigger on these particular positions in the specified order.

Setting Up the 3-Point Referencing Strategy

Setting Up the 3-point Referencing Strategy procedure works best if the 3 points are as far apart as possible in both coordinates of the geometrical plane.

If a reference strategy is used for a workpiece, the process always starts with the referencing. At the beginning of the process, only the reference points on the workpiece appear. Only after the operator has captured all reference positions, the fastener positions are displayed and can be fastened.

Compensation for Variable Workpiece Location: Dynamic Part Tracking

When the workpiece to be processed is located differently from what is defined in the model created—such as in a moving line—the ILG software running on an ILS Sensor can be configured to compensate for this. This is called Dynamic Part tracking.

Setting Up the Dynamic Part Tracking

Creating a Group or Level

Adding groups or levels is an optional step.
Many workpieces only need to have tightening positions without the need for intermediate hierarchy levels.

Configuring a Group

This video explains how to configure a group.

Creating a Position

In the simplest situation, a given workpiece model contains just tightening positions.
It is possible to add tightening positions to the workpiece through different procedures.

Manual Creation of the Tightening Positions

Teaching and Copying

To add tightening positions to the workpiece through the Teaching and Copying procedure, it is mandatory that the workpiece model has already been created.

Teaching and Renaming

To add tightening positions to the workpiece through the Teaching and Renaming procedure, it is mandatory that the workpiece model has already been created.

Creating and Reteaching

Teaching Volumes

Volume Types

Sphere

Like a circle in a two-dimensional space, a sphere is defined mathematically as the set of points that are all at the same distance r from a given point in a three-dimensional space.

The radius defines the size of the sphere.

For example, in the Volume tab of the Position pop-up window, enter and select the Enabling Volume parameters. Select Sphere as volume and enter 15mm as radius. Then, select the Same as position check box.
The Disabling Volume parameters are programmed to an upscale percentage (20%): thus, the sphere radius is 20% bigger (18mm).

The tool is enabled when into the Enabling Volume parameters. The tool is disabled when is outside the sphere of the Disabling Volume parameters.
Then, the tool is enabled again only when moved back into the Enabling Volume parameters again.

1	Tool Enabled	3	Tool Enabled
2	Tool Disabled

Cylinder

The cylinder has two identical flat circular ends and one curved side.

The radius, height, and depth define the size of the cylinder. These 3 dimensions typically originate from the X / Y / Z position. The direction of the cylinder must also be defined using a vector coordinate. Simple vectors - such as a straight vertical or horizontal cylinder - may be manually programmed.

For instance, setting X=0, Y=0, Z=1 gives a vertical cylinder.
Setting X=1, Y=0, Z=0 gives a horizontal cylinder:

Cone

The cone is similar to the cylinder, but the radius is different in length at each end.

Configuring a Position

This video explains how to configure a position.

Teaching Process

In ILG software, the Teaching process causes a completely new tightening position along with the new related coordinates.
The Reteaching process causes an update of the coordinates of an existing tightening position.
In both cases, the physical position of the tightening tool is used.

During the Teaching process, nominal positions or target coordinates are assigned to the process model in ILG software. This process defines the geometrical model of a workpiece.
After entering the coordinates, ILG software enables tightening in the correct positions of the active workpiece. Thus, it is very important that the Teaching process is run under optimal conditions.

Before running the Teaching process, make sure that:

• A real workpiece is in the system; the fastening conditions - workpiece geometry, fasteners, and so on - agree with the conditions in normal production.

• The workpiece is optimally positioned in the workspace

• The geometry of the tool is completely mapped within ILG software.

• The fastening sequence of the components is known and is observed during the Teaching process.

• The controller is configured and connected to the ILG software.

Teaching New Workpieces

The Teaching process of new workpieces is used for simple process setups, where only 1 workpiece exists. In this case, all the tightening positions are into the only existing workpiece.
If the process has a more complex structure, we recommend to create the workpiece and group structure. Then, perform the Teaching process for the existing groups.

For more information about how to edit the taught positions, see the paragraph Creating a Position.

If the Teaching process is repeated for several workpieces, the ILG software changes automatically the workpiece ID number, so that always only unique workpiece IDs exist.

Teaching Existing Workpieces / Groups

Reteaching Existing Workpieces / Groups

Sometimes it is necessary to reteach already configured tightening positions. For example, this scenario can happen in case the geometry changes due to a new workpiece carrier. For these scenarios, existing groups may be taught again without changing the already set parameters.

Reteaching Single Positions

ILG software reteaches the coordinates of a single position, if needed.

This procedure must be run by 2 people: interaction both with the ILG software user interface and the tool is needed.

Copying and Pasting

To make the assignment of tightening parameters easier, ILG software gives the possibility to copy parameters of a tightening position / group. The copied parameters can be moved to other groups.
Through ILG software, it is possible to:

• Copy the complete position: creates a copy of the tightening position within the same group or another group.

• Copy the position parameters: copies specific parameters of a tightening position. Thus, the copied parameters are moved to individual positions or to all positions within a group.

Copying the Complete Position

Copying the Position Parameters

Workpieces Page

The Workpieces page shows the position parameters with the selected image that is used with the selected workpiece, the tightening positions, and the position of the tightening tool in real life.
To make the Workipieces page running, it is essential to configure the graphical elements. Then, it is important to perform the Image Referencing for each of the workpiece models.

Selecting Workpiece Model and Image

Typically, the workpiece image uploaded into the ILG software needs a repositioning process to match the real situation at the workstation.

Rotating the Image

To display a process within ILG software graphically, the alignment of the component image must correspond to the real alignment between tool and component. ILG software cannot change image files graphically. Thus, if the image is rotated to the actual process view, this rotation cannot be compensated automatically.

If a deviation between the real and the displayed alignment happens, the Image Rotation feature, in the Workpieces page, gives the option to realign the image.

Use the Image Rotation feature always at the beginning of a graphical process representation. The image is rotated with the help of two interpolation points.

Referencing Images

The Image Referencing feature let the user to scale and to put the workpiece image in the ILG software coordinate system. Through the Image Referencing feature, the tightening positions related to the workpiece model and the corresponding points on the workpiece image can be mapped onto each other.

To do the Image Referencing procedure, use the Workpiece page of the ILG software and the tightening tool.

The Image Referencing procedure works best if the 3 points are as far apart as possible and are arranged in a triangle in both coordinates of the geometrical plane, in which the workpiece image is located.

The Image Referencing procedure shows the correct tool position (crosshair) on the workpiece image, while the real tool moves over the real workpiece. Besides, the tightening positions of the workpiece appear as yellow points on the image, depending on the taught positions.

Moving the Tightening Positions

It is possible to find some distortions in the placement of the tightening positions, especially for bigger workpieces or for images that come from photos of workpieces (rather than technical drawings). This means that the crosshair of the tool placed in the defined tightening position, in reality, is not displayed on the tightening position on the image.

The Moving the Tightening Positions procedure moves the dots that are related to the tightening positions manually. The procedure affects only the display, and not the model.

Images Page

The Images page shows a list of images already uploaded to the ILG software.
After selecting an image, on the right of the Images page, it is possible to see the preview of the selected image. Select the link at the bottom of the preview to automatically zoom in the selected image.

The buttons at the top of the Images page can be used to add, download, or delete images.

• Refresh: refreshes the Images page.

• Add: adds a new image.

• Download: downloads the selected image.

• Delete: deletes the selected image.

Uploading Images

Deleting Images

Message Mapper Page

The Message Mapper page shows a list of already created input and output messages.

The buttons at the top of the Message Mapper page can be used to add messages and handle messages.

• +: adds messages.

• ASSISTANT: creates a set of mappings to handle messages from the tightening tracker module.

In some case it is required to use an ILG connected tool for tightening's that shouldn't be controlled by ILG. Use the message-mapper to send services/disable_workflow and services/disable_fast_tool_lock to prevent ILG from locking the tool after every result generated. (Note that before any tightening's can be performed the Open Protocol must be unlocked and a Pset must be selected).

Message Mapper Assistant

The Message Mapper Assistant creates a default set of mappings to handle messages from the tightening tracker module. The selected actions will decide how the process will be handled.

Input Message

Output Message

Message Mapping

This video explains how to set up input and output messages.

Help Page

Scan the QR code or select GOTO ONLINE HELP to open the Industrial Location Guidance (ILG) User Guide.

Working with Setup Mode

• Workplaces Page
  • Creating a Workplace
  • ILG and Source Batch Behavior
  • Configuring a Workplace
    • Position Selection Method
• Licenses Page
  • Generating a License
  • Uploading a License
• Tools Page
  • Tool Tab
    • Connection Type Setting
    • Advanced Section Configuration
    • Creating a Tool for ILS
    • Creating a Tool for Arm Systems
    • Creating a Tool for ILP
  • Tags Tab
    • Adding a Tool Tag
    • Editing a Tool Tag
    • Deleting a Tool Tag
  • Geometry Tab
    • Creating the Geometry Model
  • Model Tab
• ILS Sensor Page
  • Controller Tab
    • Configuring an ILS Sensor
  • Tool Targets Tab
  • Part Target Tab
    • Adding a Part Target
    • Adding a Multi-tag Target
  • Workspace Tab
    • Dual Sensor Teaching
• Barcode Reader Page
  • Configuring a Barcode Reader
  • Configuring the BarcodeExaminer
• Security Page
  • Setting a Password
  • User Role Access
  • Downloading a Certificate
• Backup Page
  • Creating a Backup
  • Restoring from a Backup
• Help Page

Workplaces Page

The Workplace page shows the status of the current running tightening process. Besides, it let the tightening process start.

Usually, the Workplace page guides the operator.
In the Workplace page, the operator can track the tool position with the crosshair on the workpiece image; thus, it is possible to follow the progress.

The Workplaces page shows the workplaces as a list.
The buttons at the top of the workplaces list can be used to add new workplaces or make changes.

• Add: adds a new workplace to the workplaces list.
  The system adds the new workplace at the end of the list automatically.

• Edit: opens the Workplace pop-up window for the selected workplace.

• Delete: deletes the selected workplace.

Creating a Workplace

ILG and Source Batch Behavior

• The batch started workpiece: When the batch ID matches the workpiece alias the workpiece is started.

• The batch selected position: The batch ID enables positions that have batch ID = Pset actual ID (not identifier in source tightening). The ILG workpiece order still matters.

• The batch size and counter is never used in ILG.

• The total number of tightenings in the batch must match the number of positions in the ILG workpiece.

• The batch settings in Power Focus (e.g. increment on NOK, decrement on OK loosening and max consecutive NOK) also need to be considered.

• The option New workpiece finishes the current workpiece and the option Batch number matches workpiece id cannot be used together. This will cause the workpiece to be restarted after every tightening. All tightenings in batch mode generate a tc_job_info with the same ID.

• Setting legacy counter changes how the batch is counted which could affect the behavior in ILG.

Configuring a Workplace

This video explains how to configure a workplace.

Position Selection Method

Licenses Page

The Licenses page shows active licenses.

The buttons at the top of the Licenses page can be used to generate and upload licences.

• GENERATE LICENSES REQUEST: generates a request for a new license.

• UPLOAD LICENCE RESPONSE: uploads licenses from a file.

Generating a License

Uploading a License

Restart the ILG software after uploading a license.

Tools Page

The easiest method to configure the Tools page of the ILG software is using the Assistant, which can be followed by manual adjustment.

Tool Tab

The initial configuration Assistant simplifies the basic configuration of the ILG software to set up the communication interface to the sensors and the tightening controller. At the beginning of any system setup, use the assistant to decrease the setup effort.

The buttons at the upper-left corner of the Tool tab can be used to make changes to an existing tool, or delete.

• Edit: lets the user make changes to the selected tool.

• Delete: deletes the selected tool.

Connection Type Setting

ILG uses three communication channels to control the tools. This setting in the Tool tab is called Connection Types. When creating a tool the Connection Type can be selected as Open Procotol, ASDK, ASDK remote and API.

Open Protocol

Open Protocol is the default mode for all Atlas Copco tightening tools.

Supported controllers:

• Power Focus 8

• Power Focus 6000

• MT Focus 6000

• IxB

ASDK and ASDK remote

There are two ASDK modes, ASDK and ASDK remote.

The ASDK modes enables additional functions:

• Support for positioningId: an added security function where a unique identifier is assigned to every tightening operation/result.

• Support for controller/tool self-lock: an added process safety function where the controller handles the lock of the tool, refer to the Process Safety chapter.

Remote controller and firmware support:

• Power Focus 8. firmware version 3.10.11+

• Power Focus 6000, firmware version 3.10.11+

• IxB, firmware version 3.10.11+

ASDK:

Use it when ILG is running on the same controller as the one the tools are connected to. The ASDK mode is the fastest communication between ILG and the tool. It is used for ILG embedded only.

Prerequisites:

• The Px2 system API to communicate with the tightening controller.

• An ILG embedded license per tool.

ASDK remote:

Use it when ILG is running on a remote controller or an industrial PC. It is used for ILG HMI (Windows) only.

Prerequisites:

• A custom-made protocol to communicate with the tightening controller.

• ILG embedded license.

• ILG HMI license.

• If port number 0 is used in ILG the name of the Virtual Station must be the same as the name of the tool in ILG (note that the ILG tool cannot be changed after creation).

By using port number 0 and not the Open Protocol port the following functions will not be available:

• VIN number will not be received from the controller to ILG.

For full support Open Protocol should also be configured and running on the controller, and the port number in ILG should be the same as the Open Protocol port number that is configured in the controller.

API

In this mode ILG communicates indirectly with the tool. A PLC (Programmable Logic Controller) is used for the communication.

Advanced Section Configuration

Configure the Workflow for a Conditional Segment

Configure the Workflow for Release Lock

By editing the Release Lock workflow it is possible for ILG to use one of the 8 Generic I/O signals instead of the regular Open Protocol messages MID0042/0043 disable/enable tool signals.

Configure the Workflow for a Standard Tool

Creating a Tool for ILS

Creating a Tool for ILS Video

Creating a Tool for Arm Systems

Creating a Tool for Arm Systems Video

Creating a Tool for ILP

For information on how to create a tool for ILP, refer to the ILP User Guide.

Tags Tab

The initial configuration Assistant simplifies the basic configuration of the ILG software to set up the communication interface to the sensors and the tightening controller. At the beginning of any system setup, use the assistant to decrease the setup effort.

The buttons at the upper-left corner of the Tags tab can be used to add a new tag to the tool. Besides, it is also possible to make changes / delete an existing tool tag.

• Add Tag: adds a new tag to the tool.

• Edit: lets the user make changes to the selected tool tag.

• Delete: deletes the selected tool tag.

If the tool has more tags, add the missing tags through the Add Tag button.

Adding a Tool Tag

Editing a Tool Tag

Deleting a Tool Tag

Geometry Tab

The Geometry tab calculates the tool position. The ILG software uses a geometry model and ILS sensors to calculate the position of the tool in Cartesian coordinates. The result of the geometry is the tool position in X, Y, and Z.

Regardless of whether the configuration assistant is used or a completely new geometry is created, it is possible to make manual adjustments to the geometry to create a complete geometry.
For this purpose, ILG software gives an operating environment in the Geometry tab, which makes possible to set up geometries for all types of systems.

Creating the Geometry Model

When creating or adjusting the geometry model, always proceed beginning with the origin of the coordinate system, thus from the fixed suspension of the ILG hardware.

ILG software has three basic geometries for the creation or extension of a geometric model:

• Fixed Segment: rigid element for describing fixed geometric elements.

• Rotational Sensor: modeling of a rotational axis detected by an angle encoder or inclination sensor.

• Linear Sensor: modeling of a linear axis captured by a linear sensor.

The geometrical model provides the three basic geometries in a given sequence.
The Geometry tab displays the geometry elements as a list.
The buttons at the top of the geometries list can be used to add new geometry elements or make changes.

• Add: adds a new geometry element to the geometry list.
  If you select an existing geometry element, the new geometry element appears in front of the selected geometry element.
  If no geometry element is selected, the system adds the new geometry element at the end of the list.

• Edit: opens the editing menu for the selected geometry element.

• Delete: deletes the selected geometry element.

• Assistant: opens the initial configuration which simplifies the basic configuration of the ILG software.

If you select the Assistant button, the currently stored geometry elements and sensor configuration are removed.

• Rotate: rotates the tool counterclockwise in any axis.

• Cond. Geo. ON: activates the conditional geometry of this element.

• Cond. Geo. OFF: deactivates the conditional geometry of this element.

How to Create a Geometry Model

Different configurations must be made, depending on the selected geometry type:

• For a Fixed Segment:

  • Geometric expression of the element in millimeters (XYZ direction).

  • Color of the element in the geometric model: we recommend the usage of different colors for the neighboring segments.

• For a Rotation Sensor:

  • Rotation axis of the sensor: the rotation axis of the sensor can be defined by 1 or 0 in the respective axis XYZ.

  • Rotation vector of the sensor: the direction of rotation is given by + or -.

  • Sensor: it says which of the installed sensors provides the measured values for the respective direction of movement.

  • Color of the element in the geometric model (if needed).

• For a Linear Sensor:

  • Movement axis of the sensor: the movement axis of the sensor can be defined by 1 or 0 in the respective axis XYZ.

  • Movement vector of the sensor: the direction of movement is given by + or -.

  • Sensor: it says which of the installed sensors provides the measured values for the respective direction of movement.

  • Color of the element in the geometric model (recommended).

The geometry list shows all the geometry segments in a specific order. ILG software considers the exact order of the geometry segments during the operations. Add new geometry segments at the bottom of the list, after the default segments.

Rotate the Geometry

Rotating the Geometry will transform the complete geometry of the tool.

Model Tab

To facilitate and to validate the adjustment of the geometry, ILG software gives a 3D visualization of the tool geometry. The visualization consists of three screens, each showing a different viewing direction, able to capture every tool movement. The division of the viewing directions is determined by the three main planes of the coordinate system (X/Y, X/Z, Y/Z).

Real-time tool movement enables the user to validate the tool configuration is in the correct direction, and make sure that the rotation and movement is correct.

To get the full view of the tool model, select the Fit button, and the picture automatically scales to the actual tool position. The scaling in all three planes is independent from each other.

Changes in the configured geometry are immediately displayed in the Model tab. This real-time visualization makes possible to quickly verify the model and adjust movements between the geometric model and the real tool.

To validate the model, always make sure that the geometry is correct by moving the tool and watching the model on the screen. If a direction moves different than expected, then change the direction vector sign of the corresponding sensor entry.

Note that different elements of the model require different views for their verification. For example, a sensor that covers a vertical movement, cannot be verified by looking at the XY view. This is why ILG provides views in all three main planes of the 3D Cartesian system.

ILS Sensor Page

All configurations for using the ILG software with an ILS Sensor is available on the ILS Sensor page.

Controller Tab

The Controller tab shows the ILS Sensor configuration.

The button at the upper-left corner of the Controller tab can be used to configure the communication interface between the ILS Sensor and the ILG software.

Configuring an ILS Sensor

Tool Targets Tab

The Tool Targets tab shows the targets and tags for the ILS Sensor tools.

The buttons at the upper-left corner of the Tool Targets tab can be used to add, make changes to, or delete an existing target or tab.

• ADD TARGET: lets the user add a target.

• ADD TAG: lets the user add a tag.

• Edit: lets the user make changes to the selected target or tag

• Delete: deletes the selected target or tag.

Part Target Tab

The Part Targets tab shows the targets and tags for the ILS Sensor parts. The tab is used when the assembly object is not in the same position relative the ILS Sensor.

The buttons at the upper-left corner of the Part Targets tab can be used to add, make changes to, or delete an existing target or tab.

• ADD TARGET: lets the user add a target.

• ADD TAG: lets the user add a tag.

• Edit: lets the user make changes to the selected target or tag

• Delete: deletes the selected target or tag.

Adding a Part Target

The physical placement of tags relative to bolt positions must always be the same.

Adding a Multi-tag Target

Using one single part target can create accuracy errors due to incorrect rotation measurements. The bolt positions are then only referenced in relation to one single part target.

If the single part target cannot be placed close enough to the bolt locations it can be necessary to use the Multi-tag Target function.

The physical placement of tags relative to bolt positions must always be the same.

The Multi-tag part target function results in a reference frame which is only based on the x. y, z positions of the part target tags.

The Multi-tag part target function requires having at least three unique tag IDs that are always visible to the ILS sensor during operation of the workpiece.

Workspace Tab

The Workspace tab shows the targets and tags for the ILS Sensor workspace.

The buttons at the upper-right corner of the Workspace tab can be used to start and stop, or teach and clear all system datum.

• START: Starts a visualization of the ILS Sensors and the tags.

• STOP: Stops the visualization of the ILS Sensors and the tags.

• TEACH ALL SYSTEM DATUM: Finds the common origin in the xyz-plane for the tags.

• CLEAR ALL SYSTEM DATUM: Clears the common origin in the xyz-plane for the tags.

Dual Sensor Teaching

When using two ILS sensors it is necessary to teach a common origin. The following prerequisites apply for dual sensor teaching.

• Three tags with unique ID numbers.

• The tags have a space of a minimum 200 mm apart from each other.

• The tags are horizontal.

• The tags are positioned in the common field of view (FOV) of the sensors.

• The common FOV is at least 300x300 mm.

• The tags are placed near or on the same plane as the one that will be used for bolt positions in ILG.

If all bolts are on a horizontal plane the tags for dual sensor teaching could be tilted around 5 to 10 degrees. Note that it is the plane created by the tags that should be tilted and not the tags themselves.

Barcode Reader Page

The Barcode Reader page shows the configuration of the barcode reader and the barcode examiner.

The buttons at the upper-left and upper-right corner of the Barcode Reader page can be used to change the configuration.

Configuring a Barcode Reader

Configuring the BarcodeExaminer

The BarcodeExaminer filters and modifies the received Vehicle Identification Number (VIN).

Security Page

The Configuration page allows for configuration of the user roles by setting and changing passwords.

Setting a Password

User Role Access

The user roles have different access to the functionalities of the Industrial Location Guidance (ILG) system. The user roles can be password protected to limit function availability.

• Worker: has access to existing Workplaces.

• Configurator: has access to existing Workplaces and Configuration mode.

• Service: has full access to the Industrial Location Guidance (ILG) system.

User Role Access Video

Downloading a Certificate

This instruction is for adding a certificate in Google Chrome. For instructions on how to add certificates in other browsers, refer to their respective guides.

Backup Page

The Backup page shows a list of configurations that can be downloaded as backup.

The buttons at the bottom of the list can be used to download a backup or restore the system using already download backup.

• BACKUP: downloads a backup the selected configurations.

• RESTORE: restores the configurations from a downloaded backup.

Creating a Backup

Restoring from a Backup

Help Page

Scan the QR code or select GOTO ONLINE HELP to open the Industrial Location Guidance (ILG) User Guide.

Working with Diagnosis Mode

Diagnosis mode has diagnostics information about the application state.
Besides, it lets the operator to download/upload the ILG software configuration.

Modules Page

The Modules page shows the different modules for ILG.

A module can be managed by selecting the checkbox in front of the module and then using the buttons at the top of the Modules page. The buttons can be used to refresh the Modules page, and start or stop a module.

• Refresh: Refreshes the page.

• Start module: Starts the selected module.

• Stop module: Stops the selected module.

The error column in the table lists permanent errors for each module.

Tightening Tracker

The Tightening Tracker module is a system that monitors the tightening process and communication with the controllers. If it detects errors or abnormalities it will send messages in the message bus. Enabling the Tightening Tracker can help troubleshoot the tightening process.

Process Safety

It is important to have good tightening programs or Psets with reasonable torque and angle limits.

Tightening's that finish quickly, also called "rehits", can be a source of errors in the process. In many cases these types of tightenings can be avoided by using a multistep Pset. If this is not possible and the quick tightening sequence causes problems, it can be necessary to add a short waiting step of approximately 0.8 - 1.6 s at the end of the Pset.

The Self-locking Function in the Controller

To ensure a safe process in all cases it can be necessary to enable a self-locking function in the controller. The self-lock will in most cases be much faster compared to ILG in locking the tool as no signal transmission is required. The self-locking function is supported with release 3.10.11+.

Messages Page

Messages page shows a list of messages which are exchanged in the system.

The buttons at the upper-right corner of the Messages page can be used to filter or to download existing messages.

• Filter: filters the messages depending on the customer needs.

• Download: downloads the selected messages.

Downloading the Messages

Operation

• Basic Setup
• Standard Process Sequence
  • Starting a Workpiece
    • Workpiece Referencing
  • Working with a Workpiece
    • Loosening
    • Retry
  • Finishing a Workpiece
• Working with Two Different Tools

Basic Setup

Follow the steps in this guide to get started with a basic setup of the ILG software. For more information on each step consult the relevant sections in the ILG User Guide

Basic Setup Video

Standard Process Sequence

The main function of the ILG system is making sure that the tightening process has no-fault, by guiding the operator to perform tightenings in correct positions and in the correct order.

ILG software is configurable and can be influenced by the workflow details to give a custom workflow operation.

The standard process sequence assumes that the operator performs tightenings on predefined tightening positions of a defined workpiece. These tightening positions can be organized into groups.

Before any necessary operation on any workpiece, define the workpiece model in the ILG software.

The standard process sequence has a small number of steps:

1. The workpiece gets into the station. Then, the workpiece barcode is received by the controller.

2. The workpiece gets referenced.

3. The operator tightens bolts in the defined tightening positions.

4. ILG system waits for the next barcode.

Starting a Workpiece

Usually, the standard process starts with a barcode that identifies the workpiece ID. ILG software analyzes the barcode and identifies the workpiece model to be run.

The Workpiece page shows:

• The workpiece image.

• The list of the tightening groups.

• The list of the tightening positions with their status: blue – available for tightening, yellow – not tightened but not yet available for tightening.

• Optionally, information on workpiece referencing.

Workpiece Referencing

The workpiece model may need a correct referencing before any operation. The referencing process is needed because in many situations, the workpiece to be processed is located in a location which is not the one that the model assumes.
Thus, up to 3 positions - Reference Position 1, Reference Position 2, and Reference Position 3 - may be defined as Reference Positions.

The ILG software shows the reference positions to the operator as big dots (bigger than the tightening positions).

• Blue dot: this position should be now used for the referencing.

• Yellow dot: this position will be used for the referencing later on.

• Gray dot: this position has already been used for referencing.

The Workplace page does not display the crosshair until the referencing is complete.
ILG system does not know the tool position as compared to the workpiece. The Operator must find the designated points on the real workpiece.

After the Referencing process, do not move the workpiece model until the end of the process.

The operator can now perform the tightening.

Working with a Workpiece

When working with a workpiece, the operator performers the tightenings as configured for the given workpiece, depending on the order (free, forced) defined for the given active group.
ILG software shows the information on the tightening positions status through colored dots (in the standard setting):

• Blue for the position (or positions) allowed for tightening currently.

• Yellow for positions not tightened yet, but not allowed currently.

• Green for positions tightened OK.

• Red for positions tightened NOK.

Even in the free order configuration, it is necessary to finish the current group before switching to another one. Thus, if a group has been already begun, all the positions that have not been tightened, outer of this current group, are yellow colored.

Loosening

The operator can loosen an already tightened position, depending on the setting of the given group.

To perform the loosening, the operator must set the tightening tool direction to loosening.

After the loosening, the operator can retry the same position or proceed with another one, depending on the group settings such as Retries and Tightening Order.

Retry

The Operator can repeat the tightening on a position previously tightened with a NOK result, depending on the setting of the given group.
Usually, the operator must first loosen the tightening position. In a given workpiece model, it is possible to set a Retries limit value per tightening position.

To perform the retry, the operator must set the tightening tool direction to tightening.

When the operator gets to the allowed numbers of retries, it is possible to bypass this position - if the ILG system receives a previously configured bypass signal - and proceed with further tightenings. Alternatively, the ILG system can declare the whole workpiece NOK and finish working on it.

Finishing a Workpiece

After that all configured tightening positions for the given workpiece are done (OK or NOK), the ILG system considers the workpiece as finished. Thus, the ILG system waits for the new workpiece identifier.

Working with Two Different Tools

The video explains how to setup and work with two different tools in the same Workplace.

Working with Two Different Tools Video

Troubleshooting and Service

• Troubleshooting

Troubleshooting

A list of common issues and how to solve them.

Reference

• List of Third-Party Licenses
  • LGPL
• ILS Sensor Target Configuration

List of Third-Party Licenses

The ILG software incorporate third-party components whose licenses require us to publish copies of the licensing language and/or copyright notices. In compliance with those requirements, here are copies of the licenses. Please, click on any of the licenses below to show a copy of the license text.

LGPL

Copyright © 2010-2014 Stéphane Raimbault stephane.raimbault@gmail.com

This library is free software; you can redistribute it and/or modify it under the terms of the GNU Lesser General Public License as published by the Free Software Foundation; either version 2.1 of the License, or (at your option) any later version.

This library is distributed in the hope that it will be useful, but WITHOUT ANY WARRANTY; without even the implied warranty of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the GNU Lesser General Public License for more details.

You should have received a copy of the GNU Lesser General Public License along with this library; if not, write to the Free Software Foundation, Inc., 51 Franklin Street, Fifth Floor, Boston, MA 02110-1301 USA

ILS Sensor Target Configuration

Angle Tools - Angled Target Position

Angle Tools - Straight Target Position

ICB with Triple Target

STwrench with Triple Target

ETP/SRB with Dual Target

ETP/SRB with Single Target

TBP with Dual Target

TBP with Single Target