Tensioning Parameters

Under Program tab, click on the Tensioning item to open it and edit the parameters. The tensioning parameters are listed in the table below. See also Diagram of the tensioning process in the section Tensioning process.

Parameter	Default value	Unit	Description	Comment
^a All default values are tailored for an M36 bolt running with min angle 40 degrees and no max angle. ^b The rotation detection parameters define an expected play in the wrench-socket-gear box chain. The experience is that this can vary a lot depending on, mainly bolt geometry – even when the tool is attached to the same bolt but the socket aligns to different sides of the nut. ^c The rotation detection parameters define an expected play in the wrench-socket-gear box chain. The experience is that this can vary a lot depending on, mainly bolt geometry – even when the tool is attached to the same bolt but the socket aligns to different sides of the nut.
Name			User name of the step configuration, written in the xml report file and reported in the step Results.
Bolt size	M36 ^a	mm	The size of the bolt for the intended configuration. The bolt size is compared to the connected tool and if it does not match, an invalid configuration event is emitted.	The controller GUI filters out the configurations that fit the connected tools. Configurations made for other tool sizes are not displayed in the list under Tasks > Assembly or Tasks > Batch Assembly.
Tensioner type	Flange bolt		Tensioner type must match the connected tensioner. The string is compared to the string that identifies the type of tensioner which is programmed in the tensioner during its production. The string is case sensitive when compared to the string in the tensioner.	The controller GUI filters out the configurations that fit the connected tools. Configurations made for other tensioner types are not displayed in the list under Tasks > Assembly or Tasks > Batch Assembly.
Min nut rotation angle	40	Degrees	The minimum nut rotation angle for an OK tensioning.	The field can be left empty if the tensioning process does not depend on minimum tightening angle.
Max nut rotation angle		Degrees	The maximum nut rotation angle for an OK tensioning.	The field can be left empty if the tensioning process does not depend on the maximum tightening angle.
Angle approval	Approve last angle		Controls the behavior of the angle measurement when re-tensioning after NOK result. Choices are: Approve last angle: Each attempt will validate the angle result regardless of earlier angles. Approve angle sum: Summarizes the angles from earlier attempts that are done before angle evaluation for OK/NOK results.	For configurations that require max angle, it is recommended to use only the last angle. For configurations that require min angle, use angle summarization in order to consider the sum of all attempts for OK/NOK results. For configurations that define an angle range, consider which behavior applies for the job the that the configuration is tailored for.
Use clamping force estimation	On		Controls which clamping force estimation is used for the result. On -> Clamping force estimation is used: tensioning force – Estimated Initial mean settlement Off -> clamping force is calculated according to Load Transfer Factor equation: tensioning force / (1.01 + (bolt diameter / clamping length))	The Atlas Copco (AC) Load Transfer Factor (LTF) equation utilized in the STS is for use on ‘Flange’ connected joints only. Do NOT use on foundation style joints.
Clamping length		mm	The height of the flange, i.e. the distance between the nuts on each side of the flange. Active when: Use clamping force estimation is ’Off’.	Visible if Use clamping force estimation is ’Off’.
Estimated initial mean settlement	99	kN	An estimation of the average force loss when releasing the pressure. Active when: Use clamping force estimation is ’On’.	Visible if Use clamping force estimation is ’On’. It is used in the xml report generation. The value depends on the tensioner size and the type of the flange.
Estimated initial max settlement	155	kN	An estimation of the maximum force loss when releasing the pressure. Active when: Use clamping force estimation is ’On’.	Visible if Use clamping force estimation is ’On’. It is used in the xml report generation. The value depends on the tensioner size and the type of the flange.
Min required average clamping force	510	kN	The minimum average clamping force for all bolts on the flange used in flange summary section in the xml report. Active when: Use clamping force estimation is ’On’.	Visible if Use clamping force estimation is ’On’. It is used in the xml report generation. The value depends on the tensioner size and the type of the flange.
Batch job report type	General		Controls the flange summary generation in the xml reports: General: The evaluation of the flange, OK/NOK is based on the bolts run in one batch assembly job. First round: The flange summary fields for the first round are populated. Second round: The flange summary fields for the first and second round are populated.	Taylored for Vestas xml report requirements: First round, Second round, User General for Service jobs.
Angle sensor reset force	100	kN	The force at which the angle measurement reference for 0 degrees is set.	The expected angles are calculated depending on the force increase from the angle sensor reset force to Min bolt tensioning pressure. This evaluates to different pressures depending on the tensioner size, see the table in the section Pressures for Different Tensioner Sizes. The larger the tensioner is, the higher the angle reset force must be set, due to issues with control of low pressures in installation check step. This is necessary in order to avoid overshooting of Installation check hydraulic pressure higher than pressure equivalent of angle sensor reset force.
Min bolt tensioning pressure	1900	Bar	The min pressure for an OK tensioning result.	The pressure control in the system will set a target value higher than the Min bolt tensioning pressure to avoid pressure drop ending in a NOK result. See the picture in the section Hydraulic Pressure Target Window.
Max system hydraulic pressure	1980	Bar	The highest pressure the pressure control in the hand controller allows for this configuration.	The actual max pressure is the lowest of the max pressures in the pump and tensioner and the Max system hydraulic pressure of the configuration.
Min bolt tensioning force	698	kN	Force equivalent of the Min bolt tensioning pressure parameter.	Value manually calculated from bolt pressure. This value is written in the xml report files, but it is not used by the hand controller's software.
Installation check torque	20	Nm	The required torque for an acknowledged installation check.
Installation check torque duration	1.0	S	The required time the Installation check torque must be applied for an acknowledged installation check.
Tightening target torque	100	Nm	The required torque for an acknowledged tightening of the nut.
Tightening torque duration	1.0	S	The required time the Tightening target torque must be applied for an acknowledged tightening of the nut.
Tightening unexpected clockwise rotation detection angle	5	Degrees	The maximum allowed change of the nut rotation angle in clockwise direction when the process is waiting for pressure release.	To avoid the risk of nut rotation while the system waits for pressure release, activate automatic pressure release (see section Tool Configuration). ^b
Tightening unexpected counter clockwise rotation detection angle	5	Degrees	The maximum allowed change of the nut rotation angle in counter clockwise direction when the process is waiting for pressure release.	To avoid the risk of nut rotation while the system waits for pressure release, activate automatic pressure release (see section Tool Configuration). ^c
Installation check hydraulic pressure	20	Bar	The pressure set point for installation check.	The installation check pressure fixes the tensioner to the flange during the installation check. The installation check pressure, including overshoot, must not exceed the pressure equivalent of Angle reset force.
Hydraulic pressure set point factor	1.025		The actual set point for the pressure regulation is calculated as follows: Min bolt tensioning pressure times Hydraulic pressure set point factor. See the picture in the section Hydraulic Pressure Target Window.	When pressing and holding the pressurization button, the system is pressurized, the pressure will be held inside a pressure window above Min bolt tensioning pressure.

Relevant Information

Tool Configuration

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