TCA Torque Controller
TCA-2000 Torque Controller: Precision Control for Pneumatic Tools with HMI Touch Panel Interface
The TCA-2000 Torque Controller is an advanced device designed to provide precise torque management for various pneumatic tools, including impact wrenches, pulse tools, nut runners, and clutch tools. Equipped with an intuitive Human-Machine Interface (HMI) touch panel, the TCA-2000 offers user-friendly control and monitoring, making it an essential tool for applications requiring consistent and accurate torque delivery.
Key Features and Benefits
- Advanced Torque Control: The TCA-2000 is engineered to ensure precise torque control for various pneumatic tools. Accurately managing the torque output helps prevent fasteners from over- or under-tightening, ensuring the integrity and safety of assemblies in critical applications.
- Versatile Compatibility: This controller is compatible with many pneumatic tools, including impact wrenches, pulse tools, nut runners, and clutch tools. Its versatility makes it ideal for automotive, aerospace, and manufacturing industries, where different tools are often used in assembly and maintenance processes.
- User-Friendly HMI Touch Panel: The integrated HMI touch panel provides a straightforward, intuitive interface for users to set, adjust, and monitor torque settings easily. The touch panel simplifies operation, reducing the learning curve and enabling quick adjustments on the fly. The interface is designed for ease of use, with customizable settings and real-time feedback to ensure optimal tool performance.
- Real-Time Monitoring and Feedback: The TCA-2000 offers real-time monitoring of torque applications, providing immediate feedback to the operator. This feature ensures that torque is applied consistently according to the specified parameters, reducing the risk of errors and enhancing overall process reliability.
- Programmable Settings: The TCA-2000’s settings allow users to create and store multiple torque profiles for different tools or applications. This flexibility is particularly useful in production environments requiring different torque settings for various tasks, allowing quick and efficient tool changeovers.
- Data Logging and Analysis: The TCA-2000 has data logging capabilities, enabling users to record torque data for each operation. This data can be used for quality control, traceability, and analysis, helping to identify trends, optimize processes, and ensure compliance with industry standards.
- Robust Construction: Built to withstand industrial environments, the TCA-2000 features a durable design that ensures long-term reliability. Its strong construction is resistant to vibration, dust, and other harsh conditions commonly found in manufacturing and assembly settings.
- Safety Features: The TCA-2000 includes safety features such as overload protection and automatic shutoff in case of abnormal torque readings. These features help protect both the tool and the operator, reducing the risk of damage and injury.
- Ease of Integration: Designed with flexibility, the TCA-2000 can be easily integrated into existing production lines and control systems. Its compact size and versatile mounting options make it adaptable to various work environments.
Applications
The TCA-2000 Torque Controller is ideal for a wide range of industrial applications, including:
- Automotive Assembly: Ensures precise torque control for critical fasteners in automotive manufacturing, reducing the risk of assembly errors and ensuring vehicle safety and reliability.
- Aerospace Manufacturing: Provides consistent torque application in the assembly of aircraft components, where precision and reliability are paramount.
- Industrial Machinery Maintenance: Used for servicing and maintaining heavy machinery, ensuring that bolts and fasteners are tightened to the correct specifications for optimal operation and longevity.
- Electronics Assembly: Supports the precise tightening of small, delicate components in electronics manufacturing, helping to prevent damage and ensure product quality.
Why Choose the TCA-2000 Torque Controller?
The TCA-2000 Torque Controller offers precision, versatility, and ease of use, making it an indispensable tool for professionals in various industries. Its advanced features, such as the HMI touch panel, real-time monitoring, and data logging, provide the control and insight needed to achieve consistent and accurate torque application. Whether in automotive, aerospace, manufacturing, or maintenance, the TCA-2000 enhances the performance and reliability of your pneumatic tools, helping to ensure that every job is done right.
- With a patented control algorithm and device for controlling the output torque of all continuous and discontinuous air-driven torque tools, especially air impact wrenches, air ratchet wrenches, air oil pulse wrenches, as well as geared torque multipliers, regardless of tool brand and its designed mechanism with proven satisfactory control accuracy and durability.
- Programmable function of bolting sequence control while applying with the tagged bolt or sensing bolt.
- It solves problems of torque loss that may be caused by the variation of the joint hardness, the rise in temperature of hydraulic fluid in pulse tools, or the posture of holding the tool during continuous operation. It compensates the dynamic torque loss automatically within its allowable working torque range.
Standard Packaging:
Controller, Power cable, Air Hose Coupler, Antenna x 2., TCA-IPC01 Controller Inlet – 2M hose+coupler + F.R unit -10kg/cm2 max., & TCA-OPC01 Controller Outlet – 3M hose+coupler.
Optional Accessories:
- 24V Tri-color light pole w/ Buzzer
- Barcode Scanner
- Printer.
 | Optional: ZTPAMB6-73ROG 24V Tri-color light pole w/ Buzzer |
Software & Functions
- Pulse Wrench
– Transducer mode (Work with transducer)
– Pressure mode (Without transducer)
– Track mode (For soft joint) - Torque wrench
– Torque
– Torque + Angle
– Click wrench track mode
– Click wrench inspection mode - Impact Wrench
– Transducer mode (Work with transducer)
– Pressure mode (Work without transducer)
– Track mode (For soft joint) - Job sequence
Geared Wrench ( Opt. mode)
Torque Tester ( Opt. mode)
Torque multiplier ( Opt. mode) - Signal Source: Torque Transducer, Air Pressure Sensor, Sensing Bolt or Tagged Bolt.
- Torque Revise: Deviation & Replacement.
- Tool Torque Capacity Calibration: Easy set-up TH & TL within operable working air pressure range in minutes.
- Target Torque Setting: Any target torque value can be selected and inputted within the calibrated torque range.
- Working air pressure: Automatic adjusted to correspondent target torque(Inlet Air Pressure between 100~120psi is recommended).
- Air flow rate: Only TCA/TCB is equipped with a digital flow meter. Turn the tool’s airflow regulator to the maximum, and the system will automatically regulate the proper flow rate to the corresponding target torque.
- Bolting in stages: As required, set the bolting stages and the percentage of target torque for each stage from 1 to 4. The system will regulate the air pressure and flow rate accordingly.
- Number of bolts: Preset the number of bolts to be fastened. When all bolts of each stage are fastened, the system switches to the next stage and regulates the air pressure and flow rate accordingly and automatically.
- Torque Compensation: The system will automatically compensate for the torque loss that may be caused by the variation in the bolted joint hardness, the rise in temperature of the pulse wrench’s hydraulic fluid, or the operator’s posture to hold the tool during the process within its allowable working air pressure range.
- Remote monitoring: Via the Internet or Ethernet with VNC, you can monitor data on your cell phone, tablet, and PC or set parameters on the torque controller.
- Operation Management: Constraints: Via permission setting, access the operable functions, such as logging the operator’s ID and duration of operation.
- Torque Control Accuracy: ±5%~±15%.
- Job Sequence: Support 10 torque tool presets available for bolting sequentially.
- Production Record: Traceable through USB, Ethernet, or exported to the cloud server through wired or wireless connections.
- Torque Controller Warranty period:
* 12 months from purchase date.
* Manufacturer will repair or replace defects due to faulty materials or workmanship. This Warranty does not cover part failure due to broken/missing seal labels, misuse, modification, negligence, abuse, or normal wear and tear.
 |  | ||
| Model | TCA-2000 | TCB-2000 | |
| Max. Flow Rate | 2000 L/min | 2000 L/min | |
| Touch Panel Size | 10″ Touch Panel | NB / Tablet | |
| Power Source | AC 100V~240V /2A | AC 100V~240V /2A | |
| Connection Port | USB | 1 | 1 |
| RS232 | 2 | 1 | |
| RJ45 | 1 | N/A | |
| Wireless Antenna | RF2.4G | 2 | 1 |
| BT Antenna | Yes | 1 | |
| Speaker | 1 | 1 | |
| Light Tower Output Port | 1 | 1 | |
| Buzzer | 80dB | 80dB | |
| USB Charger Port | 2 | 1 | |
| Flow Rate Detection | Yes | No | |
| Automatic Flow rate Control | Yes | No | |
| Operation Mode | Oil Pulse Wrench | Yes | Yes |
| Air Impact Wrench | Yes | Yes | |
| Manual Torque Wrench | Yes | Yes | |
| Air Torque Multiplier | Yes | Yes | |
| Job Sequence | Yes | Yes | |
| Control Accuracy | Static Torque (%) | ±1%~±5% | ±1%~±5% |
| Dynamic Torque (%) | ±5%~±15% | ±5%~±15% | |
| Thread Size | Inlet | 1/2″ NPT | 1/2″ NPT |
| Outlet | 1/2″ NPT | 1/2″ NPT | |
| Language | Simplified/Traditional Chinese, English, Japanese | Simplified/Traditional Chinese, English, Japanese, Spanish, Italian, Indonesian | |
| System Parameter | Yes | Yes | |
| Static Torque | Yes | Yes ( torque & angle ) | |
| Dynamic Torque | Yes | Yes | |
| Multi-stage training | Yes | Yes | |
| Job Sequence ( Dynamic & Stastic ) | Dynamic | Dynamic + Stastic | |
| Tyre Assembly System | No | Yes | |
| Display | HMI onboard | On-board or Separate display | |
| Job Data | Full Job report | Full Job report | |
| Cloud | FTB | WEB | |
| Job Data Export | All data in CSV format | Available in Excel, PDF, or CSV format | |
| Job Data Memory | 150K | No Limit | |
| Torque Curve Display | No | Yes | |
| Dimensions | Length(L) | 370mm | 320mm |
| Width(W) | 214mm | 217mm | |
| High(H) | 266mm | 210mm | |
| Net Weight | 10.5kg±0.5kg | 6kg±0.5kg | |
