Configuring and Operating an IQi Series Smart Torque Arm

Operator Guidance works with an IQi Series Smart Torque Arm to provide visual, position-based fastening instructions. It helps operators identify the correct fastening location, confirms that the tool is positioned correctly, and guides the operator through the programmed fastening sequence.

This article explains how to configure Operator Guidance, assign screw positions, work with multiple PSETs and Screw Patterns, and run a guided fastening Job.

Before You Begin: The Smart Torque Arm must already be connected, enabled, and calibrated. A PSET and Job must also be created, and the Torque Arm interlock must be enabled. See Setting Up an IQi Series Smart Torque Arm.

How Operator Guidance Works

Operator Guidance displays an image of the assembly or workpiece and identifies the fastening location the operator should complete next.

The Smart Torque Arm tracks the physical position of the screwdriver. When the tool reaches the correct fastening location, the controller enables the tool. After a successful fastening cycle, Operator Guidance advances to the next programmed location.

The tightening sequence is controlled by the PSETs and Job configuration. Operator Guidance provides visual direction but does not change the programmed fastening order.

Open Operator Guidance

Operator Guidance is configured through the IQi Remote Browser.

1. Open the required Job.
2. Confirm that the Torque Arm interlock is enabled.
3. Verify that the required PSETs have been added to the Job.
4. Confirm that the Batch Count for each PSET matches the number of fasteners assigned to that PSET.
5. Select Operator Guidance.

A default pattern named Screw Pattern 1 is created automatically.

Add an Assembly Image

Use an image that clearly shows the joint, assembly, or workpiece from the operator's normal viewing perspective.

1. Select Screw Pattern 1.

   

2. Select Choose Image.
3. Select the image of the assembly or workpiece.
4. Upload the image.
5. Crop or rotate the image if necessary.
6. Select Apply.

7. Select the uploaded image for use.

   

A properly oriented image helps operators quickly identify the correct fastening locations during production.

Assign Screw Positions

Operator Guidance supports two methods for assigning fastening locations:

• Use previously defined PSET positions.
• Define positions dynamically using the Smart Torque Arm.

Choose the method that best matches how the application was configured.

Use Existing PSET Positions

Use this method if the physical screw coordinates were already recorded when the PSET was configured.

1. Select Assign Point.

   

2. Choose to use the existing screw coordinates.

3. Select the corresponding screw location on the image.

   

4. Repeat for each fastening point in the programmed sequence.
5. Verify that each visual location corresponds to the correct physical screw position.
6. Save the Operator Guidance configuration.

Each point becomes linked to both the image shown to the operator and the physical coordinates recorded by the Smart Torque Arm.

Define Positions While Configuring Operator Guidance

For a simpler application, screw coordinates can be defined at the same time that the Operator Guidance image is configured.

This avoids having to teach the screw positions separately before creating the visual guidance.

1. Open Operator Guidance and select the Screw Pattern.
2. Upload and configure the workpiece image.

3. Select Assign Points.

   

4. Choose the option to assign screw coordinates while creating the Operator Guidance pattern.
5. Move the Smart Torque Arm to the first physical fastening location.

6. Select the matching fastening location on the image.

   

7. Repeat for each remaining fastener.
8. Review all assigned points.
9. Save the Job.

The controller records the Smart Torque Arm coordinates while simultaneously linking the physical fastening location to its position on the image.

Configure Multiple PSETs

A single Job can contain multiple PSETs when different fasteners require different tightening strategies.

For example, one group of fasteners may use one tightening strategy while another group uses a different target or fastening strategy.

When using multiple PSETs:

1. Add each required PSET to the Job.
2. Set the Batch Count for each PSET to match the number of fasteners assigned to that strategy.
3. Record or assign the required fastening positions for each PSET.
4. Confirm the order of the PSETs in the Job.

The IQi controller follows the PSET and Job sequence to determine which tightening strategy is applied at each stage of the fastening process.

Important: Operator Guidance does not define the tightening sequence. The tightening order follows the PSETs and Job configuration.

Use Multiple Screw Patterns

Multiple Screw Patterns can be used when an application benefits from more than one image or workpiece view.

For example, a Job might include one group of fasteners on one side of an assembly and another group that is easier to identify from a different image.

When multiple PSETs are added, all fastening points are initially assigned to the first Screw Pattern. Additional Screw Patterns can then be created and the required points moved between them.

Create an Additional Screw Pattern

1. Open Operator Guidance.
2. Add a new Screw Pattern.
3. Upload or select the image for the new pattern.
4. Identify the points that should appear in the new pattern.
5. Move those points from the original Screw Pattern to the new pattern.
6. Assign each point to the correct visual location on the new image.
7. Verify the sequence numbering.
8. Save the configuration.

The sequence numbering continues across Screw Patterns. For example, if the first pattern contains screws 1 through 4, the second pattern can continue with screws 5 through 8.

During operation, Operator Guidance automatically transitions to the next Screw Pattern when the preceding pattern has been completed.

Run a Guided Fastening Job

Once Operator Guidance has been configured:

1. Return to the Home screen.
2. Select the required Job.
3. Open Operator Guidance.
4. Follow the highlighted fastening location.
5. Move the Smart Torque Arm to the indicated screw.
6. Wait for the system to confirm that the tool is correctly positioned.
7. Complete the fastening operation.
8. Follow the guidance to the next fastening location.
9. Continue until all required fastening cycles are complete.

The tool is enabled only when the Smart Torque Arm is within the programmed position tolerance for the required screw location.

Understanding Operator Guidance Status

During operation, the display uses visual status changes to indicate fastening progress.

After a successful fastening, the system automatically advances to the next required location.

What Happens After a Failed Fastening?

If a tightening cycle fails, Operator Guidance does not advance to the next fastening location.

1. The current location remains the required fastening point.
2. Correct the condition that caused the failed cycle.
3. Complete the fastening successfully.
4. After a Pass result, the system advances to the next programmed location.

This prevents the operator from unintentionally skipping a required fastening operation.

What Happens If the Tool Is Moved to the Wrong Screw?

If the operator moves the Smart Torque Arm to a location that does not match the required step in the programmed sequence, the tool will not run.

Return the tool to the fastening location indicated by Operator Guidance. Once the Smart Torque Arm confirms the correct position, the tool is enabled and the fastening sequence can continue.

This position interlock helps prevent:

• Missed fasteners.
• Out-of-sequence tightening.
• Fastening the wrong location.
• Assembly errors.

Complete the Job

Continue through the guided sequence until all required fastening locations have been completed successfully.

When the final fastening cycle passes:

• All fastening locations show successful completion.
• The Job is complete.
• The controller resets for the next assembly cycle.

For applications using multiple Screw Patterns, Operator Guidance automatically transitions between the configured images as the fastening sequence progresses.

Manuals & Downloads

• How to Set Up and Configure a Smart Arm with the IQi Series Controllers
• IQi controller documentation
• Smart Torque Arm documentation
• Torque Arm 2D drawings
• Torque Arm 3D drawings
• IQi Software Release Notes
• Updating Firmware on the IQi Series Controller and Tools