Atlas Copco PowerFocus (3000/4000) / Nutrunner Tools Ethernet communication using C#.Net

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Introduction 

In one of my project I had a chance to create an Atlas Copco PowerFocus (3000/4000) Nutrunner Tools communication using c# socket programing. The main aim of this article is due to when i start the Nutrunner tool communication program it was like a blank page. I don’t have an idea how to complete the task even i was been googling for 2 or 3 days but can’t find a sample code to communicate with Nutrunner tools using c#.Finally I got a solution using an Open protocol.
Today I will explain you what is

1) Atlas Copco PowerFocus (3000/4000) Nutrunner Tools.
2) How to use Open protocol.
3) C# Socket communication program for Nutrunner tool communication.

First we start with.

1)Atlas Copco PowerFocus (3000/4000) Nutrunner Tools,
Power Focus 3000/3100 is the latest generation of control and monitoring systems for advanced tightening technology. Power Focus 3000/3100 is a complete solution for the modern assembly industry with high demands and stringent quality and efficiency requirements. The concept offers full modularity through combinations of hardware and software.
The PF 4000 is a new generation of control systems suitable for Tensor S, ST, DS and ETX models. Unlike its predecessor, the PF 3100, the PF 4000 is available in one model with two versions (Compact and Graph) that can handle all torque levels. This favours your maintenance budget, since fewer backup units are required.

Simply say Power Focus (3000/4000) is used to read the Torque data. It’s a machine where we can set the Bach Size, Batch Count, Tightening Status, Torque Status, Angle Status, Torque Min limit, Torque Max limit and etc. We can get the final Torque data , compare the Limit value and produce the final result.

2) How to use Open protocol.
Open Protocol is an interface for building applications for remote control or data subscription of controllers. It is platform independent and can be implemented on Linux, PLC, printers, and all Windows platforms for example. The Open Protocol supports both serial and Ethernet connection.

Open Protocol supports Power Focus, and PowerMACS controllers.
Communication
The Open Protocol can be run using Ethernet or serial communication. The Open Protocol is a full duplex protocol, which means that data can be sent and received at the same time. Every communication partner must be able to operate a send and receive facility simultaneously.
Ethernet protocol
The integrator connects to the controller, and the controller accepts the connection. The controller is the server, and the integrator application is the client. The protocol used is TCP/IP. The default port used for the communication is 4545.
Serial ASCII protocol
All messages sent from the integrator to the controller must be stamped with a 4 ASCII character tag before the STX character: BEL (ASCII 0x07 bell) HT (ASCII 0x09 horizontal tab) BEL (ASCII 0x07) HT (ASCII 0x09).
All messages must be encapsulated between STX (ASCII 0x02 Start of Text) and ETX (ASCII 0x03 End of Text).
Message structure
All information sent over the communication links is ASCII format. A message consists of three parts; header, data field and message end. For example here we see how to start a communication. For Communication start we need to use the MID 0001
Communication messages
MID 0001 Communication start
This message enables the communication. The controller does not respond to any other command before this.
Message sent by: Integrator
Answers: MID 0002 Communication start acknowledge or MID 0004 Command error, Client already connected.
If the Communication is accepted the we can receive the result as MID 0002 if not we receive the MID 0004.
For more details about Open Protocol, please review the attached open Protocol PDF document.

3) C# Socket communication program for Nutrunner tool communication

1) Connect
2) Communicate
3) Data send and receive
4) Disconnect.

The detailed code will be listed below.

Background

The main aim was to develop a simple easy to use .Net communication program for Atlas Copco Power Focus (3000/4000) – Nutrunner Tool.

Using the code 

The code is very simple and has comments on all functions. The main aim is to make the program very simple and easy to use all the functions has been well commented in project.
1) First we start with namespace declarations.

using System.Net;
using System.IO;
using System.Net.Sockets;

2) Variable Declarations  

Socket server;// Declare your Socket
 IPEndPoint ip; // Declare your IPEndpoint

3) Connect (to connect the Nutrunner tool for communication).

For connection we need the Nutrunner tool IP Address.Here my tools IP Address was “10.126.224.186” and the default port for comuncication is “4545” corss check with your hardware eng for the port used on your tools.Here we use the Socket communication program for connection. After the connection is ok we need to send the Communication Start signal to the nutrunner tools “ MID 0001” – (“00200001000000000000#)
Server.Send()

String szData = "00200001000000000000#";//Nutrunner Communication Start
byte[] byData = Encoding.Default.GetBytes(szData);//convert the string as Byte
int sent = server.Send(byData, SocketFlags.None);

server.Receive()  

byte[] bytesFrom = new byte[1025];
int iRx = server.Receive(bytesFrom);
string dataFromClient = System.Text.Encoding.ASCII.GetString(bytesFrom);
String resultchk = dataFromClient.Substring(4, 4).ToString();

If we receive MID 0002 as result then the communication start is successful .If we receive MID 0004 as result then there is an error in a communication start.
The detail connect functions

 private void button1_Click(object sender, EventArgs e)
        {
            try
            {
                server = new Socket(AddressFamily.InterNetwork, SocketType.Stream, ProtocolType.Tcp);
                String ipaddress = “10.126.224.186”;
                ip = new IPEndPoint(IPAddress.Parse(ipaddress), 4545);
                server.Connect(ip);
                
                label2.BackColor = System.Drawing.Color.GreenYellow;
                label2.Text = "Connected";
                connectServer();

            }
            catch (Exception ex)
            {
            }

        }

private void connectServer()
        {
            try
            {
                if (server.Connected == false)
                {
                    label2.BackColor = System.Drawing.Color.Red;
                    server = new Socket(AddressFamily.InterNetwork, SocketType.Stream, ProtocolType.Tcp);
                    String ipaddress = textips.Text.Trim();
                    ip = new IPEndPoint(IPAddress.Parse(ipaddress), 4545);
                    server.Connect(ip);
                    label2.BackColor = System.Drawing.Color.GreenYellow;
                    label2.Text = "Connected";
                }
                if (server.Connected == true)
                {
                    String szData = "00200001000000000000#";//Nutrunner Communication Start
                    byte[] byData = Encoding.Default.GetBytes(szData);//System.Text.Encoding.ASCII.GetBytes(szData);

                    int sent = server.Send(byData, SocketFlags.None);
                    byte[] bytesFrom = new byte[1025];
                    //  string bytesSent = server.Send(
                    int iRx = server.Receive(bytesFrom);
                    string dataFromClient = System.Text.Encoding.ASCII.GetString(bytesFrom);
                    String resultchk = dataFromClient.Substring(4, 4).ToString();

                    ////String szData = "00200060000000000000#";//Nutrunner Communication Start
                    ////byte[] byData = Encoding.Default.GetBytes(szData);//System.Text.Encoding.ASCII.GetBytes(szData);
                    ////int sent = server.Send(byData, SocketFlags.None);
                    timer1.Enabled = true;
                }
            }
            catch (Exception ex)
            {
                MessageBox.Show(ex.Message.ToString());
            }
        } 

4) Torque Data Receive.
Here in my program I have used a Timer control for Torque data receive.
In timer we frequently check for the connection. If connection fails we reconnect to the nutrunner tools.
To receive the Torque data we use the message id MID 0060.
For Torque data receive we send the MID 0060 to the Nutrunner tool.
MID 0060 Last tightening result data subscribe
Set the subscription for the result tightenings. The result of this command will be the transmission of the tightening result after the tightening is performed (push function). The MID revision in the header is used to subscribe to different revisions of MID 0061 Last tightening result data upload reply.
Message sent by: Integrator
Answer: MID 0005 Command accepted or MID 0004 Command error, Last tightening subscription already exists or MID revision not supported
Send data to get Torque result:

String szData = "00200060000000000000#";//Torque data Request Send
 byte[] byData = Encoding.Default.GetBytes(szData);
 int sent = server.Send(byData, SocketFlags.None);

Receive Torque result

byte[] bytesFrom = new byte[1025];
 int iRx = server.Receive(bytesFrom);
 string dataFromClient = System.Text.Encoding.ASCII.GetString(bytesFrom);
 String resultchk = dataFromClient.Substring(4, 4).ToString();

We receive the MID 0061 as result with Torque data.
We will receive the result data something like this.
"023100610010 010001020103airbag7 04KPOL3456JKLO897 05000600307000008000009010011112000840 130014001400120015000739160000017099991800000 1900000202001-06-02:09:54:09212001-05-29:12:34:3322123345675 NUL"
Format the result string and get the Torque final result.
For example I have used the substring and get the final torque result here
txtfinaltorque.Text = dataFromClient.Substring(132, 6).ToString();
The detailed Timer code.

private void timer1_Tick(object sender, EventArgs e)
        {
            try
            {
                if (server.Connected == false)
                {
                    label2.BackColor = System.Drawing.Color.Red;
                    label2.Text = "Not Connected";
                    server.Disconnect(true);
                    server.Close();
                    server.Dispose();
                    connectServer();
                }
                String szData = "00200060000000000000#";//Nutrunner Communication Start
                byte[] byData = Encoding.Default.GetBytes(szData);//System.Text.Encoding.ASCII.GetBytes(szData);

                int sent = server.Send(byData, SocketFlags.None);

                byte[] bytesFrom = new byte[1025];
                //  string bytesSent = server.Send(
                int iRx = server.Receive(bytesFrom);

                string dataFromClient = System.Text.Encoding.ASCII.GetString(bytesFrom);
                String resultchk = dataFromClient.Substring(4, 4).ToString();
                if (resultchk == "0061")
                {
                    label2.BackColor = Color.Violet;
                    label2.Text = "Torque Data Readed ";
                    textBox1.Text = dataFromClient.ToString();

                    txtcellid.Text = dataFromClient.Substring(22, 4).ToString();

                    txtchannelid.Text = dataFromClient.Substring(28, 2).ToString();

                    txtjobid.Text = dataFromClient.Substring(86, 2).ToString();

                    txtControlorName.Text = dataFromClient.Substring(32, 25).ToString();

                    txtBatchSize.Text = dataFromClient.Substring(95, 4).ToString();

                    txtBatchCount.Text = dataFromClient.Substring(101, 4).ToString();

                    txttighteningstatus.Text = dataFromClient.Substring(107, 1).ToString();
                    if (txttighteningstatus.Text.Trim() == "0")
                    {
                        txttighteningstatusok.Text = "NOK";
                    }
                    else
                    {
                        txttighteningstatusok.Text = "OK";
                    }

                    txttorquestatus.Text = dataFromClient.Substring(110, 1).ToString();

                    if (txttorquestatus.Text.Trim() == "0")
                    {
                        txttorquestatusok.Text = "Low";
                    }
                    else if (txttorquestatus.Text.Trim() == "1")
                    {
                        txttorquestatusok.Text = "OK";
                    }
                    else 
                    {
                        txttorquestatusok.Text = "High";
                    }

                    txtanglestatus.Text = dataFromClient.Substring(113, 1).ToString();

                    txttorqueminlimit.Text = dataFromClient.Substring(116, 6).ToString();

                    txttorquemax.Text = dataFromClient.Substring(124, 6).ToString();

                    txtfinaltorque.Text = dataFromClient.Substring(132, 6).ToString();


                    txttorque.Text = dataFromClient.Substring(142, 2).ToString() + "." + dataFromClient.Substring(144, 2).ToString();//dataFromClient.Substring(140,6).ToString()

                    txtTighteningID.Text = dataFromClient.Substring(221, 10).ToString();


                    String szData3 = "00200062000000000000#";//Nutrunner Communication Start
                    byte[] byData3 = Encoding.Default.GetBytes(szData3);//System.Text.Encoding.ASCII.GetBytes(szData);

                    int sent3 = server.Send(byData3, SocketFlags.None);

            }
        }
            catch (Exception ex)
            {
            }
     }

5) Disconnect the Connection.
Check for the connection if its connected then disconnect the communication the detail code below.

 private void button2_Click(object sender, EventArgs e)
        {
            if (server.Connected == true)
            {
                label2.BackColor = System.Drawing.Color.Red;
                label2.Text = "Not Connected";
                server.Disconnect(true);
                server.Close();
                server.Dispose();
                clears();
            }
        }

Points of Interest

I love to work and play with the HMI (Human Interface Program).I have worked with several HML programs using c#.net like PLC,Sensor Programing and Nutrunner tool communication Program. While working with this program i didn’t get the proper guides to achieve the result finally I got it. I want the end users who read this article should be benefited by this program.

History

Initial release NutrunnerFirstProgram- 2013/07/03..