Verify every screw: present, sequenced & torqued.
The FlexIPS Screw Tightening Station uses machine vision to confirm every screw is present, in the right position, and driven in the right sequence, with optional FlexProjector guidance showing the operator exactly where to drive. With a guidance fixture or completely fixture-free, every result is captured and traced to the serial.
of screws verified present, in position, and in sequence before release
captured per screw from the screwdriver and stored with the vision result
full-assembly verification keeps pace with the line
Sequence
gated
Torque
captured
Projector
ON
Pull a screw. Watch vision respond.
This is a live simulation of a FlexIPS Screw Tightening Station. Click any screw on the housing to make it missing, under-torqued, or cross-threaded. Toggle between a guidance fixture and fixture-free mode, switch the projector on to see sequence guidance, then run a scan.
Screws
8 / 8 OK
Defects
0
Confidence
0.99
Try it: change a screw
Click any screw on the housing to cycle it: present → missing → under-torque → cross-threaded. Toggle the fixture and projector, then run a scan.
Detection results
PASSMissing, under-torqued, or complete, classified on every assembly.
A missing screw is the most common and most expensive assembly escape. FlexIPS inspects each screw position individually, catching the defects that cause leaks, rattles, and recalls.
Missing screws
- Screw never inserted; hole empty
- Screw dropped or skipped during the sequence
- Wrong screw count on the assembly
- Screw present at goods-in but lost in rework
- Empty hole masked by oil or swarf; still flagged
Under-torqued & wrong
- Screw seated but below the torque threshold
- Cross-threaded or stripped screw, driven but not holding
- Wrong screw grade or length in the position
- Screw driven out of sequence
- Duplicate screw in one hole, none in another
Correct & complete
- Every screw present in the correct position
- Drive sequence followed end-to-end
- Torque and angle within spec for every screw
- No cross-threaded or stripped fasteners
- Assembly complete; released to the next station
With a fixture, without a fixture, or projector-guided.
The same verification engine runs whether your part sits in a dedicated jig or loose on a pallet. Add the projector to guide the operator screw-by-screw - or run vision-only for full automation.
With a guidance fixture
Screw positions are fixed by a locating jig or nest. The recipe inspects nominal positions for fastest cycle and repeatability, ideal for high-volume, low-mix assemblies where the part is always pinned in the same place.
Without a fixture (vision-located)
No dedicated jig; the vision system locates each hole dynamically on the part. Verification tolerates part shift on the pallet and supports flexible, high-mix assemblies and variants without re-tooling.
With FlexProjector guidance
A projector beams a light spot onto the exact screw to drive next, in sequence. Combined with vision verification and torque capture, it is a full poka-yoke for the operator: guide, drive, verify, release.
One screw-verification engine, every assembly.
Anywhere screws, bolts, or fasteners are driven, in a manual cell or on an automated line, FlexIPS confirms the joint is right before the assembly moves on.
Transmission & Gearbox
Verify every bolt on a transmission case (pan bolts, valve-body bolts, sensor retainers) with torque capture per position before the case is sealed.
Engine & ECU Covers
Confirm cover and bracket screws are present and torqued; catch the one missing screw that causes a leak or rattle downstream.
Electronics Enclosures
Verify standoffs and screws on electronics housings and ECU boxes (including sequence) before mating the connector and closing the lid.
Battery & Power Electronics
Inspect high-current busbar and module screws; combine presence with torque and angle for safety-critical joints.
Manual Assembly Cells
Guide operators through the screw sequence with the projector, then vision-verify every position: poka-yoke for mixed-model manual cells.
Brackets & Sub-Assemblies
Verify bracket, clamp, and retainer screws on sub-assemblies before they are released to the main line.
Precise, guided, and line-paced.
Per-Screw Classification
Every screw position is individually classified present, missing, under-torqued, or cross-threaded, with its position, sequence, and confidence.
Projector Sequence Guidance
FlexProjector beams the next screw to drive directly onto the workpiece, so the operator always drives the right screw in the right order.
Torque and Angle Capture
Screwdriver torque and angle are captured per screw and stored next to the vision result, with presence and torque on one record.
Step-Gated Release
The station cannot advance until every screw is verified present and in sequence, a true poka-yoke that blocks escapes at the source.
Fixture or Fixture-Free
Inspect nominal positions with a guidance jig, or let vision locate each hole dynamically on flexible, high-mix assemblies with no dedicated fixture.
No-Code Recipes
Define screw positions, sequence, and torque thresholds visually, with no vision expertise needed. Variants swap automatically with the work order.
Every screw, every assembly, tied to the serial.
Screw verification is not just a pass/fail light. Each screw, its classification, the captured image, torque, angle, sequence, and verdict are stored against the serial, so you can prove the state of every joint on any unit, any time.
Serial-linked proof
Every screw result, image, torque, angle, and verdict is tied to the serial and searchable in FlexDashboard for any assembly, any time.
Catch the one missing screw
A single missing or under-torqued screw is caught before the assembly leaves the station, never discovered later as a field leak or recall.
Audit-ready
Prove every screw was present, sequenced, and torqued on every unit shipped, exportable for audits, PPAP, and containment.
M8 · Mid-T missing
No screw detected in hole (seq 3)
M8 · C under-torqued
17.2 Nm recorded · spec 22 Nm
M6 · BL cross-threaded
Screw seated at an angle and not holding
When a screw is missing or wrong, the operator sees exactly which one and why.
If any screw fails (missing, under-torqued, or cross-threaded) the assembly is routed to FlexCheck. The failed position is highlighted on the stored image, labeled with the defect and the recorded torque, and paired with the action to take: rework, re-torque, replace, or controlled override.
- Every screw classified present, missing, under-torqued, or cross-threaded
- Failed positions highlighted directly on the captured image
- Recorded torque and angle shown next to each failed screw
- Clear action label per failure: REWORK, RE-TORQUE, REPLACE, or Override PASS
- Every decision logged against the serial for traceability
From trigger to traced verdict in one paced cycle.
Step 1
Trigger
Part-present signal or barcode read starts the cycle and loads the matching screw-verification recipe for that assembly variant.
Step 2
Capture
A calibrated top-down image of the assembly is grabbed with controlled lighting so every screw and hole is resolved cleanly.
Step 3
Detect
Every position is classified present, missing, under-torqued, or cross-threaded, with hole location, drive sequence, and a confidence score.
Step 4
Decide
Release PASS to advance the assembly, or route FAIL to FlexCheck showing exactly which screw is missing or wrong and where it sits.
Drops into any station.
FlexIPS bridges IT and OT without middleware, from part-present sensors and screwdriver controllers to MES genealogy records.
Screwdrivers & PLC I/O
Capture torque and angle from the screwdriver controller, trigger on part-present, and return pass/fail to the line PLC with 24V logic, with station-lock on any missing or under-torqued screw.
MES & Traceability
Serial, variant, every screw result, torque, angle, image, and verdict written to your MES or SQL store, with full genealogy tied to each assembly shipped.
FlexProjector Guidance
Optional projected light-spot guidance shows the operator the next screw to drive, in sequence - turning a manual cell into a guided, step-gated poka-yoke station.
Common questions from assembly and quality teams.
Presence, sequence, torque, projector guidance, and fixture options, answered for production and quality teams.
What is the Screw Tightening Station?
The Screw Tightening Station is a machine vision inspection station that confirms every screw or bolt on an assembly is present, driven in the correct position and sequence, and (combined with screwdriver torque capture) torqued to specification. It prevents missing-screw escapes, wrong-position errors, and under-torqued joints from leaving the station.
How does machine vision detect a missing screw?
FlexIPS compares a calibrated image of the assembly against the expected screw pattern for that variant. For each position it classifies whether a screw head is present, the hole is empty (missing screw), the screw is seated but under-torqued, or the screw is cross-threaded or stripped. Results are produced and re-checked every cycle until PASS, within the station cycle.
Does the Screw Tightening Station need a guidance fixture?
No. The station supports both modes. With a guidance fixture, screw positions are fixed by a locating jig and the recipe inspects nominal positions. Without a fixture, the vision system locates each hole dynamically on the part, so tightening works on flexible, high-mix assemblies and even when the part shifts slightly on the pallet.
What does the projector do during screw tightening?
The FlexProjector projects a light spot or ring directly onto the workpiece showing the operator exactly which screw to drive next and in what sequence. Combined with machine vision verification and torque capture, this gives full poka-yoke: the operator is guided to the right position, the screwdriver torque is recorded, and vision confirms the screw is correctly seated before the next step unlocks.
Is the FlexProjector required, or is it optional?
The FlexProjector is fully optional. The Screw Tightening Station verifies screw presence, position, sequence, and torque on its own, with no projector fitted. Adding the FlexProjector turns the station into a guided, mistake-proofed process: it beams the next screw position and drive order directly onto the workpiece so the operator cannot drive the wrong hole or the wrong sequence, while vision and torque capture still confirm every screw before the next step unlocks.
Can FlexIPS verify screw torque as well as presence?
Yes. FlexIPS captures screwdriver torque and angle per screw (via screwdriver controller integration) and stores it alongside the vision result for the same position and serial. So for every screw you get presence, position, sequence, torque, and angle, all tied to the unit serial in FlexDashboard for full traceability.
How fast is the Screw Tightening Station?
A full assembly (even with dozens of screws) is verified and re-tested every cycle until PASS within a normal station cycle, typically well under one second, so the check keeps pace with the line and never becomes the bottleneck.
Have a question we didn't answer? Request a demo and we'll map it to your line.
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Test FlexIPS on your Screw Tightening Station
Send a sample assembly, a screw pattern drawing, or a work instruction and we will map a tailored demo around your screw positions, torque specs, sequence, and traceability requirements.