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Control position of your fastening tools

Tool position control refers to the ability to precisely monitor and manage the exact location and movement of a tightening tool during the assembly process. It ensures that each fastener is tightened at the correct position, in the correct sequence, and with the correct parameters - such as torque and angle. 

In modern manufacturing tool position control is achieved through sensors, cameras, or digital tracking systems that communicate with our operator guidance system. This allows the system to verify that the operator is tightening the right bolt in the right place before tool is released to tighten bolts. 

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Kolver Tool 1200x1200c

Difficulties in achieving the correct bolt tightening sequence

Tool position control is designed to solve several critical challenges in modern manufacturing, especially in complex assembly environments where precision and traceability are vital. Some of the main challenges it addresses include: 

  • Tighten wrong bolts : In manual assembly, operators may accidentally tighten the wrong bolt or skip one entirely. Tool position control ensures that the tool only activates when it is positioned correctly, preventing these errors and ensuring every joint is properly completed. 
  • Lack of traceability: Without position control, it can be difficult to verify whether each fastener was tightened at the correct location. 
  • Inconsistent tightening results: Even with smart tightening tools, results can vary if the tool is not applied to the correct joint. Position control ensures that torque and angle values are only applied to the intended fastener, maintaining consistent quality and repeatability. 

Technologies to ensure tool position control

Tighten always the right bolt

Real-time location systems

Track exact location in 3D space

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Machine Vision

Track the back of the tool through vision system

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Reaction-arm with encoders

Encoders track x,y,z position

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Real-time-location system

An ultrasonic RTLS uses high-frequency sound waves to determine the precise position of a tightening tool within a workstation. The tool (or a tag attached to it) emits ultrasonic signals detected by fixed receivers placed around the work area. By measuring the time it takes for the signals to reach each receiver, the system calculates the tool’s exact 3D location in real time. 

Advantages

  • Achieves position accuracy within a few millimeters 
  • Enables position control in all orientations — horizontal or vertical 
  • Maintains accuracy regardless of whether the operator is left- or right-handed 
  • Eliminates the need for a long reaction arm, offering greater freedom of movement 
  • Scalable for additional use cases such as part picking, operator movement tracking, and asset management, all using the same core technology 
  • Suitable for factory-level tracking by adding more anchors to expand coverage beyond individual workstations 

Considerations

  • Requires an initial setup and calibration 
  • Accuracy may decrease if line-of-sight is obstructed 
  • Physical obstacles between transmitters and receivers may require additional anchors to maintain precision 

Machine vision

Machine vision–based tool position control uses cameras to track and verify the tightening tool’s position in real time. The system detects visual markers, reference points, or tool features within the workspace to confirm that each fastener is tightened in the correct location and sequence. By processing images through intelligent software, the system ensures the tool is correctly positioned before torque is applied. 

Advantages

  • Non-contact system — no need for mechanical attachments or tags on the tool
  • Visually confirms the correct bolt and sequence, reducing assembly errors
  • Provides traceability through image documentation and picture capture
  • Can support additional applications such as component verification, part presence detection, or visual quality inspection 

Considerations

  • Requires good lighting conditions and clear visibility of the working area
  • May need regular cleaning of camera lenses and calibration for consistent accuracy
  • Obstructions or operator movement can temporarily block the line of sight
  • Limited by the camera’s field of view — additional cameras may be needed for large or complex workstations
  • Provides 2D position control only, not full spatial (3D) tracking 

Reaction arm with encoders

A reaction arm with encoders is a mechanical device attached to a tightening tool that serves two key functions: it absorbs the reaction torque generated during tightening, and it tracks the tool’s angular and positional movement. 
Integrated rotary or linear encoders measure the exact position and orientation of the arm in real time, allowing the system to verify that the correct fastener is being tightened before torque is applied. 

This approach provides both ergonomic support for the operator and position verification within the defined workspace. 

Advantages

  • Combines torque reaction absorption with position control — no additional tracking equipment needed 
  • Highly accurate and stable within its defined working envelope 
  • Not affected by lighting or line-of-sight issues 
  • Provides real-time feedback to ensure the correct tightening sequence 
  • Cost-effective and robust for fixed workstations with repetitive tightening patterns 

Considerations

  • Limited movement range: The tool must remain physically connected to the arm, not suitable for mobile or large-area applications 
  • Restricted flexibility: Less freedom of motion compared to camera- or RTLS-based systems 
  • Maintenance required: Mechanical parts and encoders can wear over time and need calibration 
  • Station-bound: Ideal for single-station or small-area applications, while vision and RTLS systems can cover multiple work zones or operators 
  • No operator or asset tracking: Unlike RTLS or vision systems, it cannot extend to other use cases beyond tightening not ideal for accommodating both left- and right-handed operator actions due to the fixed arm configuration

Comparison Table

Technology  Advantages Considerations Typical use cases Best Fit / Summary Use Case 
Ultrasonic RTLS 

• Full 3D tracking
• Works in all orientations 
• Can track tools, assets or people

• Scalable for large area’s

• Needs setup and calibration  
• Line-of-sight required  
• May need extra anchors 		• Large, flexible areas 
• Multiple tools or operators  
• Asset and movement tracking 		Flexible, large area tracking 
Machine Vision • No tags needed
• Provides visual verification 
• Supports inspection tasks 

• needs good lightening and clear view 

• 2D only, not full spatial  
• Obstructions affect tracking 

• Multi-bolt assemblies  
• Visual inspection  
• Medium work cells 		Compact to mid-size visual tracking 
Reaction Arm with Encoders • High accuracy
• No line-of-sight needed 
• Absorbs reaction torque 
• Easy to integrate		• Limited range, station-bound  
• Less flexible for left/right-handed use  
• Mechanical wear, calibration needed 		• Fixed stations  
• High-torque tightening  
• Repetitive assembly 		Ideal for fixed tightening in dedicated workstations 

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