Error-Proof Every Fastening Step with 1.5 mm
Position Validation
Eliminate missed or out-of-sequence tightening operations with millimeter-accurate real-time tool tracking. Quantum RTLS 2.0™ integrates with smart tools to enforce correct torque order and location automatically, eliminating rework, downtime, and waste from the manual fastening process.
The Problem
Tightening and fastening operations account for 40% of total defects in complex builds. Skipped or out-of-sequence tightening steps can lead to catastrophic in-the-field failures, especially for safety-critical assemblies.
The Solution
ZeroKey integrates hyper-accurate real-time location data with smart torque tools to enforce tightening locations and sequences, verify torque at every fastener, and ensure no steps are skipped. An optional tool lockout feature can also be enabled to eliminate assembly errors entirely.
Real-Time
QA/QC
Ensure bolts are tightened in the correct order and with the right torque, every time. Automated sequencing and immediate operator feedback guarantee process compliance every time.
Integrates with
Smart Torque Tools
Quantum RTLS integrates with smart torque controllers, including Torque Open Protocol tools such as Atlas Copco, Cleco, Ingersoll Rand, Stanley-Black & Decker, Desoutter, and Kolver. An optional tool lockout feature eliminates operator bypass and ensures strict compliance with procedures.
Jig-less Bolt
Sequencing
Verify torque order and completion without static fixtures. ZeroKey maps bolt geometry dynamically to ensure no fastener is missed, regardless of where work takes place.
Audit-Ready
Traceability
Every torque event and position is automatically logged with 3D location and torque data, creating a complete digital record for instant verification and compliance audits.
Real-Time 3D Sequencing for Every Bolt
ZeroKey captures every torque event with millimeter accuracy, providing a live digital record of each tightening operation.
Use ZeroKey Workflows to enable live validation and tool control out of the box or connect through our API to stream spatial event data directly to your PLC, MES, or existing digital work instruction platform.
fetch("https://yourdomain.edge.zerokey.com/v3/modules/historian/workflowCompletions", {
method: "POST",
headers: {
"Content-Type": "application/json",
"Authorization": "Bearer <YOUR_ACCESS_TOKEN>"
},
body: JSON.stringify({
"StartTime": "2025-07-01T08:00:00Z",
"EndTime": "2025-07-01T18:00:00Z",
"StepTypes": ["BoltSequence"],
"IncludeStepData": true
})
})
.then(res => res.json())
.then(data => console.log("TaskID:", data.TaskID));{
"Timestamp": "2025-10-08T15:42:11Z",
"WorkflowID": "WF-TRK-042",
"StepType": "BoltSequencing",
"OperatorID": "E0:05:6E:B9:C1:0A",
"Status": "Completed",
"Bolts": [
{ "ID": 1, "TorqueNm": 320.4, "Status": "OK" },
{ "ID": 2, "TorqueNm": 322.1, "Status": "OK" },
{ "ID": 3, "TorqueNm": 319.7, "Status": "OK" },
{ "ID": 4, "TorqueNm": 318.9, "Status": "OK" }
],
"Summary": {
"CompletedBolts": 4,
"Missed": 0,
"OutOfOrder": 0,
"AvgTorqueNm": 320.7
}
}import paho.mqtt.client as mqtt
import json
BROKER = "yourdomain.edge.zerokey.com"
TOPIC = "zerokey/tools/torqueEvents"
TOKEN = ""
def on_message(client, userdata, msg):
data = json.loads(msg.payload)
print(f"{data['Timestamp']} | {data['ToolID']} | {data['TorqueNm']} Nm | {data['Status']}")
client = mqtt.Client()
client.username_pw_set(username="token", password=TOKEN)
client.connect(BROKER, 1883, 60)
client.subscribe(TOPIC)
client.on_message = on_message
client.loop_forever()
Simplify Industrial Integration
ZeroKey’s open API and MQTT interfaces make it easy to integrate spatial and torque data directly into your systems. Automatically log torque events, trigger workflows, or stream clean JSON data to your data lake without any extra infrastructure.
TICO Tractors Digitized Manual Processes, Slashing Rework and Inspection Time by 60%
The Challenge
One of TICO’s critical quality concerns was bolt-tightening during manual assembly, so they introduced smart tools to track the torque applied to each fastener. However, the team at TICO quickly realized the system was unable to identify exactly which bolt an operator was tightening due to the lack of precise 3D positioning.
The Solution
TICO deployed Quantum RTLS 2.0 in assembly cells, with tags mounted on the tools. Real-time workflow tracking with 1.5 mm accuracy matches torque events to specific fasteners, creating a digital record of completion for every truck.
The Impact
With Quantum RTLS 2.0, TICO achieved:
- • Exact Tool Positioning: Real-time spatial tracking at 1.5 mm accuracy pinpoints every torque event to it’s corresponding fastener.
- • Sequencing Verification: Each bolt is tightened in the correct order, with immediate alerts for skipped or repeated steps.
- • Torque Traceability: Integrated torque and position data create a complete digital record of every truck built.
- • Instant Feedback: Operators receive real-time guidance to correct errors without interrupting production.
By replacing reactive inspection with real-time verification, TICO shifted from quality control to full process assurance.
How It Works: Tool Tip Projection
Quantum RTLS 2.0 incorporates 6 degrees of freedom (6DoF) with 1.5 mm accurate real-time position to provide full spatial orientation of tools. This enables the system to project the exact contact point of the tool, capturing true interaction with each fastener.
Unlike vision systems that fail under obstruction, or other legacy RTLS limited to low-resolution 2D data, Quantum RLTS 2.0 delivers robust, live positioning in any environment.
WANT MORE INFO?
DOWNLOAD OUR WHITE PAPER
ZeroKey’s Quantum RTLS 2.0 technology is backed by more than thirty patents and extensive research and development! Want to learn why we’re the most accurate RTLS technology in the market? Read all about how we do it in our white paper.
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CALGARY
HEAD OFFICE
3120 – 12 St. NE
Calgary, Alberta T2E 8T3