Global 400 Torque Controller System

If you are hardening your assembly processes you want flexibility AND control. The Global 400 gives you that and a lot more.

When ordering the Global 400 use part number 10497

The Global 400 for MES Interface

The Global 400 performs as a station dedicated process controller that organizes, directs workers, tools, and tasks. It also brings a powerful networking capability not previously available in the Global 8 and the Global 100 series.

Benefits:

Less rework and lower warranty costs to increase profits.
Increased throughput and increased productivity.
Minimal implementation time, training costs are very low.
Pairing tools with a Global 400 are as simple as providing power to the tool.
The Global 400 helps provide continual guidance to new workers, for improved performance and reduced learning cycle.
Helps you to achieve your quality goals and gain complete control over assembly processes where hand torque and pneumatic tools are used.
Great for flexible assembly lines where multiple products are assembled with a variety of optional components and configurations.
Flexibility in changing a single element of the process or the entire process with a few keystrokes in a very intuitive, easy to use utility software provided with your Global 400.
Connect with your MES in multiple protocols via Ethernet or 24 Volt I/O and PLC.
Simultaneous Ethernet communication allows for production control via MES and data acquisition through GlobalHost or ToolsNet.
Units can be chained together via one Ethernet drop reducing installation costs.

Manages

Tools are learned into a tools bank. These tools may then be paired with a parameter set that can be used individually or combined into groups and/or jobs.

Error Proofing By Guidance: Global 400 Manages up to 16 torque tools and 8 “holding tools**” in up to 100 parameter sets.
Parameters can be organized into 100 groups.
A group has the capacity of up to four parameter sets organized together for simultaneous use in production.
Groups and individual parameter sets can be organized into jobs.
A job is a predefined, preset sequence of events (parameters and groups) in an assembly operation (Capacity is a combination of 35 parameter sets or groups).
Jobs, groups, or parameter sets can be accessed by keypad, I/O, barcode scan, or network assignment.

When tools are organized into groups, up to four torque tools and four holding tools can operate simultaneously or in any order. The Global 400 indexes to the next step in the job after all four tool tasks are complete.

The Global 400 has two separate event logs. The memory capacity for network events, including power-up and password changes are 20,000 events. The capacity for logging torque events is 10,000. Data can be exported in CSV. format.

All reporting includes date/time stamped torque event results plus the unit of measure, attribute/actual torque value (depending on tool capability), job number, product ID, unit number, event number, etc. Reporting is completely configurable with the Global 400 Manager Software.

**Holding tools: Some torque applications (especially with hydraulic connections are best done using two tools. A torque wrench is used to tighten the fastener and the other wrench is used to hold the mate so the fastener can be fastened.

The Tools

The Global 400 works with:

The 1350 Series Exacta digital torque and angle wrench.
The TAC digital torque and angle click wrench.
The 1350 TD digital torque and angle driver.
Our SLTC FM 2.4 GHz click wrenches
The all-new patented Holding Tool
The 1200 Series Exacta 2 digital torque wrench
The 1250 Series Exacta 2 digital torque and angle wrench
The PST 1200 Pneumatic Sensor Transceiver
The Global I/O Multiplier 400 (GIM 400)

The tools and controller broadcast in our proprietary code within 12 channels at 2.4 GHz. The tool and controller distance is recommended to be not more than 15 meters. Brick walls, steel beams, welders, autonomous vehicles, and other environmental factors can impact the WiFi broadcast.

To ensure robust radio contact, we created a radio noise analyzer and added it to the Global 400. You always want to keep all of the tools in a controller on the same channel. That said, one controller may be operating on Channel 6 and the controller in the next station may be on Channel 10.

How do you know which channel to use? This video explains.

Order the Global 400 using part number 10497

Error Proofing (Mistake Proofing) With Wireless Tools Does Not Require an MES

Gaining the benefits of a wireless torque tools error-proofing system is not dependent on having an MES. Error-proofing torque application requires a systems-oriented approach; the Global 400 was designed for that.

An assembly operation without an MES has significantly more to gain by adding the Sturtevant Richmont Global 400 Torque Application Process Monitor and intelligent tools to the process.

The Global 400 takes a giant leap in performing as a station dedicated system. It organizes, directs and controls both multiple types of assembly tools and people within a work cell. It also brings a powerful networking capability not previously available in the Global 8 and the Global 100 series. Global 400 units can be easily daisy-chained into their own networks.

A barcode scanner can capture product serial numbers, select parameters, and jobs in the workstation. The 10,000 torque event log provides you with all the history of the work completed in that particular station. If you have several workstations working on the same product the Global Host software can extract historical data from all the connected Global Controllers. The software allows you to document every torque event by your product's serial number. Using the Global Host software you can also track all the work completed by a particular tool. This can be important in quickly isolating any production issues in the case of significantly out-of-tolerance tools.

Benefits:

Less rework and lower warranty costs to increase profits.
Increased throughput and increased productivity.
Very short implementation time, training costs are minimal.
Pairing tools with a Global 400 are as easy as tripping the power switch on the tool.
Pairing the SLTC FM click wrench is done by simply holding the wrench in the clicked position for a few seconds.
The Global 400 helps provide continual guidance to new workers, for improved performance and reduced learning cycle.
Helps you to achieve your quality goals and gain complete control over assembly processes where hand torque and pneumatic tools are used.
Great for flexible assembly lines where multiple products are assembled with a variety of optional components and configurations.
Flexibility in changing a single element of a process or the entire process with a few keystrokes in a very intuitive, easy-to-use utility software provided with your Global 400.
You can have all the functionality and advantages of a PLC system or even an MES without the cost.
The optional GIM 400 provides communication with light-stacks, and socket /tool trays all operated via 24 Volt I/O.
The GIM 400 in conjunction with the utility software creates a Windows-based, virtual PLC.
Data acquisition through GlobalHost or Global 400 Manager software.
Your analog torque hand tools can now be part of your Internet of Things.

Managing Tools

Tools are learned into a tools bank. Global 400 Manages up to 16 torque tools and 8 “holding tools**” in up to 100 parameter sets. Tools can be selected from the:

These tools may then be paired with a parameter that can be used individually or parameters may be combined into groups and/or jobs.

100 Parameters can be organized into 100 groups.

A group has the capacity of up to four parameters organized together for simultaneous use in production.

Groups and individual parameters can be organized into jobs.

A job is a predefined, preset sequence of events (parameters and groups) in an assembly operation. A job can have up to a combination of 35 parameters or groups.

Jobs, groups, or parameter sets can be accessed by keypad, I/O, barcode scan, or network assignment.

When tools are organized into groups, up to four torque tools and four holding tools can operate simultaneously or in any order. The Global 400 can be programmed to advance to the next step in the job after all four tool tasks are complete

If, after all the parameters are complete you do not want it to index to the next group of parameters you have total control and can direct the system to do what makes the most sense for your operation.

The Global 400 has two separate event logs. The memory capacity for network events, including power-up and password changes are 20,000 events. There is a 10,000 item capacity for logging all torque application data. Data can be exported.

All reporting includes date/time stamped torque event results plus the unit of measure, attribute/actual torque value (depending on tool capability), job number, unit number, event number, etc. Reporting is completely configurable with the Global 400 Manager Software.

While many of our wireless tools and torque controller systems have been around for more than fifteen (15) years, the Global 400 is literally brand new. As a result, we continue to develop new operational capabilities and new tools to work within the Global 400 framework. Any decision to purchase and implement the Global 400 should be based solely on the existing capabilities. We have always worked to make advancements as compatible as possible.

There is more about error proofing in our tool pages. Need more? Your Sturtevant Richmont Sales Professional is a great resource for help.

Driving Error Rejects From Your Assemblies

You can tell someone not to make errors. Just because you told someone not to make errors, how do you actually prevent them from making them?

The solution really requires two parts. The first part is letting them know that they've made an error. Our Wireless Error-Proofing systems do that with each and every fastener. And you can set up your torque controller to not advance the batch count on rejects. If there are five fasteners in a batch, the batch won't complete until there are five compliant fastenings. We call that Error Proofing by Behavior Modification.

Do you need something more than that? Sometimes the answer is YES. When that is the case, we have a solution that is built into our Global 400 and Global 400mp controllers. It provides you with notification that an error or a reject has been made. You can set the limit on rejects on a batch basis. Once the reject limit has been reached in a batch, the next reject in the batch triggers the system and it freezes. It can be set so only a supervisor can come to the controller, investigate the cause of the reject, and reset the controller.

This short video tells the story:

TAC Wrench New Features

To utilize the four new features outlined on the TAC new features page, you'll need Global 400 firmware 1.6.0 or later. Your TAC wrench will also need to be upgraded to tool firmware R002-8.

Managing Data

Data has become increasingly important in manufacturing and assembly. Data alone isn't valuable. The ability to parse the data and mine it for trends or aspects of a specific build is where the value lives. That is why Sturtevant Richmont created the Global Host data repository.

Global Host is a web-based data repository that can be accessed from anywhere in the world as long as you have an internet connection. Global Host pulls data from all torque-related devices that are connected to the network.

To learn more about the Global Host data repository, and how it can help your assemblies, go to our Global Host page.