Global 400mp Torque Controller

If you have an assembly cell with multiple operators and a lot of tools, this is the controller you want. 

The Global 400mp is Here!

When ordering the Global 400mp please use part number 10612

Are you building mixed model assemblies?

Do you need to integrate hand tools into your IoT?

Are hydraulics part of your build responsibility?

The Global 400mp cuts rework and warranty costs while increasing throughput and improving quality in each of these situations. 

What is the Global 400mp?

The Global 400mp is a wireless error-proofing system that integrates hand tools into your MES. The Global 400mp has four (4) network connections house in one box. These network connections, or interfaces, communicate with up to four operators working independently. The operators can use any of the following tools:

• The TAC digital torque and angle click wrench
• 1350 TD digital torque and angle screwdrivers. 
• 1350 Series Exacta 2 digital torque and angle wrenches
• 1250 Series Exacta 2 digital torque and angle wrenches
• 1200 Series Exacta 2 digital torque wrenches
• 1200 Series PST (Pneumatic Sensor Transceiver)
• SLTC FM 2.4 GHz preset wireless click wrenches
• The patented Holding Tool Technology wrenches

All wrenches but the Holding Tools come with options for:

• Fixed ratchet
• Traditional pin and spring dovetail
• Quick Change dovetail. 

The Holding Tool Technology wrenches come with the pin and spring dovetail only.

With the traditional pin and spring dovetail and the Quick Change dovetail, you have access to well over 200 interchangeable heads. Every head that we make fits on every wrench that we make that is equipped with either the traditional dovetail or the Quick Change dovetail. Unlike competitors, there is no need to buy multiple wrenches within the same torque range to accommodate multiple fastener sizes within that torque range. 

Global 400mp Overview

The Global 400mp is remarkably simple to use and has a very short learning curve. 

Customers often ask, what is the primary difference between the Global 400 and a Global 400mp? After all, both have similar operations and both can support up to 4 operators working with one controller. The difference is simple. If you have an operator with a lot of tools in one station, the Global 400 is the ideal solution. If you have up to four operators in an assembly cell, then the Global 400mp is likely to be the best choice. Why?

In the Global 400, P-Sets are placed in groups. All operators must complete their work before the group can advance to the next work instruction. In essence, the slowest operator controls the pace of the group. In the Global 400mp, there are no groups. Operators work independently. They don't even have to work on the same job. It truly is as if they all worked out of their own controller. 

The Global 400mp comes with Global Manager Freeware. Global Manager Freeware is used to set up parameters and jobs in each of the interfaces. Parameter and job specifications can also be set up at the Global 400mp using the soft keypads. The Global 400mp is both key and password protected. This eliminates any inadvertent parameter or job changes made at the tool level. 

Tools are matched with, or "Learned In" to an interface. Each interface has its own network connection and communicates directly with the MES. The MES sends parameter and job selections to each interface. The work is completed and the Global 400mp responds to the MES that the work has been completed. There is robust communication between MES, Global 400mp, the operators, and the tools. 

With Global Manager Freeware you can create parameters or make changes from anywhere in the world where you have an internet connection. 

How Does the Global 400mp Work?

Having tools paired with parameters and active only when the parameter is active, only work done with active tools is recognized. We support the operators with differing modes of guidance at every turn. 

Consistency and repeatability are key elements of your quality program. We work to ensure that our tools and the Global 400mp provide your operators with that. 

Once the operator has the right tool, work can begin. With each fastening, error proofing by guidance is provided. The tools and the Global 400mp communicate with each fastening. The Global 400mp and the MES also communicate. 

With the 1200 Series Exacta 2 digital torque wrench and 1250 Series Exacta 2 digital torque and angle wrench as well as the 1350 Series Exacta 2 digital torque we provide additional process error proofing. Although our XBee radios have very robust communication, the modern factory can have some interference with radio signals. XBee radio signals are much less prone to disruption than Bluetooth signals. 

In the unlikely event that the radio signal between the Global 400mp and the digital wrench is disrupted, the operator can complete the current batch with visual and auditory guidance from the wrench. When the radio signal resumes, the wrench uploads all the parameter information to the Global 400mp, and it, in turn, updates the MES. 

The Global 400mp reconciles each parameter with how many fasteners in the batch and how many were completed. We call that "Countability."

Our radios use our proprietary code. We broadcast on 12 channels in the XBEE radio range. Welders, autonomous vehicles, steel beams, large aluminum barriers, and other items can impact the radio signal. We recommend a max range of about 10 meters between tools and the controller. Can the radio signal broadcast farther? Yes. Again, there are environmental factors that can impact radio signal strength. 

That is why we build in a radio signal noise analyzer into each Global 400mp. The radio signal noise analyzer gives you a graphical representation so you can see the best channel and select it. 

Global 400mp: Complete Traceability

Each fastening is date and time stamped, assigned a unique tightening ID tied to P-Set, Job ID, tool serial number, product serial number, and interface. This gives your IoT all the information it wants. 

The Global 400mp also tracks tool calibration dates to inform you that a tool is due for calibration. Torque tool calibration provides you with "As Found" and "As Left" information. If a wrench is found to be out of calibration, the calibration team cannot tell you when the tool moved from a within tolerance to an out of tolerance condition. 

Because you have complete traceability, you can go back at any time and verify the state of products recently completed with that tool. In today's competitive environment did you want customers telling you there is a problem or did you want to identify the problem before the product leaves the factory? 

Error Proofing By Guidance

It starts with the Tools. Since the very first torque wrench, we have always accounted for human influence in our tool design. We look at the human influence on how operators use the tools. We design every wrench and torque tester to eliminate the human influence on our tools. We call that Error Proofing by Design. An example of that is our flattened cases. The flattened case design prevents the wrench from deflecting away from the required 90 degrees from the fastener relationship.  Varying from 90 degrees changes the torque equation and now more variables are introduced into the fastening. 

But eliminating the human influence on the torque application process is not enough because errors occur in other aspects of a fastening. So our engineers look at Error Proofing by Guidance. 

We start with ensuring that the operator has the right tool in hand. The tools assigned to a parameter remain in suspended mode until the parameter with which they are paired is active. The Global 400mp does not recognize any work attempted with a suspended tool. Once paired with the Global 400mp that tool cannot be used in another workstation unless the connection between the tool and Global 400mp has been removed. Then the tool must be relearned into a new Global 400mp. 

Once a parameter is active, the operator selects the appropriate tools. The display informs the operator of the batch count. The operator goes to work. With each fastening, the operator is provided with visual and auditory error-proofing guidance from both the tool and the Global 400mp. 

The visual guidance comes from either the display changing colors or the LED changing colors. Green is good. Red is bad. The auditory tones are distinctly different so there is no mistake as to the result. 

In the 1250 Series Exacta 2 digital torque and angle wrench, the handle vibrates on acceptance. The SLTC FM 2.4 GHz wrenches provide an auditory and tactile click when the target value is reached. 

Both the 1200 Series and the 1250 Series Exacta digital torque and angle wrenches have our customizable pull to green technology. In the parameter screen, the minimum torque is set. The max torque is set. And the "green torque" is set. Green torque is the point at which the wrench display and the Global 400mp screen turn green, indicating a compliant fastening.

The 1250 Series wrench also has the ability to set a secondary value to the "green screen" when using angle calculations. For more information on that please see your local Sturtevant Richmont Sales Professional. 

When using the 1200 Series PST the Global 400mp provides a graphical representation of a fastening. The graph tracks air pressure and time. If a fastening is non-compliant the operator can look at the screen and view the graph to see the source of the mistake. Was the fastener cross-threaded? Was it a double hit? Did the operator prematurely release the clutch? 

If a fastening is non-compliant it must be redone before the operator can move on. In the parameter screen, the option is provided to either suspend upon batch complete or index to the parameter or job. Upon batch complete, the Global 400mp interface display turns blue to indicate batch completed. 

Using a combination of lights changing color, numbers, symbols, sound, and touch, the error-proofing by guidance approach has something to reach each operator. In a noisy environment hearing the tone may be difficult. The visual guidance is still there to inform the operator. If the operator is using an SLTC FM 2.4 GHz wrench or out 1250 Series digital torque and angle wrench there is also tactile guidance as well as the guidance from colors, symbols, and numbers.

Error Proofing By Behavior Modification

Repeatability is the key to creating consistent quality programs. How do you get high repeatability with the Global 400mp? There is a small but important feature native in the Global 400mp called "Reject Limit." This feature helps you drive errors from your assemblies. 

This two-minute, forty-second video tells the story.

Muscle Memory

Watch an experienced operator for a short time and you soon realize that the operator has developed "muscle memory."  

Muscle memory is developed only when there is consistent feedback or guidance. The multi-mode error proofing by guidance helps change behavior to create and reinforce muscle memory. Muscle memory is a good example of error-proofing by behavior modification. 

Muscle memory works to your advantage if your operators are all experienced. If you have a changing workforce, muscle memory hasn't yet been fully established and so it needs to be developed, reinforced, and cemented. The Global 400mp and the tools with which it works provide your operators with the consistent guidance that is needed to create muscle memory. 

If you have hydraulic assemblies as part of your responsibility, you should get to know the Global 400mp. Preventing hydraulic leaks before they start is our specialty. Our customers have seen dramatic decreases in instances of hydraulic leaks after implementing the Global 400mp.

TAC Wrench Four New Features

 If you've paired your TAC wrench with the Global 400mp and are looking to upgrade to the latest four new features, you'll need to upgrade your TAC wrench tool firmware to R002-8 or later.