Operators are on the front lines of production, facing the pressures head-on. In this fast-paced environment, it's essential to support both the precision needed for product quality and the conditions that safeguard operator wellbeing. Smart tools make it possible to meet both demands: delivering consistent, high-quality tightenings while reducing the strain and fatigue on operators behind them.
Low reaction strategies for every application
In manufacturing, joint behavior can vary significantly from one tightening to another. As a result, different applications require different tightening approaches to achieve the target torque, failing to do so increases the risk of inconsistencies and quality issues. Tightening strategies help you stay in control.
What is a tightening strategy and why does it matter?
A tightening strategy is the method your smart tool uses to reach the target torque. Choosing the right one ensures accuracy, repeatability, and operator comfort.
With Atlas Copco’s low-reaction tightening strategies, you get the best of both worlds: ergonomic operation and precise performance. Below are three standout examples designed to reduce reaction forces and optimize productivity.
TurboTight
The TurboTight tightening strategy significantly lowers reaction force by monitoring joint stiffness, and calculates the speed required to reach the target torque without any overshoot.
This strategy works particularly well on hard joints and is available in our STR and SRB family of tools.
Impulse
This strategy combines the benefits of pulse tools from low reaction force to high speed with the benefits of an electric tool such as torque control, angle monitoring, and above all traceability.
How this strategy works: After each pulse period the resulting torque in the screw is gradually increased, and after a series of pulses the final torque is reached. This strategy is available in our TBP/TBP-S tools.
TensorPulse
TensorPulse delivers consistent pulses until the target torque is reached. Further it stops tightening immediately when either torque, angle, or time is exceeded from the pre-programmed limits.
How this strategy works: Each pulse consists of two phases: a phase that applies the torque and a reaction phase that creates counterforce to reduce the reaction force experienced.
Ultimately, the most ergonomic option doesn’t just depend on the strategy itself, but also on your specific application and production demands.
Pulsing tools are a strong choice, particularly as they can reach higher torque levels than conventional direct driven tools while virtually eliminating reaction force. However, they can also produce significant noise and vibration. To explore how to mitigate these effects, check out our vibration exposure assessment pocketguide. In such cases our pocket guide suggests the TurboTight strategy, especially on hard joints, could offer a better ergonomic solution.
From torque to tightening strategies with smart tools
To unlock the full potential of your tools, combine them with a torque controller for smarter tightening strategies and reliable data tracking.
At Atlas Copco, we offer a range of controllers to choose from:
Physical controller
Our Power Focus 8 controller connects up to 20 tools, whether through a hybrid setup of one cable tool and up to 19 battery tools, or a fully wireless configuration with up to 20 battery tools.
Virtual controller
ToolsControl is our fully remote virtual controller that centralizes asset management for greater efficiency with ease. By eliminating the need for dedicated hardware, it clears the shop floor of unnecessary equipment, improving accessibility and creating a more streamlined production environment.
Integrated controller
With an integrated controller you combine the functionality of a tightening controller with the ease of a wireless smart tool. Our Tensor IxB tools operate with a fully embedded controller. This reduces hardware on the line, enabling faster setup and more agile production. With confirmation directly in hand, there's no need to search for external validation, giving you greater confidence in every tightening.
To extend the capabilities of whichever controller option you choose, we have set up Virtual Stations. Virtual Stations help define tool type, tool functionalities such as tightening strategies, and the kind of data that should be reported, all while also enabling control and connection of up to 15 different tool families. With different levels to choose from, Virtual Stations allow for flexible, program-specific setups, that match your application.
Explore our full range of Virtual Station offerings. Dive deeper into how to work with Virtual Stations here.
Smart Integrated Assembly: Our roadmap to a Smart Factory
Low reaction tightening strategies play a key role in improving tightening efficiency and operator wellbeing. But to fully harness the potential of your production, seamless communication between the tool, controller, and other connected solutions is just as critical. With Smart Integrated Assembly, this connection becomes effortless, enabling data-driven manufacturing that acts on real-time insights generated directly from the production process. The result is a factory that is efficient, responsive, and smart.
Smart Integrated Assembly is our concept for building the smart factory, combining tools, software, and services into one powerful ecosystem. With Smart Integrated Assembly you gain the ability to adapt, optimize, and continuously improve every step of your production process.
Conclusion
Low reaction tightening strategies are more than a feature, they help build a production environment where efficiency and operator wellbeing go hand in hand. By reducing strain without sacrificing precision, they enable consistent, high-quality results while supporting the people behind them. In fast-paced, high-demand environments, our smart tools and solutions can help find the balance between precision and wellbeing.
Curious to learn which strategy is best suited for your application? Contact us today.
