smartTOOL – Acquisition of process data close to the point of action

In modern manufacturing, especially in the machining industry and other areas of production technology, ever more efficient and precise processes are required. Challenges arise in the production process such as deviations in product quality, tool wear or unexpected machine downtimes. Tools are often monitored manually or by external sensors, which can lead to delays or inaccurate data. This creates a risk of production downtime, increased material wear and machine running times that are often not optimal. Digitalization creates new opportunities to optimize manufacturing processes and increase productivity and efficiency. 

smartTOOL offers a solution that starts process monitoring directly at the point of action. The intelligent tool holder smartTOOL was developed by Fraunhofer IWU and Fraunhofer IIS as part of the Fraunhofer Cluster of Excellence Cognitive Internet Technologies. The tool holder records real-time data during machining using integrated sensors to directly measure parameters such as process forces, temperature and unwanted vibrations or accelerations. The sensor data enables optimization and adaptive machining control.

A Bluetooth Low Energy (BLE) module is integrated into the smartTOOL and acts as an interface for wireless communication. The data is transmitted to an external evaluation unit with a graphical user interface, where evaluation algorithms draw conclusions about the status of the process and the tool as well as the quality of the machining results.

The electrical energy required for continuous operation of the smartTOOL is provided by an innovative energy harvesting technology that minimizes intervention in the actual machine tool and thus enables the use of the sensor-based smartTOOL for all machines, even as a retrofit solution. All that is needed is a simply designed component with permanent magnets attached to the spindle nose of the machine. The rotation of the tool generates electrical energy, which powers the radio transmitter, the sensors and the signal processing elements.

Thanks to sensor integration close to the point of impact, smartTOOL can meet the high demands on measurement sensitivity, such as when monitoring tool wear or deviations in component accuracy and surface quality. Critical faults such as collisions, chattering or tool breakage are also reliably detected.

Almost all electronic components of the tool holder are housed in a compact, universal segment between the tool and spindle interface. As a result, these two geometries can be selected flexibly and a wide range of application-specific combinations can be realized. As all the hardware is integrated into this universal sensor segment, the smartTOOL has no disruptive contours. The optimized geometry also ensures high static and dynamic rigidity. This means that the smartTOOL can be used in the same way as conventional tool holders without any problems.

The powerful data transmission enables both real-time process monitoring and offline diagnostics. The collected data initially serves as a basis for manual optimization of the machining process. In addition, the system can be linked to the machine control system in order to implement adaptive process control, which represents a step towards cognitive production. Meaningful characteristics are extracted from the sensor signals and converted into action decisions using specific algorithms. The effects of these actions are also analyzed, making it possible to automatically adjust the process parameters.

By implementing smartTOOL, the entire production process can be optimized and competitiveness increased in an increasingly demanding market environment.

Our tailor-made solutions in the field of wireless communication help you to increase your operational efficiency while meeting the requirements of Industry 4.0.