Up until recently, the above notion have been just wishful thinking, it is now becoming a reality with Tool·ID from Walter. This solution means that the manufacturer of precision tools is well on the way to becoming a smart factory – a production environment in which manufacturing machinery and logistics systems are largely organising themselves, without any human intervention.
For a manufacturing company to be able to work in a profitable manner, processing times and machine down-times have to be kept to a minimum. In short: A transparent manufacturing process is required. With Tool·ID, the precision tool specialist Walter has developed an appropriate solution that ensures comprehensive transparency of production processes.
This innovative solution allows the user to transfer tool data from the pre-setting device to the machine and to evaluate the parameters that are run on the machine. The data is assigned to the tool via an identifier, for example a laser-engraved data matrix code on the tool. Information about the manufacturer or user can then be added to this.
The data is called up using a scanner and automatically transferred to the machine control unit – meaning that time-consuming and error-prone manual entry becomes superfluous. “Thanks to Tool ID, the user can save time.
They also benefit from improved process reliability and gain an insight into the real application of tools in production,” explains Holger Langhans, director of Walter Multiply. The system is currently being tested by a customer in the automotive sector.
It is an essential component for communication between the tool and the machine. The tool also provides production information in a form that can be read by the machine. Using this information, for example tool life or pre-setting data, the individual production steps can be controlled. Thanks to this comprehensive overview, it is possible to detect potential problems early on and remedy them in good time. With this new system, Walter sees itself as being one step closer to Industry 4.0.
All Data At The Touch Of A Button
In the smart factory, production sites and operating sites are linked in such a way that all processes can be coordinated centrally and controlled automatically. Walter is currently developing a system in addition to Tool ID which sees it taking yet another step towards the smart factory and Industry 4.0.
This solution allows all the accessible data within the production environment to be viewed and processed according to the user group. The open, independent system takes the current situation at each customer as its basis. “The aim of this new development is to digitalise all relevant information relating to the production process and make it available for analysis and for the purpose of optimisation,” explains Mr Langhans.
This universal, fully integrated “System of Systems” digitally links all production units involved in the process via a shared server. This means that the user can, for example, see all changes made in the machining programs. “In future, the user will be able to view, combine and evaluate data at the touch of a button – also using apps on a smartphone or tablet,” explains Mr Langhans.
This gives them a complete view of the processes in real time. Downtimes and processing times are reduced, and damage to components and equipment is minimised, which all has a positive impact on productivity. The solution is aimed at users who employ ten or more CNC machines.
The direction the system should pursue is currently being specified in consultation with potential users. Mr Langhans hopes to see the initial concrete results during the test phase. The first pilot customers are due to implement the solution in the near future.
