CNC machine tools have become the core equipment in modern manufacturing workshops. In a small CNC machining workshop, the number of tools can reach up to 1,000, and when combined with their accessories, the total count exceeds tens of thousands with hundreds of different types. As the variety and quantity of tools increase rapidly, both standard and non-standard tools coexist in the workshop, leading to frequent exchanges between the tool storage and the machines. Currently, domestic workshops rely on manual methods and paper-based barcode systems for tool management. However, these methods are inefficient—paper barcodes tend to get damaged in oily environments, and tool life is often estimated based on experience. This results in frequent machine downtime due to missing tools, and operators spend significant time searching for them. With the growing complexity of CNC machines and new product demands, traditional solutions are no longer sufficient, prompting the need for advanced technologies like RFID.
RFID (Radio Frequency Identification) is a non-contact automatic identification technology that gained popularity in the 1990s. It offers fast scanning, compact size, resistance to contamination, durability, reusability, and the ability to read through obstacles. Its large memory capacity makes it ideal for data collection, monitoring, and transmission in industrial settings. By embedding RFID chips into tool holders, this system enables real-time tracking of tool information, improving efficiency and reducing overall production costs.
**1 Current Status and Needs in Tool Management**
Despite the development of various tool management software by researchers worldwide, existing systems still fail to meet all the requirements of effective tool management. Common issues include:
- Limited lifecycle analysis of tools, focusing only on real-time data without capturing usage history.
- Lack of M2M (Machine-to-Machine) communication, resulting in fragmented management.
- Overlooking the total lifecycle cost of tools during design.
To address these challenges and enhance automation in manufacturing, RFID has emerged as a promising solution. For instance, Jinsheng Precision Components Co., Ltd. uses RFID to manage tool usage in mobile phone component machining. Tools are automatically identified, their parameters are sent to the machine, and they are added to the tool magazine for program access. When a tool completes its task, its usage time is recorded in the RFID chip, enabling real-time tracking and status updates.
**2 Tool Information Management System: Data Collection and Setup**
The tool information management system involves communication between machine tools (like CNC machines) and RFID readers. Wireless communication and serial interfaces are used to monitor and store tool data throughout its lifecycle. A typical tool lifecycle includes planning, purchasing, marking, warehousing, lending, assembly, use, return, resharpening, and disposal.
Sigu Digital Technology's RFID-enabled tool holders are used in this system. The RFID tag takes 500ms to read or write data. Before any tool operation, the tool must be properly set up using a tool setter. To ensure accurate RFID data transfer, a pneumatic device is used to bring the antenna close to the RFID tag.
**3 Hardware and Software Development**
The system consists of RFID tags, antennas, readers, and data interfaces. Each RFID tag contains a unique electronic code, and the reader communicates wirelessly with the tag. The system operates in a C/S (Client/Server) architecture, developed using Microsoft Visual Studio .NET 3.5 and C#, with an Oracle database.
The RFID chips used in the system are EEPROM type, and the system communicates via RS232. Real-time updates are crucial, so whenever a tool is changed, its data is immediately updated in the RFID chip and stored in the NCK variable of the CNC system.
**Summary**
By embedding RFID tags on tools for lifecycle tracking and data exchange, the system allows real-time interaction between the tool and the control system. This enhances tool life prediction and improves operational efficiency. The implementation has led to a 20% reduction in tool inventory, 10% lower tool costs, 15% less preparation time, 10% higher equipment efficiency, 10% shorter delivery times, and over 15% reduction in overall costs. This innovative approach significantly improves the effectiveness of tool management in modern manufacturing.
Vertical Light Tower
Vertical Light Tower
A vertical light tower is a tall structure that is designed to provide high-intensity lighting for various purposes. It typically consists of a vertical pole or mast with multiple light fixtures mounted at different heights. The tower is usually made of durable materials such as steel or aluminum to withstand harsh weather conditions.
Vertical light towers are commonly used in construction sites, outdoor events, sports fields, and emergency situations where temporary lighting is required. They provide bright and uniform illumination over a large area, making them ideal for nighttime operations or areas with limited natural light.
These towers are often portable and can be easily transported and set up at different locations. They may have adjustable heights and angles to direct the light where it is needed most. Some models also come with additional features such as telescopic masts, generators, and remote control systems for convenient operation.
Vertical light towers can be powered by various sources such as electricity, diesel, or solar energy. They are designed to be energy-efficient, minimizing power consumption while providing maximum brightness. Some models also incorporate advanced technologies such as LED lights, which offer longer lifespan and lower maintenance requirements compared to traditional lighting options.
Overall, vertical light towers are essential tools for illuminating large areas and ensuring safety and productivity in various industries and applications.
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Grandwatt Electric Corp. , https://www.grandwattelectric.com