CNC machine tools have become the backbone of modern machining workshops. In small CNC machining facilities, the number of tools can exceed 1,000, and when combined with their supporting components, the total reaches into the tens of thousands with hundreds of different types. As the variety and quantity of tools increase, both standard and non-standard tools coexist in the workshop, often moving frequently between the tool storage and the machines. Currently, most domestic workshops still rely on manual methods and paper-based barcode systems for tool management. However, these systems are prone to damage in oily environments, and determining tool life is largely based on experience. This leads to frequent disruptions in the machining process, as operators spend significant time searching for the right tools. With the growing diversity of CNC machines and new product demands, traditional solutions are no longer sufficient, prompting the need for more advanced technologies like RFID.
RFID (Radio Frequency Identification) is a non-contact automatic identification technology that has gained popularity since the 1990s. It offers fast scanning, compact size, resistance to pollution, durability, reusability, and the ability to read through barriers. Additionally, it provides large memory capacity, making it ideal for data collection, monitoring, and transmission in industrial settings. By embedding RFID chips into tool holders, this system enables efficient tool information tracking and management, ultimately reducing overall production costs.
**1. Current Status and Needs in Tool Management**
Despite the development of various tool management software by experts worldwide, many of these systems fail to meet all the requirements of comprehensive tool management. Existing challenges include:
- Limited ability to analyze the entire lifecycle of a tool, only capturing data at specific moments.
- Lack of M2M (Machine-to-Machine) communication, preventing integrated management.
- Focus on immediate production needs without considering the full lifecycle cost of tools.
To address these issues and achieve greater automation in manufacturing, new technical approaches are urgently needed. For example, Jinsheng Precision Components Co., Ltd. uses RFID to manage tool usage during precision machining processes. The system transfers tool parameters to the machine, updates the tool magazine, and records machining time directly into the RFID chip, enabling real-time tracking and improved efficiency.
**2. Tool Information Management System: Data Collection and Configuration**
The tool information management system involves communication between machine equipment (such as CNC machines and tool setters) and RFID readers. Wireless communication and serial communication between CNC and RFID readers allow for continuous monitoring and storage of 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-equipped tool holders are used in this system. Each RFID tag can be read and written within 500ms. To ensure proper functionality, the tool must be properly aligned using a tool setter before being initialized in the machine tool magazine. The RFID tag is then programmed with the machining time, which is essential for tracking tool wear and predicting replacement.
**3. Hardware Composition and Software Development**
The system consists of RFID tags, antennas, readers, and data interfaces. RFID tags store unique electronic codes and communicate wirelessly with the reader via induction. The system operates in a C/S (Client/Server) mode, developed using Microsoft Visual Studio .NET 3.5 and C#, with an Oracle database. The RFID chips used are EEPROM-based, and the system communicates via RS232 to ensure real-time updates of tool life data.
**Summary**
By embedding RFID tags on tools, the system allows for accurate tracking of tool lifecycles, from initial use to final disposal. The RFID reader, installed on the CNC machine, acts as an interface between the tool and the control system, enabling seamless communication. This solution improves tool management, reduces inventory by 20%, lowers tool costs by 10%, cuts preparation time by 15%, increases equipment efficiency by 10%, shortens delivery times by 10%, and reduces overall costs by over 15%.
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