RFID brings transparency to CNC tool logistics

In a manufacturing environment where every micrometer counts and tools are complex, high-precision assemblies, transparency in tool management is key to productivity and efficiency. This is exemplified by CERATIZIT, one of the leading companies in the field of cutting and milling tools for CNC machines and machining centers. CERATIZIT manufactures tools for high-precision machining processes, including fine-boring tools with micrometer-level precision, modular drilling tool assemblies with up to ten individual components, and electronic U-axes for complex profile machining and demanding contours. The company owes its strong reputation to its many years of experience in developing sophisticated cutting tools, its continuous drive for innovation, and, not least, its high quality standards.

Over 700 three-component molds, several thousand individual parts

To manufacture its cutting tools, CERATIZIT uses its own CNC and machining tools on its in-house machine tools. The growing number and technical complexity of these tools posed increasing challenges for production planning. In CERATIZIT’s in-house production, the number of tool variants in use rose to over 700.

A typical tool consists of three main components: the hollow taper shank for clamping into the machine, the shrink fit shank for connecting the tool tip, and the tip itself, which is usually a precision-ground cutting tool. The cutting tool is fitted into the shrink fit shank by heating it. Behind the approximately 700 variants lie significantly more actual tool examples: In total, each plant manages between 6,000 and 8,000 tools comprising more than 20,000 individual components, which are combined into individual, customized complete tools depending on the application. Many of these tools are identical in design but differ in their geometric data, particularly in length. This is due to shrinkage processes and the thermal clamping of the cutting tools. These differences are technically unavoidable but highly relevant to production, as CNC machines rely precisely on this data. Unambiguous identification of each individual tool is therefore a prerequisite for high process reliability and reproducible quality. The goal was therefore to make tool management more transparent and to digitize it end-to-end in order to reliably track stock and tool life.

Background: Complex manufacturing, increasing demands

In practice, this results in considerable complexity: Thousands of components—such as tool holders, cutting tools, taper adapters, and coolant carriers—must be managed. At the same time, there are numerous preconfigured complete tools that, despite having the same design, differ in length due to shrinkage and wear. The requirements for setup and calibration are correspondingly high. Each tool requires a unique identifier to ensure that machines can be operated reliably. Existing methods were increasingly reaching their limits. Engraved markings were barely machine-readable, adhesive tags came loose under production conditions, and optical codes were sensitive to contamination. The transfer of geometric data to machine controls also remained prone to errors.

Wanted: Economic Tool Identification Using RFID with Long Read Ranges

With this in mind, CERATIZIT restructured the entire tool flow—from assembly, through presetting and storage in the central warehouse, to use in the machines. The goal was end-to-end digitization with unique identification of each tool, automatic transfer of geometry data, and complete transparency across all units. This is based on reliable RFID identification that tracks stocks and processes down to the individual tool and component level. The RFID system was initially implemented at one plant and serves as a scalable solution for further applications within the CERATIZIT Group.

A team led by Jochen Hirschmüller, who is responsible for manufacturing technology, implemented the project. The goal was to find an RFID system with tags that could be integrated into the standardized recess of the tool holder while offering the greatest possible read range. At the same time, a unique identification number was to be transmitted to the WinTool tool management system.

The TURCK RFID system's long read range as a decisive factor

The reading ranges of three to four millimeters typically used in practice would have required complex mechanical designs for the precise positioning of the tools. For this reason, Hirschmüller specifically sought a system with a longer reading range. In addition, many established RFID solutions did not meet the economic requirements, as the cost per RFID tag was significantly higher than the target specifications.

After comparing various approaches—ranging from the use of its own transponders to solutions from different vendors—CERATIZIT opted for TURCK’s RFID system. In addition to its integration with WinTool, the decisive factor was, in particular, the long read range of 15 to 20 millimeters, which is achieved reliably even in metallic environments. The greater distance significantly simplifies handling: read heads need to be positioned with less precision, tools do not require additional clamping or alignment mechanisms, and the reading stations are easier to implement and require minimal maintenance. “The increased read range is what made the project possible in the first place,” explains Hirschmüller. “We were able to design the reading stations to fit perfectly into our shop floor.”

To ensure that the RFID system works seamlessly with the WinTool tool management system, the interface of TURCK’s TBEN-S RFID interfaces was expanded. The Application Support Team provided a corresponding Windows DLL that establishes the connection between the RFID interface and the Windows PC. Through this interface, individual tools can be uniquely identified, measurement data can be imported from the presetting device, geometric data can be automatically transferred to the machine control system, and inventory movements can be digitally recorded. The specific implementation of the interface and the shop floor handling were carried out in collaboration with a software developer specializing in WinTool.

End-to-End Digital Tool Lifecycle in Production

In practice, the digital tool lifecycle begins as early as the assembly stage. Individual components—such as the holder, shrink adapter, and cutting tool—are combined to form individual, complete tools, with each component identified by a barcode either before or after it is used in a tool. After assembly, each tool is stored as a unique item in automated warehouse systems. As soon as the components are assembled into a tool, they are uniquely identified via RFID. To do this, an employee inserts the finished tool into a plastic bracket that incorporates a TURCK Q14 read/write head. CERATIZIT manufactured the corresponding brackets itself using 3D printing.

Before storage, RFID identification ensures that each tool is correctly recorded, located, and linked to its individual geometric data. For production, the tools are retrieved from the warehouse on a job-by-job basis and loaded into the respective CNC machines. Before being inserted into the machining center’s magazine, the tool is re-identified via a bracket on the machine, which uniquely assigns the tool to a magazine slot. Further identification then takes place within the machine’s logic without RFID. The transfer of exact length data, as well as feedback on usage, return to stock, and service life, is fully integrated via WinTool.

Conclusion: End-to-End Digitization Thanks to RFID, Software Integration, and Application Support

With TURCK’s RFID system, CERATIZIT has implemented a fully digital tool management system that tracks each tool individually. The long read range of TURCK’s HF RFID technology ensures reliable identification even in environments with metal obstructions and provides additional flexibility in shop floor design. The key lies in the interplay between RFID technology, software integration, and application support. The Windows interface provided by TURCK connects the RFID interface directly to WinTool and ensures a secure, automated data flow. Working closely with CERATIZIT and the integration partner, a practical, scalable, and economic solution was developed. The result: maximum transparency, greater process reliability, and a scalable architecture for additional locations.

Client | www.ceratizit.com