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How TSN boosts efficiency by setting priorities for network bandwidth

As manufacturers move toward Industry 4.0 and the Industrial Internet of Things (IIoT), common communication platforms are needed to achieve the next level of efficiency boost. Using common communication platforms, like Time-Sensitive Networking (TSN), significantly reduces the burden of separate networks for IT and OT without compromising the separate requirements from both areas of the plant/enterprise.

TSN is the mother of all network protocols. It makes it possible to share the network bandwidth wisely by allocating rules of time sensitivity. For example, industrial motion control related communication, safety communication, general automation control communication (I/O), IT software communications, video surveillance communication, or Industrial vision system communication would need to be configured based on their time sensitivity priority so that the network of switches and communication gateways can effectively manage all the traffic without compromising service offerings.

If you are unfamiliar with TSN, you aren’t alone. Manufacturers are currently in the early adopter phase. User groups of all major industrial networking protocols such as ODVA (CIP and EtherNet/IP), PNO (for PROFINET and PROFISAFE), and CLPA (for CC-Link IE) are working toward incorporating TSN abilities in their respective network protocols. CC-Link IE Field has already released some of the products related to CC-Link IE Field TSN.

With TSN implementation, the current set of industrial protocols do not go away. If a machine uses today’s industrial protocols, it can continue to use that. TSN implementation has some gateway modules that would allow communicating the standard protocols while adding TSN to the facility.

While it would be optimal to have one universal protocol of communication across the plant floor, that is an unlikely scenario. Instead, we will continue to see TSN flavors of different protocols as each protocol has its own benefits of things it does the best. TSN allows for this co-existence of protocols on the same network.

 

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RFID: Using Actionable Data to Make Critical Decisions

While RFID technology has been in use since the 1950s, wide-spread implementation has come in waves over the years. Beginning with military applications where it was used to identify friend or foe aircraft, to inventory control in the retail industry, and now to the manufacturing space where it is being used to manage work in process, track assets, control inventory, and aid with automatic replenishment.

The bottom line is RFID is critical in the manufacturing process. Why? Because, fundamentally, it provides actionable data that is used to make critical decisions. If your organization has not yet subscribed to RFID technology then it is getting ready to. This doesn’t mean just in the shipping and receiving area.  Wide-spread adoption is happening on the production line, in the tool room, on dies, molds, machine tools, on AGV’s, on pallets, and so much more.

Not an RFID expert? It’s ok. Start with a quick overview.

Learn about the fundamentals of a passive RFID system here.

In the past, controls engineers, quality assurance managers, and maintenance supervisors were early adopters because RFID played a critical role in giving them the data they needed. Thanks to global manufacturing initiatives like Smart Factory, Industry 4.0, the Industrial Internet of things (IIOT) and a plethora of other manufacturing buzz words, CEOs, CFOs, and COOs are driving RFID concepts today. So, while the “hands-on” members of the plant started the revolution, the guys in the corner offices quickly recognized the power of RFID and accelerated the adoption of the technology.

While there is a frenzy in the market, it is important to keep a few things in mind when exploring how RFID can benefit your organization:

  • Choose your RFID partner based on their core competency in addressing manufacturing applications
  • Make sure they have decades of experience manufacturing and implementing RFID
  • Have them clearly explain their “chain of support” from local resources to experts at the HQ.
  • Find a partner who can clearly define the benefits of RFID in your specific process (ROI)
  • Partner with a company that innovates the way their customers automate
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How IO-Link is Revolutionizing Overall Equipment Efficiency

Zero downtime.  This is the mantra of the food and beverage manufacturer today.  The need to operate machinery at its fullest potential and then increase the machines’ capability is where the demands of food and beverage manufacturers is at today.  This demand is being driven by smaller purchase orders and production runs due to e-commerce ordering, package size variations and the need for manufacturers to be more competitive by being flexible.

Using the latest technology, like IO-Link, allows manufacturers to meet those demands and improve their Overall Equipment Efficiency (OEE) or the percentage of manufacturing time that is truly productive.  OEE has three components:

  1. Availability Loss
    1. Unplanned Stops/Downtime – Machine Failure
    2. Planned Downtime – Set up and AdjustmentsS
  2. Performance Loss
    1. Small Stops – Idling and Minor Stops
    2. Slow Cycles – Reduced Speed
  3. Quality Loss
    1. Production Rejects – Process Defects
    2. Startup Rejects – Reduced Yield

IO-Link is a smart, easy and universal way to connect devices into your controls network.

The advantage of IO-Link is that it allows you to connect to EtherNet/IP, CC-Link & CC-LinkIE Field, Profinet & Profibus and EtherCAT & TCP/IP regardless of the brand of PLC.  IO-Link also allows you to connect analog devices by eliminating traditional analog wiring and provides values in actual engineering units without scaling back at the PLC processor.

Being smart, easy and universal, IO-Link helps simplify controls architecture and provides visibility down to the sensor and device.

IO-Link communicates the following:

  • Process data (Control, cyclical communication of process status)
  • Parameter data (Configuration, messaging data with configuration information)
  • Event data (Diagnostics, Communication from device to master (diagnostics/errors )

This makes it the backbone of the Smart Factory as shown in the graphic below.

 

IO-Link Simplifies the Controls Architecture

IO-Link OEE1

IO-Link OEE2

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The Emergence of Device-level Safety Communications in Manufacturing

Manufacturing is rapidly changing, driven by trends such as low volume/high mix, shorter lifecycles, changing labor dynamics and other global factors. One way industry is responding to these trends is by changing the way humans and machines safely work together, enabled by updated standards and new technologies including safety communications.

In the past, safety systems utilized hard-wired connections, often resulting in long cable runs, large wire bundles, difficult troubleshooting and inflexible designs. The more recent shift to safety networks addresses these issues and allows fast, secure and reliable communications between the various components in a safety control system. Another benefit of these communications systems is that they are key elements in implementing the Industrial Internet of Things (IIoT) and Industry 4.0 solutions.

Within a typical factory, there are three or more communications levels, including an Enterprise level (Ethernet), a Control level (Ethernet based industrial protocol) and a Device/sensor level (various technologies). The popularity of control and device level industrial communications for standard control systems has led to strong demand for similar safety communications solutions.

Safety architectures based on the most popular control level protocols are now common and often reside on the same physical media, thereby simplifying wiring and control schemes. The table, below, includes a list of the most common safety control level protocols with their Ethernet-based industrial “parent” protocols and the governing organizations:

Ethernet Based Safety Protocol Ethernet Based Control Protocol Governing Organization
CIP Safety Ethernet IP Open DeviceNet Vendor Association (ODVA)
PROFISafe PROFINET PROFIBUS and PROFINET International (PI)
Fail Safe over EtherCAT (FSoE) EtherCAT EtherCAT Technology Group
CC-Link IE Safety CC-Link IE CC-Link Partner Association
openSAFETY Ethernet POWERLINK Ethernet POWERLINK Standardization Group (EPSG)

 

These Ethernet-based safety protocols are high speed, can carry fairly large amounts of information and are excellent for exchanging data between higher level devices such as safety PLCs, drives, CNCs, HMIs, motion controllers, remote safety I/O and advanced safety devices. Ethernet is familiar to most customers, and these protocols are open and supported by many vendors and device suppliers – customers can create systems utilizing products from multiple suppliers. One drawback, however, is that devices compatible with one protocol are not compatible with other protocols, requiring vendors to offer multiple communication connection options for their devices. Other drawbacks include the high cost to connect, the need to use one IP address per connected device and strong influence by a single supplier over some protocols.

Device level safety protocols are fairly new and less common, and realize many of the same benefits as the Ethernet-based safety protocols while addressing some of the drawbacks. As with Ethernet protocols, a wide variety of safety devices can be connected (often from a range of suppliers), wiring and troubleshooting are simplified, and more data can be gathered than with hard wiring. The disadvantages are that they are usually slower, carry much less data and cover shorter distances than Ethernet protocols. On the other hand, device connections are physically smaller, much less expensive and do not use up IP addresses, allowing the integration into small, low cost devices including E-stops, safety switches, inductive safety sensors and simple safety light curtains.

Device level Safety Protocol Device level Standard Protocol Open or Proprietary Governing Organization
Safety Over IO-Link/IO-Link Safety* IO-Link Semi-open/Open Balluff/IO-Link Consortium
AS-Interface Safety at Work (ASISafe) AS-Interface (AS-I) Open AS-International
Flexi Loop Proprietary Sick GmbH
GuardLink Proprietary Rockwell Automation

* Safety Over IO-Link is the first implementation of safety and IO-Link. The specification for IO-Link Safety was released recently and devices are not yet available.

The awareness of, and the need for, device level safety communications will increase with the desire to more tightly integrate safety and standard sensors into control systems. This will be driven by the need to:

  • Reduce and simplify wiring
  • Add flexibility to scale up, down or change solutions
  • Improve troubleshooting
  • Mix of best-in-class components from a variety of suppliers to optimize solutions
  • Gather and distribute IIoT data upwards to higher level systems

Many users are realizing that neither an Ethernet-based safety protocol, nor a device level safety protocol can meet all their needs, especially if they are trying to implement a cost-effective, comprehensive safety solution which can also support their IIoT needs. This is where a safety communications master (or bridge) comes in – it can connect a device level safety protocol to a control level safety protocol, allowing low cost sensor connection and data gathering at the device level, and transmission of this data to the higher-level communications and control system.

An example of this architecture is Safety Over IO-Link on PROFISafe/PROFINET. Devices such as safety light curtains, E-stops and safety switches are connected to a “Safety Hub” which has implemented the Safety Over IO-Link protocol. This hub communicates via a “black channel” over a PROFINET/IO-Link Master to a PROFISafe PLC. The safety device connections are very simple and inexpensive (off the shelf cables & standard M12 connectors), and the more expensive (and more capable) Ethernet (PROFINET/PROFISafe) connections are only made where they are needed: at the masters, PLCs and other control level devices. And an added benefit is that standard and safety sensors can both connect through the PROFINET/IO-Link Master, simplifying the device level architecture.

Safety

Combining device level and control level protocols helps users optimize their safety communications solutions, balancing cost, data and speed requirements, and allows IIoT data to be gathered and distributed upwards to control and MES systems.

 

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Smart choices deliver leaner processes in Packaging, Food and Beverage industry

In all industries, there is a need for more flexible and individualized production as well as increased transparency and documentable processes. Overall equipment efficiency, zero downtime and the demand for shorter production runs have created the need for smart machines and ultimately the smart factory. Now more than ever, this is important in the Packaging, Food and Beverage (PFB) industry to ensure that the products and processes are clean, safe and efficient.

Take a look at how the Smart Factory can be implemented in Packaging, Food, and Beverage industries.

Updating Controls Architecture

  • Eliminates analog wiring and reduces costs by 15% to 20%
  • Simplifies troubleshooting
  • Enables visibility down to the sensor/device
  • Simplifies retrofits
  • Reduces terminations
  • Eliminates manual configuration of devices and sensors

Automating Guided Format Change and Change Parts

  • Eliminates changeover errors
  • Reduces planned downtime to perform change over
  • Reduces product waste from start-up after a change over
  • Consistent positioning every time
  • Ensures proper change parts are swapped out

Predictive Maintenance through IO-Link

  • Enhances diagnostics
  • Reduces unplanned downtime
  • Provides condition monitoring
  • Provides more accurate data
  • Reduces equipment slows and stops
  • Reduces product waste

Traceability

  • Delivers accurate data and reduced errors
  • Tracks raw materials and finished goods
  • Date and lot code accuracy for potential product recall
  • Allows robust tags to be embedded in totes, pallets, containers, and fixtures
  • Increases security with access control

Why is all of this important?

Converting a manufacturing process to a smart process will improve many aspects and cure pains that may have been encountered in the past. In the PFB industry, downtime can be very costly due to raw material having a short expiration date before it must be discarded. Therefore, overall equipment efficiency (OEE) is an integral part of any process within PFB. Simply put, OEE is the percentage of manufacturing time that is truly productive. Implementing improved controls architecture, automating change over processes, using networking devices that feature predictive maintenance, and incorporating RFID technology for traceability greatly improve OEE and reduce time spent troubleshooting to find a solution to a reoccurring problem.

Through IO-Link technology and smart devices connected to IO-Link, time spent searching for the root of a problem is greatly reduced thanks to continuous diagnostics and predictive maintenance. IO-Link systems alert operators to sensor malfunctions and when preventative maintenance is required.

Unlike preventative maintenance, which only captures 18% of machine failures and is based on a schedule, predictive maintenance relies on data to provide operators and controls personnel critical information on times when they may need to do maintenance in the future. This results in planned downtime which can be strategically scheduled around production runs, as opposed to unplanned downtime that comes with no warning and could disrupt a production run.

blog 2.20 1

Reducing the time it takes to change over a machine to a different packaging size allows the process to finish the batch quicker than if a manual change over was used, which in turn means a shorter production blog 2.20 2run for that line. Automated change over allows the process to be exact every time and eliminates the risk of operator error due to more accurate positioning.

 

 

blog 2.20 3Traceability using RFID can be a very important part of the smart PFB factory. Utilizing RFID throughout the process —tracking of raw materials, finished goods, and totes leaving the facility — can greatly increase the efficiency and throughput of the process. RFID can even be applied to change part detection to identify if the correct equipment is being swapped in or out during change over.

Adding smart solutions to a PFB production line improves efficiency, increases output, minimizes downtime and saves money.

For more information on the Smart Factory check out this blog post: The Need for Data and System Interoperability in Smart Manufacturing For a deeper dive into format change check out this blog post: Flexibility Through Automated Format Changes on Packaging Machines

 

 

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Collaborative Automation…It’s Not Just for Robots

Manufacturing is made up of hundreds of discrete operations. Some are repetitive, while others are more diverse. Repetitive tasks are ideal for automation while diverse tasks require more flexibility. And while automation can be extremely flexible, that comes with a high initial investment costs and significant deployment time. The alternative? People!

Humans have the unrivaled ability to adapt to a diverse and flexible manufacturing environment. They can be productive relatively quickly with proper guidance without high initial cost investments.

But as we all know, “to err is human” and this is one of the biggest issues with manual operations. People need a little guidance from time to time. Collaboration is not just for robots; It’s for complete automation systems as well.

Collaborative automation is most important at the point-of-use, where humans are performing critical operations. Some of those common operations include:

  • Manual assembly for low volume or highly flexible operations
  • Delivery of raw materials to the point-of-use
  • Kit assembly for down-stream operation
  • Machine setup and change-over
  • Machine maintenance and calibration

All of these functions can be done error-free and with little training by simply guiding people within their current work envelope, also referred to as their point-of-use. This type of a lean function provides hands-free guidance in the form of indication devices connected directly to your automation system allowing workers to stay focused on the task at hand instead of looking elsewhere for instructions.

With the technology of IO-Link, smart indication devices can now show much more information to all the people involved in specific manufacturing tasks. Automation has an immediate and direct connection to the people that are so vital.

For example, in a manually-fed weld-cell, the smart indicators are capable of not only signaling that the part is loaded correctly, but also whether the part is out of alignment (shown here by the red indicator) or that something wrong with one of the automation components such as a stuck pneumatic clamp.

Figure 1
A manually-fed weld-cell with smart indicators is capable of not only signaling that the part is loaded correctly, but also if the part is out of alignment (shown by the red indicator) or that there is something wrong with one of the automation components such as a stuck pneumatic clamp.

Even better, with IIoT technology, trends can be analyzed to determine if the fixture/tool could be optimized for production or to identify common failure points. This all leads to tighter collaboration with operations, maintenance personnel and production supervisors.

A traditional kitting station, sometimes referred to as a supermarket, is another ideal application for smart indicators. Not only can they guide a single operator to the intended part to pull, they can guide multiple operators at the same time.  Also, smart indicators can inform of incorrect pulls, potential bin options (a physically closure bin), directional information, and inventory levels. And again, with IIoT technology, trends can be analyzed to determine proper layout, individual personnel performance and system throughput. The automation system collaborates with operations, forklift drivers and production supervisors.

Regal_v06_01_V3
A traditional kitting station, sometimes referred to as a supermarket, with smart indicators to guide operators to the intended part to pull.

So, take a look and see what a collaborative automation system utilizing smart indicators can do for your manual operations. You might be surprised.

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The Need for Data and System Interoperability in Smart Manufacturing

As technology advances at a faster pace and the world becomes flatter, manufacturing operations are generally focused on efficient production to maximize profitability for the organization. In the new era of industrial automation and smart manufacturing, organizations are turning to data generated on their plant floors to make sound decisions about production and process improvements.

Smart manufacturing improvements can be divided roughly into six different segments: Predictive Analytics, Track and Trace, Error Proofing, Predictive Maintenance, Ease of Troubleshooting, and Remote Monitoring.IOLink-SmartManufacturing_blog-01To implement any or all of these improvements requires interoperable systems that can communicate effectively and sensors and devices with the ability to provide the data required to achieve the manufacturer’s goals. For example, if the goal is to have error free change-overs between production cycles, then feedback systems that include identification of change parts, measurements for machine alignment changes, or even point of use indication for operators may be required.  Similarly, to implement predictive maintenance, systems require devices that provide alerts or information about their health or overall system health.

Traditional control system integration methods that rely heavily on discrete or analog (or both) modes of communication are limited to specific operations. For example, a 4-20mA measurement device would only communicate a signal between 4-20mA. When it goes beyond those limits there is a failure in communication, in the device or in the system. Identifying that failure requires manual intervention for debugging the problem and wastes precious time on the manufacturing floor.

The question then becomes, why not utilize only sensors and devices with networking ability such as a fieldbus node? This could solve the data and interoperability problems, but it isn’t an ideal solution:

  • Most fieldbuses do not integrate power and hence require devices to have separate power drops making the devices bulkier.
  • Multiple fieldbuses in the plant on different machines requires the devices to support multiple fieldbus/network protocols. This can be cost prohibitive, otherwise the manufacturer will need to stock all varieties of the same sensor.
  • Several of the commonly used fieldbuses have limitations on the number nodes you can add — in general 256 nodes is capacity for a subnet. Additional nodes requires new expensive switches and other hardware.

IOLink-SmartManufacturing_blog-02IO-Link provides one standard device level communication that is smart in nature and network independent, thus it enables interoperability throughout the controls pyramid making it the most suitable choice for smart manufacturing.

We will go over more specific details on why IO-Link is the best suited technology for smart manufacturing in next week’s blog.

 

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Connecting Fluid Power to the Industrial IoT and Industry 4.0

The next industrial revolution has already begun. To remain a viable business, it’s time to invest in IIoT and Industry 4.0 applications, regardless of whether you are a “mechanical-only” company or not.Industry 4.0 & Industrial IoT

Industrial Internet of Things

IIoT is simply about connecting devices on the plant floor to a network. These connections provide new ways to generate and collect useful data. This network can provide visibility down into the machine, enabling predictive maintenance and big data analytics. With IIoT, we are able to improve overall equipment effectiveness and provide new insights into our business.

Industry 4.0

On a grander scale, Industry 4.0 is a blend of digitalization, new technology and practical decisions to improve manufacturing. Industry 4.0 aims to achieve unprecedented flexibility, efficient production and visibility at every level of production. Industry 4.0 has impact throughout our processes and across the supply chain. Its philosophy blends lean initiatives, automation, technology, materials, downtime reduction upgrades, and investments in overall equipment effectiveness. This philosophy keeps the current generation of manufacturers competitive in a global market. While the German government set this precedent for Industry 4.0, the entire manufacturing world must now take on this challenge.

Implementing IIoT and Industry 4.0

Standard systems like hydraulic power units (HPUs) are receiving a major boost by becoming IIoT-ready. Traditional on/off flow or pressure switches are upgrading to provide information beyond the simple switch points. In addition, analog devices like temperature, pressure, flow, and level transducers can become IIoT-ready through open standard technologies like IO-Link. These technologies add additional value by incorporating easy-to-report parameters, diagnostics, events and warnings. A standard HPU can become a smart power unit with minimal modification.

The value of IIoT increases with predictive maintenance, remote monitoring and ease of troubleshooting. Imagine not having to climb down into the oil-drenched pit of a stamping press to trouble shoot an issue. With IIoT-ready technologies, we can connect to the devices and know exactly what needs fixing. In addition, we can possibly predict the failure before it occurs. This can dramatically reduce machine downtime as well as the time spent in hazardous locations.

Selecting IIoT-ready technologies is only one step of the program to fully leverage the value of Industry 4.0. We must also analyze processes and determine how to implement flexibility into production. After that, we must then discuss where automation technology makes sense to support lean processes. Manufacturers can see into every aspect of their production while manufacturing hundreds of variations of product in the same line, all while assuring quality standards with virtually zero machine downtime.

The difference between Industry 4.0 and IIoT

Industry 4.0 is a cultural philosophy about how we can use increased visibility, flexibility and efficiency to be more competitive. IIoT’s connectivity is an enabling force for Industry 4.0. IIoT connects our devices, our data, our machines and our people to the advantage of our company and customers.  By embracing both, it is easier to achieve positive results and sustain global competitiveness.

Article originally posted on Hydraulics & Pneumatics.

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Everything You Need to Know to be Successful at IIoT

Do you need to quickly ramp up your IIoT knowledge? Do you want to know why manufacturers are investing in IIoT? For years this blog has shared many of the individual values that smart manufacturing, Industry 4.0 and the Industrial Internet of Things can bring to manufacturers. I am going to quickly summarize the key findings and provide links to the full entries so you can easily have at your fingertips all of the advice you need to be successful at IIoT.

  • Industry 4.0 & IIoT, who cares?!?! You should. Even in 2016, IIoT investments were rapidly growing and more than a fifth of technology budgets were being invested in data analytics, IIoT and Industry 4.0. This has not slowed down in 2018!
  • 5 Common IIoT Mistakes and How to Avoid Them. The first point is the best point, every IIoT project that ignores the IT department is doomed for failure. IT & OT must work closely together for a successful data project in the factory.
  • Capture vs Control – The Hidden Value of True IIoT Solutions. In automation, everything seems to revolve around the PLC. This is very much an Industry 3.0 way of thinking. As we take on the next industrial revolution, devices can talk to each other in new and incredible ways, and we can capture data without impacting a working production line or modifying PLC code.
  • JSON Objects and How They Can Streamline an IIoT Application. How the data is captured is important to understand when you are ready to take action and implement your first project. By utilizing web tools like JSON, we can effectively capture data for IIoT applications.
  • What does that “Ready for IIoT” tag really mean? But how do I select a device that is going to be actually ready for IIoT? Features like condition monitoring, automatic configuration and scalability make for robust IIoT projects that can stand the test of time.

When you are convinced and ready to take action on an IIoT project kickoff for an Industry 4.0 team, take a look at the blogs below which can help you make an action plan for success and get buy-in from management.

  • How to Balance the IIoT Success Equation. What should you and your team be focusing on? How do we set a strategy, manage data, and take action to run a successful project? All of these need to be in balance and planned for to have long term vitality in your IIoT investments.
  • How do I justify an IIoT investment to my boss? We can show ROI through reduced downtime, by tying our project to corporate goals of productivity or utilization and you can point out that your competitors are heavily investing in this topic.
  • Enabling the Visibility Provided by the Industrial Internet of Things. And last but not least, there is a seriously strong technology available on the market from virtually every automation vendor that enables and scales IIoT like no other. That technology is IO-Link. With IO-Link you can create visibility down to every sensor in the plant and gain the flexibility and reliability that you need for sustainable competitiveness in the global market.

To learn more about IO-Link and how it enables machine builders and manufacturers to be successful with IIoT, check out this interactive infographic.

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The Evolution of RFID in Metalworking

RFID – A key technology in modern production

It’s not just IIoT that has focused attention on RFID as a central component of automation. As a key technology, radio frequency identification has been long established in production. The inductive operating principle guarantees ruggedness and resistance to environmental stress factors. This makes the system highly reliable in function and operation. With unlimited read/write cycles and real-time communication, RFID has become indispensable. The beginnings for the industrial use of RFID go far back. RFID was first successfully used on machine tools in the mid-1980’s. Since the usage of RFID tags on cutting tool holders has been internationally standardized (ISO 7388 for SK shanks, ISO12164 for HSK shanks), there has been strong growth of RFID usage in cutting tool management.

Cutting tool in tool taper with RFID chip

Track-and-trace of workpieces

Modern manufacturing with a wide bandwidth of batch sizes and ever compressed production times demands maximum transparency. This is the only way to meet the high requirements for flexibility and quality, and to minimize costs. Not only do the tools need to be optimally managed, but also the finished parts and materials used must be unambiguously recognized and assigned.

Workpiece tracking with RFID on pallet system

RFID frequencies LF and HF – both RFID worlds come together

In terms of data transmission for cutting tool identification, established systems have settled on LF (Low Frequency), as this band has proven to be especially robust and reliable in metal surroundings. Data is read with LF at a frequency of 455 kHz and written at 70 kHz.

When it comes to intralogistics and tracking of workpieces, HF (High Frequency) has become the standard in recent years. This is because HF systems with a working frequency of 13.56 MHz offer greater traverse speeds and a more generous read/write distance.

As a result, RFID processor units have been introduced that offer frequency-independent application. By using two different read-/write heads (one for tool identification and one for track-and-trace of workpieces) that each interface to a single processor unit, the communication to the control system is achieved in an economical manner.

RFID processor for both tool identification and workpiece tracking

New Hybrid Read-Write Head

Industrial equipment is designed for a working life of 20 years or even more. Therefore, in production you often find machines which were designed in the last century next to new machines that were installed when the production capacity was enlarged. In such a brown field factory you have the coexistence of proven technology and modern innovative equipment. For the topic of industrial RFID, it means that both low frequency and high frequency RFID tags are used. To use both the existing infrastructure and to introduce modern and innovative equipment, RFID read/write heads have been recently developed with LF and HF technology in one housing. It does not matter whether a LF RFID tag or a HF RFID tag approaches the RFID head. The system will automatically detect whether the tag uses LF or HF technology and will start to communicate in the right frequency.

This hybrid read-write head adds flexibility to the machine tools and tool setters as you can use the entire inventory of your cutting tools and tool holders.

RFID Tool ID tag ready for the Cloud

The classical concept of data storage in Tool ID is a decentralized data storage, which means that all relevant data (tool dimensions, tool usage time, machining data, etc.) of a tool/tool holder is stored on the RFID tag which is mounted on the single tool holder. The reliability and availability of this concept data has been proven for more than 25 years now.

With the Internet of Things IIOT, the concept of cloud computing is trendy. All — tool setter, machine tool and tool stock systems — are connected to the cloud and exchange data. In this case only an identifier is needed to move and receive the data to and from the cloud. For this type of data management Tool ID tags with the standard (DIN 69873) size diameter 10 x 4,5 mm are available now in a cost effective version with a 32 Byte memory.

Evergreen – more modern than ever: RFID Tool ID in Metalworking

Learn more about the Evolution of RFID in Metalworking from true experts at www.balluff.com  or at  Balluff events worldwide