Physical and Virtual Tool Management

Physical and Virtual Tool Management

As it is already the norm in CAD/CAM and many other areas, digital twins are also used in tool management. A distinction is often made between physical and virtual tool management. The following example shows a possible mode of operation in both systems and illustrates the common points.

The physical tool management still partially follows a traditional concept in which tools are organized and managed in real-existing storage systems such as paternoster or tool magazine. The tooling assemblies that are currently in use on the machine tools are not the only items being stored, all individual components required for the construction are also maintained. During the tool setup, components are taken from the inventory and reordered as needed. The search and reordering of the tools is done manually by the employee. After assembly, the complete tools are measured for their exact dimensions; many companies use a tool presetting device. The determined tool geometry data is typically printed on labels or lists and attached to the tool. During the machine loading process, these data are manually input into the control system by the employee.

Virtual tool management uses digital solutions and technologies to optimize the tool management process, minimize errors and depict the manufacturing process as realistically as possible. As mentioned at the beginning, when using the tools in CAM software for achieving a highly accurate simulation, a precise digital twin for each tool is required. Each of these tools is enriched with master data during creation and stored in a database, e.g., Siemens Teamcenter with Manufacturing Resource Library (MRL) or Janus Technology Manager (TMGR). Since the data is stored and managed centrally, this results in comprehensive data availability. By categorizing all tools and resources, the CAM programmer is facilitated in their search for the correct tool through relevant attributes. This not only saves time and money but also simplifies the management of components and tools.

Tool Management Software

From a critical size of the tool inventory, conventional tool management reaches its limits. With the use of an own tool management software, master data from virtual tool management can be inherited and used. At the same time, this eliminates the need for manual inventory overview, and reordering can be automated. Long searches for the desired tool become unnecessary. With a simple click, you can get a list of materials for each tool to be set up, including its storage location. By managing the tool assemblies, the system recognizes which tools are still missing for the next order and automatically generates a loading and unloading list. With the right interface to the ERP or MES system, you can obtain all the necessary information for setting up the tools for the next orders. Orders with the same tools can be combined or the number of setup operations minimized. By means of suitable interfaces, the measurement data can be directly transmitted to the control system or a Distributed Numerical Control (DNC) system. Alternatively, it can be stored in the physical tool through a scannable code or memory chip with a unique identifier.

In machining manufacturing, tool management software can be very valuable in systematically organizing information about existing tools and seamlessly integrating it into the production process. It is not uncommon for tooling costs to take up a significant factor in manufacturing costs. This makes it even more important to look into suitable systems and make their advantages work for oneself.

Advantages and Disadvantages of Tool Management

Advantages of Tool Management:

• Digitalization: Tool management software serves as a bridge between physical and virtual tool management, creating a seamless connection between machines, presetting devices, storage systems, and ERP, PLM, and MES systems.
• Cost Efficiency: Optimized demand planning and tool utilization can lower tool costs.
• Standardization: Standardizing tool data helps curb proliferation and reduces tool variety.
• Higher Productivity: Digitalization enables an efficient production workflow and minimal waiting times at machines.
• Reduced Setup Times: Pre-set tools with stored tool offset data minimize setup times on machines.
• Real-time Data: Information on tool lifetimes and usage is immediately available, enabling informed decisions.
• Automation: The process of tool identification, monitoring, and reordering can be automated.
• Process Security: Using correct and precise tools ensures higher process security and quality control.

Disadvantages of Tool Management:

• Initial Effort: The introducing of a new tool management software requires time and resources.
• Technological dependence: Faulty virtual solutions can disrupt the workflow. Dependable technology is crucial for the smooth operation of the system.