Tool monitoring: how it enhances efficiency, precision and TCO

In the competitive world of modern manufacturing, efficiency and precision are not just goals; they are necessities. Every second counts, and every tool must perform flawlessly to maintain the high standards expected in today’s market. 

One of the critical strategies to achieve these standards is through effective tool monitoring. By predicting and preventing tool failures, manufacturers can significantly reduce downtime, enhance product quality and ultimately lower the total cost of ownership (TCO). 

This blog explores the importance of tool monitoring, how it works and highlights the advanced solutions offered by HEIDENHAIN, including the TD 110 and VT 121 systems. Discover how these technologies can transform your operations, making them more efficient, reliable and cost-effective.

What is Tool Monitoring

Tool monitoring refers to the process of continuously observing and analyzing the performance and condition of tools used in machining operations. It aims to predict and prevent tool failure, ensuring optimal tool usage and minimizing disruptions. By using advanced sensors and systems, tool monitoring can detect anomalies in tool behavior and trigger necessary actions to mitigate potential issues.

How Does Tool Monitoring Work

Tool monitoring systems use a variety of sensors and technologies to track tool conditions in real-time. These systems measure parameters such as vibration, force, temperature, and other operational metrics to identify signs of wear or potential breakdowns. 

By continuously analyzing this data, tool monitoring systems can provide insights that help improve overall production efficiency and precision. They enable manufacturers to make informed decisions about tool maintenance, replacement and process adjustments, enhancing productivity and product quality.

Key Benefits of Tool Monitoring

Reduced Downtime

The primary benefit of tool monitoring is the significant reduction in downtime. By detecting tool wear or breakage early, operators can take preventive actions before a complete failure occurs, thus minimizing production interruptions and maintaining production schedules.

Increased Productivity

Tool monitoring helps in identifying and replacing worn or broken tools quickly, preventing unplanned work stoppages. This leads to an overall boost in productivity, as machines spend more time operating efficiently and less time in maintenance or rework.

Improved Safety

Early detection of tool breakage reduces the risk of accidents and injuries. By preventing damaged tools from continuing to operate, tool monitoring systems help maintain a safer working environment.

Cost Savings

Reducing downtime and preventing damage to workpieces and equipment directly translates to cost savings. Tool monitoring systems help avoid the high costs associated with unplanned downtime, scrap parts and extensive repairs.

Enhanced Quality

Monitoring tools in real time ensures that any deviations in tool performance are detected and addressed promptly. This leads to higher quality and consistency in the final products, as defects and rework are minimized.

Predictive Maintenance

Tool monitoring supports predictive maintenance by using data analytics to predict when a tool will need replacement. This approach allows for optimal tool usage and scheduling of maintenance activities, reducing waste and ensuring that tools are replaced only when necessary.

Types of Tool Monitoring Systems

Tool monitoring systems come in various types, each designed to address specific challenges in manufacturing. Understanding these different systems reveals their unique features and benefits.

Tool Breakage System

Tool breakage is a common challenge in machining operations. The right tool breakage detection system can help detect and deal with breakages immediately, minimizing disruptions. Modern systems are more affordable and advanced, making them accessible for the average shop.

The TD 110 is a high-performance tool breakage detection system that uses inductive, non-contact sensors. It can detect breakages at rapid traverse speeds and is capable of inspecting HSS and carbide microtools down to 0.4mm in diameter. The compact and robust housing of the TD 110 ensures durability and ease of integration into existing workflows. It reduces scrap, prevents secondary damage, and lowers TCO by eliminating the need for compressed air and requiring minimal maintenance.

Vision System for Tool Inspection (VT 121)

The VT 121 is a vision system designed for comprehensive tool inspection beyond tool life. It optimizes cutting parameters, NC programs and monitors tool breakage. The system features a rugged and compact design with an IP68 protection rating and protective lenses. It allows for tool inspection directly on the control, saving time and enabling automated inspections during machining. The VT 121 provides panoramic and close-up images of tools, facilitating detailed analysis and optimization.

Laser-Based Systems

Laser-based tool monitoring systems use light to detect changes in tool conditions. These systems are highly sensitive and ideal for high-speed operations where physical contact is not feasible. However, they can be expensive, difficult to install and require frequent maintenance to ensure accuracy.

Infrared Sensors

Infrared sensors monitor temperature spikes in tools and materials. They are useful for detecting thermal anomalies that indicate tool wear or impending failure. These systems are non-contact and provide real-time data but may require calibration and maintenance to remain effective.

Machine Vision Systems

Machine vision systems use cameras and image processing software to analyze tool performance. These systems can provide detailed visual data on tool conditions but may be complex to integrate and require significant processing power.

Considerations for Selecting the Right Tool Monitoring System

Choosing the appropriate tool monitoring system involves evaluating several critical factors to ensure it meets your operational needs. Carefully weighing these elements can guide you to the best decision for your specific requirements.

Cost

When selecting a tool monitoring system, consider the initial investment and long-term cost savings. Systems that reduce downtime, improve quality and extend tool life can offer significant cost benefits over time.

User Training

Ensure operators are adequately trained to use and interpret data from the tool monitoring system. Training can maximize the effectiveness of the system and ensure that potential issues are promptly addressed.

Integration and Compatibility

Choose a tool monitoring system that is compatible with your existing equipment and workflows. Systems that can be easily retrofitted or integrated with minimal disruption will be more effective and cost-efficient.

Tool monitoring is a vital strategy for enhancing efficiency, precision and reducing the total cost of ownership in machining operations. By understanding the various types of tool monitoring systems and considering key factors such as cost, user training and compatibility, manufacturers can select the right system for their needs. HEIDENHAIN offers advanced solutions like the TD 110 and VT 121, which provide reliable, cost-effective and high-performance tool monitoring capabilities.

For more information on how HEIDENHAIN’s tool monitoring systems can benefit your operations, contact us today and ask about the TD 110 and VT 121 products.

Written by: Milton Willis—Business Development Specialist, Machine Tool 

Milton Willis has an impressive track record of over 32 years in the machine tool industry and 26 years with HEIDENHAIN CORPORATION. He has established himself as a technical service expert with a deep understanding of mechanical and electrical machine tools for CNCs. Whether it’s providing technical support or training, Milton is committed to delivering the highest level of service to his clients.