Retrofit Tool Tracking Assembly for Cross-Press Usage History
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Solution Overview
Problem
Tools used in industrial machines, such as punch presses, press brakes, and compression machines, face challenges in tracking their use history, particularly the hit/stroke count, when removed from presses and used in different machines, leading to difficulties in maintenance planning, tool location, and compliance with regulations.
Innovation Solution
A tracking assembly is provided that includes a sensor and counter mechanism, either mechanical or electronic, which increments with each machining operation, allowing for continuous tracking of tool usage even when the tool is moved between machines, using technologies like Bluetooth Low Energy for data transmission to cloud services.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If tools are moved between different machines for manufacturing operations, then tool versatility and adaptability are improved, but tracking and locating the tool becomes more difficult and time-consuming
Solution Approach 1:
The patent uses RFID tags and sensors to create digital copies/representations of physical tools. These digital twins track tool location, usage history, and condition data, allowing operators to locate and monitor tools remotely without physically searching for them, thus resolving the contradiction between tool mobility and tracking difficulty
Solution Approach 2:
The patent introduces RFID tags, sensors, and a central tracking system as intermediaries between the physical tool and the operator. This intermediary system automatically captures and transmits tool data, eliminating the need for manual tracking and enabling real-time location and condition monitoring of mobile tools
2Adaptability or versatility
If tools are frequently removed and exchanged between presses, then manufacturing flexibility is improved, but maintaining accurate use history records becomes more difficult
Solution Approach 1:
The patent implements self-service tracking where RFID tags and sensors attached to tools automatically record their own usage data, location, and condition information. This eliminates the need for manual record-keeping and ensures continuous, accurate tracking of use history even when tools are frequently exchanged between presses
Solution Approach 2:
The patent establishes a feedback loop where sensors continuously monitor tool usage and transmit data to a central system. This real-time feedback mechanism ensures that use history records are automatically updated and maintained accurately, regardless of how frequently tools are removed or exchanged between different presses
3Reliability
If mechanical counters are used to track hit count, then the system is simple and reliable, but the data cannot be transmitted remotely or accessed in real-time
Solution Approach 1:
The patent replaces purely mechanical counters with hybrid systems that combine mechanical counting mechanisms with electronic RFID tags and sensors. This substitution enables the reliable mechanical counting function to be augmented with electronic data transmission capabilities, allowing remote access and real-time monitoring of hit count data while maintaining the reliability of the counting mechanism
Data Source
AI summary
Tooling and corresponding tool assembly configurations equipped with exemplary designs of tracking assemblies configured to track information, such as use history, and perform a variety of processing and storage functions relative to the same for more efficient use and maintenance of the tooling over their lifetimes. The tracking assemblies can have retrofit-ready constructions.