RFID Brings Transparency to CNC Tool Logistics

CERATIZIT is digitizing its CNC tool management with TURCK’s RFID solution—read ranges of up to 20 millimeters and seamless integration with WinTool increase efficiency and process reliability

CERATIZIT, a manufacturer of cutting and milling tools, manages over 700 tool variants, up to 8,000 individual tools, and constantly changing geometry data in its CNC production. The company addresses this challenge with an RFID solution from TURCK: A custom-developed Windows DLL seamlessly integrates the TBEN-S-RFID interface with the WinTool software. In this way, the system identifies the variants and tools and automatically transfers their geometric data to the machine control system. In addition to the WinTool integration, the decisive factors were, above all, the read range of 15 to 20 mm and the system’s reliable operation even in metallic environments.

With a read/write distance of up to 20 mm, the TURCK RFID system offers one of the longest ranges
The in-metal RFID tag is securely integrated into the tool holder and enables reliable identification
he tools are identified by the red bracket and assigned to their respective slots in the tool magazine
Each tool has its own individual dimensions, which the machining center must know
The TBEN-S-RFID transmits all data to the tool management system via a specially developed Windows DLL
CERATIZIT produced the special mounting bracket for tool identification using 3D printing
These cabinets hold a fraction of the thousands of tools stored there for quick access
''It was the increased reading distance that made this project possible in the first place.''

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.

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. 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. Many of these tools are identical in design but differ in their geometric data, particularly in length. These differences are technically unavoidable but highly relevant to production, as CNC machines rely precisely on this data. 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. 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 TURCK RFID system's long read range as a decisive factor

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.

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.

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.

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 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.

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