Intelligent tool holders precisely capture measurement data, thereby offering the potential to optimally exploit the productivity and accuracy of modern machine tools. smartTOOL enables comprehensive process monitoring with complete transparency over the machining process, the occurrence of process anomalies, the tool condition, or the quality of the manufactured components through sensitive sensor technology. The key to this is the integration of sensors close to the point of action. The next generation of the versatile tool holder is now ready to launch: with even more powerful electronics and sensors for monitoring process forces and vibrations in all spatial directions, and thus for each individual cutting edge – integrated into an even more robust and compact design.
smartTOOL is thus ready for use in finish machining, heavy cutting, and a variety of other machining processes.
Numerous improvements
In the further development of the tool holder, the focus was initially on the sensors. Extensive experience from use in many machining applications showed which sensors could be omitted and where, in terms of more sensitive sensors, 'fine-tuning' was necessary. The result of the extensive revision is an even more compact mechanical design that requires 25 percent less installation space and is compatible with almost any clamping chuck geometry. Newly developed antennas also ensure enhanced performance in data transmission rates.
The electronic hardware has also been newly developed and equipped with even more powerful components. In combination with the new antennas, it ensures particularly high transmission rates of the sensor signals. With sampling rates of up to 10 kHz, smartTOOL reliably detects even very high-frequency vibrations and can contribute more than ever to the quality assurance of the components.
Many proven features are also adopted by the new generation.
Direct application at the point of action
The smart tool holder measures vibrations, process forces, and temperatures directly at the tool. The collected data is wirelessly transmitted to an evaluation unit and analyzed. This allows even minimal changes, such as tool wear or slight vibrations, to be detected early. This not only enables real-time monitoring but also optimization and automation of manufacturing processes.
Autonomous power supply and flexibility
The patented energy harvesting solution has also been adopted. It permanently and wirelessly supplies smartTOOL with power – entirely without external power supply. For this, a small stator component only needs to be mounted on the spindle housing of the machine. This innovative technology does not restrict automated tool changes or the working space. Since the electronics are located in a compact segment between the clamping chuck and spindle interface, the tool holder is flexibly usable on almost any machine.
Compatible with the flexible automation solution 'Edge Cloud Continuum for Production' ECC4P
smartTOOL is tailor-made for milling and drilling processes and can be integrated into ECC4P just like the products smartGRIND (grinding processes) and smartNOTCH (forming processes). The AI-based production monitoring and control based on ECC4P (Edge Cloud Continuum for Production) offers medium-sized companies individual solutions with comprehensive data security from a single source. More information on ECC4P: Automation for the manufacturing SME sector
Premiere at EMO Hannover 2025
The new smartTOOL will celebrate its premiere at the joint stand of the Fraunhofer Cluster of Excellence Cognitive Internet Technologies (CCIT). In Hall 6, Stand B18, the CCIT presents intelligent production technologies based on cognitive internet technologies. A focus is on efficient data collection and processing to optimize production processes – as with smartTOOL.
Presentation at EMO Hannover 2025, in Hall 6, Stand B18
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