Industrial production of cutting tools requires marking solutions that combine speed, accuracy and operational flexibility. When production volumes are high and the dimensional variety of tools is significant, traditional marking systems show their limits in terms of productivity and ability to handle complexity.
The answer to these needs comes from an integrated solution that combines fiber laser technology, robotic automation and customized software in a system designed specifically for the cutting tool industry. TowerTool represents a fully automated laser marking station developed to handle tools with lengths ranging from 40 to 370 mm and diameters from 4 to 25 mm, while maintaining high standards of quality and traceability.
The Heart of the System: Integration of Laser and Robotics
The system is based on an architecture that integrates a fiber laser with configurable powers from 20 to 200W with an industrial robotic arm positioned centrally in the work booth. The choice of laser power depends on the specific application: the most common configurations use 30 to 50W sources, which represent the best compromise between marking speed, result quality, and operating costs for most carbide and high-speed steel tools.
The central positioning of the robot ensures maximum flexibility of movement and optimal reaching of all loading points on pallets. The 90°-mounted laser scanning head allows marking along the tool shank or on the tool base, but the true versatility of the system lies in the robot’s ability to orient the tool at variable angles from 0° to 90°, making it possible to mark on any tool surface while always keeping the laser beam perpendicular to the work surface.
Production Capacity: Up to 1000 Pieces in Autonomy
TowerTool’s productivity represents a qualitative leap from manual marking systems. The system is designed to accommodate
The fully automated cycle eliminates downtime between parts: while the laser is marking one tool, the system is already ready to pick up the next. The combination of fast handling and high-powered lasers enables the processing of hundreds of tools per shift, while maintaining consistent quality of each individual marking.
Once the pallets are loaded, the operator can devote himself to other activities while the machine works in complete autonomy for hours. This configuration keeps production running for extended periods, maximizing plant utilization and freeing up human resources for higher value-added activities.
Mechanical Construction: Welded, Stretched and Milled Steel Structure
TowerTool’s mechanical strength is what really sets the system apart. The all-welded steel structure is the engineering heart of the system, designed and built in-house to ensure rigidity, precision and reliability over time.
The construction process follows a strict three-stage methodology. In the first stage, steel components are welded together to create the load-bearing frame. Welding, if left untreated, introduces internal stresses into the material that could cause deformation over time. For this reason, in the second stage, the welded frame undergoes thermal stress relief, a treatment that completely releases internal stresses through controlled cycles of heating and cooling.
Only after stress relief, in the third stage, is the structure machined mechanically by CNC milling of the reference surfaces. This process ensures tight dimensional tolerances and flatness of the mounting surfaces, which are key to maintaining precision of movement and repeatability of marking operations.
Unlike bolted-assembled aluminum profile frames, the welded steel frame offers much higher torsional and flexural stiffness. This rigidity is critical for absorbing the dynamic stresses generated by the rapid movements of the robot and for maintaining unchanged working conditions even after thousands of operating hours.
The mass of the steel structure also contributes to vibration absorption, providing stability during acceleration and deceleration of the robotic arm. This results in greater positioning accuracy and, consequently, superior marking quality.
Precision in Mechanical Details
In addition to the main frame, all motion components are selected to ensure high-level industrial performance. Bosch Rexroth linear guides and high-precision ball screws ensure smooth and repeatable movements for the motorized Z-axis, if any.
The ballscrews are free of axial backlash and mounted with double bearings on the gear side to provide higher rotational speed and high radial stiffness. This assembly allows them to be twice as fast as standard configurations, increasing the radial stiffness factor from 12.1 to 18.9.
All motors are equipped with built-in 2048-pulses-per-revolution encoders that enable precise position control in real time. Marking begins only when all axes have reached the correct position, avoiding errors due to inaccurate positioning. All fastening components are made of stainless steel, ensuring durability and corrosion resistance even in demanding production environments.
Integrated Industrial Robotics
The system integrates robotic arms from industrial manufacturers such as ABB, selected for reliability, precision and speed of execution. The robot simultaneously handles picking, positioning in front of the laser and manipulating the tool to mark on different surfaces, all with smooth, coordinated movements that minimize cycle times.
The choice of industrial robotics ensures repeatability of movements essential when working with tight marking tolerances, allowing the tool to be precisely oriented for markings on angles ranging from 0° to 90°.
Dimensional Variability Management
One of the main challenges in automated marking of cutting tools is the considerable dimensional variability between different products. TowerTool addresses this issue through a gripper system with automatically interchangeable fingers, which allows the robot to adapt to tools of different diameters without manual intervention.
The gripper grabs tools by the shank, preventing any contact with the cutting edge and preventing damage to the active part of the tool. Automatic finger changing allows mixed batches to be handled without interruption, maintaining high productivity even with frequent product changes.
Multi-Position Marking Flexibility
The robot’s ability to orient the tool at variable angles from 0° to 90° provides complete versatility in the application of markings. The system can mark vertically along the shank, horizontally on the base, or at any intermediate angle required by the application. Robotic handling ensures that the tool is always positioned at the correct focal distance from the laser, regardless of geometry or size.
For applications requiring markings at different heights, the system can be equipped with a fully software-programmable motorized Z-axis, which coordinates its movements with the robotic arm for multi-level markings without the need for manual repositioning. The Z-axis is constructed with a double profile to maximize rigidity and uses a trapezoidal screw that prevents dropping if the motor loses torque.
Integrated Quality Verification
The presence of the marking is automatically verified through a TTL (Through The Lens) vision system integrated directly into the laser scanning head. This solution eliminates the need for additional robot or laser head movements for inspection, reducing the overall cycle time.
The system uses OCR technology to recognize a portion of the marking and confirm the presence of the code. Specific lighting designed to prevent reflections on the metal surface of tools ensures optimal conditions for recognition, increasing the reliability of quality control and contributing to overall productivity by eliminating manual inspection time.
Customized Software for Industry 4.0
The entire system is controlled through a software interface that can be customized according to specific customer requirements. The software manages simultaneously the 4 pallets loaded on the machine, displaying for each one the essential information: product type, pallet identifier, total number of pieces to be marked, possibility to select specific rows and columns in case of partial marking.
The application can receive markup data from different types of connectors (SQL, Oracle, XML, CSV, text files) and use them to automatically populate layouts containing dynamic fields. A local SQL Express database records a complete log of operations, accessible by the client via ODBC connection or simple Excel spreadsheets.
The system is prepared tointerface with enterpriseIT systems such as ERP or MES through standard communication protocols (including OPC-UA), enabling full integration into the Industry 4.0 environment. Comprehensive monitoring of I/O and machine functions allows maintenance personnel to access all critical information in case of anomalies, reducing downtime and maintaining high productivity.
Production Flow Automation
The operating cycle is designed to minimize downtime and maximize system autonomy. The operator loads up to four pallets onto a manual sliding table that pulls completely out of the cab to facilitate loading and unloading: two complete pallets of tools to be marked and two empty pallets intended to receive machined tools.
Once the cycle is started, the pneumatic door closes automatically and the system starts working completely autonomously. The robotic arm picks up each tool from the loading pallet, positions it in front of the laser head at the required angle while maintaining the correct focal distance, performs marking at the programmed positions, verifies the quality via vision system, and finally deposits the marked tool into the unloading pallet following predetermined trajectories.
Each pick position in the loading pallet corresponds to a specific storage position in the unloading pallet, ensuring complete traceability of the process. The system is designed to use the customer’s existing pallets, simplifying integration into the existing production line without the need for additional investment in dedicated equipment.
Integration into Existing Production
The ability to use the customer’s existing pallets is a significant advantage for integrating the TowerTool system into already operating production lines. The work table is customized to accommodate pallets of different sizes, avoiding additional investment in dedicated equipment and simplifying material logistics.
The preinstalled remote support system (TeamViewer or other software according to customer preference) enables rapid technical support interventions, reducing downtime and ensuring business continuity.
Aspiration and Work Environment Management
A suction system with a three-stage filter built into the base of the machine ensures a clean working environment. The side channel pump with die-cast aluminum construction ensures high airflow, while the filtration system combines HEPA H14 elements and activated carbon to remove microparticles and odors. Full integration of the vacuum system into the machine base eliminates the need for bulky external equipment, optimizing production space.
Safety and Regulatory Compliance TowerTool is a Class I laser system designed according to safety category PL. The front pneumatic door is equipped with a sensitive edge that detects obstacles during closing, while lighted safety barriers provide operator protection. The Siemens S1200 controller handles all safety functions, with specific relays and dual contactor circuits.