Laser marking of cutting tools represents a complex challenge in the world of modern manufacturing, where precision and productivity must coexist with increasingly stringent traceability requirements. LASIT’s TowerTool system responds to these challenges by integrating a state-of-the-art robotic system with advanced laser technology and automatic quality verification systems, allowing the entire process to be managed completely autonomously.
The System Architecture
The TowerTool is designed as a Class 1 laser marking system with an all-steel structure that ensures maximum stability during marking operations. The structure, which has undergone post-weld stabilization heat treatment, ensures accuracy and repeatability over time.
At the center of the system is a 6-axis anthropomorphic robotic arm that ensures precision and repeatability in positioning. The laser scanning head, mounted with a configuration designed to optimize access to all surfaces to be marked, is equipped with a TTL (Through The Lens) vision system for real-time verification of marking quality.
Operational safety is ensured by a pneumatic automatic door cabin equipped with a sensitive edge and protective barriers that comply with the latest laser safety regulations. The entire structure is designed according to PL (Performance Level) criteria to ensure maximum operational safety.
Productive Autonomy: The Key to Efficiency
The heart of the TowerTool’s innovation lies in its ability to operate completely autonomously for long periods. The system has a large loading area with multiple magazines that can accommodate up to 400 tools. This configuration allows entire production batches to be loaded and let the system work autonomously, freeing operators for other tasks.
The warehouses are designed for maximum accessibility: while the system is working on one batch, the operator can already prepare the next one, eliminating downtime and maximizing productivity. Intelligent warehouse management allows production to be organized optimally, adapting to different production needs without compromising the system’s autonomy.
Tool marking
The bidirectional marking capability is a distinctive feature of the TowerTool that offers significant advantages in the tool marking process. The robot is designed to manipulate the tool with extreme flexibility, being able to rotate and position the element so that it can mark both the side of the tool and the back/opposite surface of the tool.
This versatility eliminates the traditional orientation constraints that would normally limit a marking system. In practice, it means that:
- No need to manually reposition the tool
- Processing time is reduced
- You increase the accuracy of the process
- Full coverage for tool identification or traceability is provided
The ability to mark both on one side and the other in a single cycle is a key innovation that distinguishes the TowerTool from more traditional marking systems. The robot can rotate the tool with pinpoint accuracy, ensuring that any desired surface can be marked efficiently and uniformly.
Marking and Quality Control System
The marking system is based on fiber laser technology, which can be configured with powers from 20W to 200W according to specific application needs. The scanning head, equipped with a high-resolution TTL vision system, enables not only the precise marking of DMC/QR codes, but also their immediate verification according to AIM-DPM standards.
The lighting system was specifically developed to eliminate reflections typical of metal surfaces, enabling reliable verification even on particularly reflective surfaces. Integrated quality control verifies in real time:
- Presence and placement of marking
- Quality and readability of DMC/QR codes.
- Compliance with required dimensional parameters
- Contrast and depth of marking
Fume extraction is provided by a three-stage system with a side channel pump that ensures a flow rate of more than 500 m³/h. The filtration system includes mechanical pre-filters, activated carbon filters and high-efficiency HEPA filters, ensuring the cleanest working environment.
Process Management and Connectivity
The brain of the system is a Siemens S1200 PLC that manages all machine functions and interfaces with FlyCAD control software through industry-standard protocols. The software allows:
- Dynamic management of marking data
- Integration with enterprise ERP/MES systems
- Complete traceability of the production process
- Automatic quality exception handling
- Real-time monitoring of process parameters
Connectivity is provided through industry-standard protocols such as PROFINET, with the possibility of implementing specific protocols such as OPC-UA on request. The system supports remote diagnosis and constant monitoring of operating parameters.
Control System and Operator Interface
The control station is equipped with a dual-screen operator interface that allows:
- Real-time visualization of the marking process
- Immediate quality control through the vision system
- Production recipe management
- Monitoring of system parameters
- Access to advanced diagnostics
The interface has been developed according to principles of cognitive ergonomics, making access to all the functions needed to manage the system immediate.
An Investment for the Future
The TowerTool represents the evolution of laser tool marking from a manual process to a fully automated system, where quality and productivity are guaranteed by constant monitoring. Its ability to operate autonomously, combined with automatic verification of marking quality, makes it the ideal solution for companies striving for excellence in tool manufacturing.
Robust construction, combined with operational flexibility and process reliability, makes TowerTool a strategic investment for companies looking to the future, where automation and quality are prerequisites for maintaining market competitiveness.
