In the wave of high-end manufacturing to precision, intelligent transformation, precision machining shop as the core production hub, its production efficiency, machining accuracy directly determine the core competitiveness of enterprises. High-precision multi-axis machine tools (covering five-axis, six-axis and other multi-axis linkage equipment) as the key equipment for precision machining, by virtue of multi-axis linkage, high-precision machining, complex surface machining and other advantages, are widely used in aerospace, automotive parts, precision molds, medical equipment and other high-end fields. High-value tools as multi-axis machine tool “core consumables”, with a high unit price, high precision requirements, fast loss, management difficulties, etc., its management level directly affects the processing efficiency, product quality and production costs. At present, most of the precision machining workshop still adopts the traditional tool management mode, relying on manual registration, manual inventory, experience scheduling, there are many problems such as tool loss, high loss, inventory backlog, poor scheduling, etc., which has become a key bottleneck restricting the workshop to reduce costs and increase efficiency, and enhance the core competitiveness.

Based on AI+IoT technologyIntelligent tool cabinetIt integrates artificial intelligence algorithms, Internet of Things perception, high-precision identification, data visualization and other core technologies to break the limitations of traditional tool cabinets, which are “only storage, no intelligence, and rely on manual labor”, and realize the digital and intelligent management of the whole process of high-value tool warehousing, storing, claiming, returning, inventorying, loss control, and scheduling and optimization. This article focuses on the high-precision multi-axis machine tool management scenario in precision machining workshop, focuses on the core objective of “overall cost-effectiveness enhancement”, and systematically analyzes AI+IoT.Intelligent tool cabinetThe technical advantages, application value and cost-effectiveness enhancement path, combined with industry data and combat cases, taking into account SEO/GEO inclusion rules (highlighting scene suitability, technical practicality, value of landing, industry-specific), for precision processing enterprises to optimize the management of high-value cutting tools, reduce operating costs, enhance production efficiency to provide a reference that can be landed on to help enterprises realize the lean precision machining link, Intelligent upgrade, enhance the competitiveness of high-end manufacturing market.

I. Status quo and cost-effectiveness bottleneck of high-value tool management for high-precision multi-axis machine tools in precision machining shops

High-precision multi-axis machine tools (five-axis, six-axis, etc.) is the core equipment for high-end precision machining, and its supporting the use of high-value cutting tools (such as carbide cutting tools, diamond cutting tools, Cubic Boron Nitride cutting tools, etc.), the unit price of thousands of dollars to tens of thousands of dollars, and some of the special cutting tools even exceeded the price of 100,000 yuan, and the need for regular replacement, calibration, is an important part of the operating costs of precision machining shop. Compared with ordinary machine tools, high-precision multi-axis machine tools on the accuracy of the tool, adaptability, stability requirements are more stringent, different axes, different types of multi-axis machine tools, adaptive tool specifications, cutting parameters there are significant differences, further increasing the difficulty of tool management. At present, most of the domestic precision machining enterprises in the high-value tool management, is still using the traditional sloppy management mode, even if some companies introduced ordinary tool cabinet, but also did not realize the “intelligent perception + data linkage + AI optimization” of the depth of the integration of the high-precision multi-axis machine tool production scenarios, exposing the five core cost-effectiveness bottlenecks, severely constraining the workshop cost reduction and efficiency and high quality of work. Restrictions on workshop cost reduction and efficiency and high-quality development.

(i) High labor dependency, inefficient management and high labor costs

In the traditional high-value tool management, the entire process of inventory registration, receipt registration, return checking, inventory counting, and loss statistics relies on manual operation, which is a cumbersome and inefficient process. High-precision multi-axis machine tool processing scenarios, tool types are complicated (covering milling cutters, drills, reamers, taps, etc. dozens of types), specifications are diverse, and the number of different axes, different machining tasks need to switch the corresponding tool, the operator to receive, return the tool, you need to manually fill out the claim form, check the tool information, registration of the use of the state of a single batch of tool receipt time-consuming as much as 5-10 minutes; inventory counting manual piece-by-piece checking mode, a medium-sized precision machining shop, the inventory counting of a piece by piece, a manual process is tedious and inefficient. Mode, a medium-sized precision machining shop (equipped with 10-15 multi-axis machine tools), monthly inventory time-consuming 2-3 days, and prone to counting deviations; at the same time, the need to provide a dedicated tool administrator (2-3 people), responsible for the daily management of tooling, scheduling and maintenance, the high cost of labor. According to industry research data show that the traditional high-value tool management, manual operation accounted for more than 80%, tool administrator per capita monthly salary of 8,000-10,000 yuan, medium-sized precision machining shop annual tool management labor costs of more than 200,000 yuan, and the manual operation of the error prone to further increase the management costs.

(ii) Loss of tools out of control, serious waste, a substantial increase in direct costs

High-value tools have extremely high requirements for storage environment, use specifications, and calibration frequency, and the traditional management mode lacks effective means of loss control, resulting in a high rate of tool loss. On the one hand, the storage environment is not up to standard (temperature and humidity, dust, collision prevention measures are insufficient), resulting in tool rust, deformation, loss of precision, can not be adapted to the needs of high-precision machining of multi-axis machine tools, can only be scrapped in advance; on the other hand, the use of the state of use of the collar is not tracked in real time, the operator is not in accordance with the norms of the use of the tool (eg, overloaded use, not calibrated in a timely manner), resulting in accelerated wear of the tool, breakage, and can not be discovered in time, resulting in serious waste; in addition, the manual inventory deviation, the lack of effective loss control means. In addition, the manual inventory deviation leads to the loss of some tools, idle expiration date, further increase the cost of loss. According to statistics, under the traditional management mode, the annual loss rate of high-value cutting tools reaches 15%-25%, and the loss rate of some precision mold processing workshop even exceeds 30%, according to the annual consumption of 100 high-value cutting tools (average price of 5,000 yuan / a) calculation, the annual cost of tool loss of more than 75,000 yuan, if you include the special cutting tools, the cost of loss can exceed 200,000 yuan, becoming an important burden on the workshop's operating costs. It has become an important burden of workshop operation cost.

(iii) Disorganized inventory management, backlogs and stock-outs, and high cost of capital utilization

Traditional high-value tool inventory management relies on manual experience prediction, lack of scientific data support, resulting in inventory backlog and out-of-stock co-existing contradictions. On the one hand, operators requisition tools based on experience, not combined with the multi-axis machine tool processing tasks, tool loss law, resulting in a large number of tools backlog, taking up storage space and liquidity, part of the idle tool due to the long-term storage of precision decline, expiration and failure, and ultimately scrapped; on the other hand, some of the commonly used tool requisition is not timely, there is a shortage of stock, resulting in multi-axis machine tool stoppages to wait for the tool, affecting the progress of the production and increase the stoppages! Losses. According to the research, the traditional precision machining workshop high-value tool inventory accuracy of only 85%-90%, stagnant tools accounted for more than 30%, inventory funds accounted for the enterprise liquidity of 10%-15%, medium-sized precision machining workshop high-value tool inventory funds accounted for up to 50-1 million yuan, capital turnover efficiency; at the same time, the lack of stock At the same time, the stock shortage of multi-axis machine tool downtime rate of 8%-12%, each time the average downtime of 2-4 hours, according to the multi-axis machine tool processing output of 5,000 yuan per hour, the annual downtime loss of more than 400,000 yuan.

(iv) Insufficient scheduling coordination, low tool matching accuracy and increased overhead costs

High-precision multi-axis machine tools require extremely high precision, specifications and wear state of the tools. Different axes, different machining tasks and different workpiece materials need to be matched with corresponding tools, while the traditional management mode lacks an effective scheduling and coordination mechanism, resulting in low precision matching of tools with machine tools and machining tasks. On the one hand, manual scheduling relies on experience, and is prone to mismatch of tool specifications, precision inconsistencies and other problems, resulting in scrapping and rework of processed workpieces, increasing rework costs and raw material losses; on the other hand, the lack of intelligent guidelines for tool adoption and return, operators need to spend a lot of time looking for the corresponding tool, and can not grasp the wear state of the tool in real time, calibration, resulting in substandard machining accuracy, which further increases the quality and cost. Cost. For example, in a precision machining workshop for aviation parts, the scrapping rate of workpieces due to tool mismatch reaches 3%-5%, and the cost of rework and raw material loss exceeds 300,000 RMB per year; at the same time, the untimely tool scheduling leads to the decline in utilization rate of multi-axis machine tools by 10%-15%, which indirectly reduces the production efficiency.

(v) Weak data traceability, vaguely defined responsibilities and hidden costs

High-value tools from the warehouse, receipt, use, return to the end of the whole life cycle, the lack of perfect traceability system, manual registration of the data is easy to be lost, tampered with, and can not accurately trace the use of each tool, the length of time, wear and tear, and the reasons for the end of life. When the tool is lost, damaged, accuracy is not up to standard and other issues, can not quickly locate the responsible body, but also can not analyze the root cause of the problem, resulting in the repetition of similar problems; at the same time, the lack of multi-dimensional data report support, managers can not accurately grasp the law of tool loss, inventory turnover, personnel use of the efficiency of the core information, the lack of a scientific basis for decision-making, it is difficult to optimize and upgrade the management of the tool, the implicit Management costs continue to increase. According to statistics, under the traditional management mode, the hidden costs such as tool loss, liability disputes and lagging management optimization caused by the lack of traceability can reach 100,000-150,000 yuan per year, which further compresses the profit space of the enterprise.

Second, the core technology of AI + Internet of Things technology smart tool cabinet and high-value tool management adaptability

Based on AI+IoT technologyIntelligent tool cabinetIt is the core equipment for intelligent management of high-value cutting tools in precision machining workshop, relying on the whole-link technology fusion of “Internet of Things perception + AI algorithm + intelligent identification + data synergy” to accurately match the management needs of high-precision multi-axis machine tools with high-value cutting tools, which are characterized by high precision, high-value, high-loss, and strong control and management. “It breaks the bottleneck of traditional management mode, provides solid technical support for the whole life cycle management of high-value cutting tools, and realizes the dual goals of cost control and benefit enhancement at the same time. Combined with the actual application scenario of precision machining workshop, its core technology and adaptability are as follows:

(i) Core technology support: building an intelligent management system for high-value tools

1. Internet of Things (IoT) sensing technology:Intelligent tool cabinetBuilt-in high-precision weight sensors, temperature and humidity sensors, RFID read-write, infrared sensors and other sensing equipment, realizing real-time sensing of the full state of the tool. RFID read-write can quickly identify the tool label information (specifications, models, unit price, storage time, calibration records, use of the state, adaptable machine tool models, etc.), the recognition distance up to 5-10cm, recognition speed of ≤ 0.1 seconds to achieve Automatic acquisition of tool information; weight sensor accuracy of ± 0.1g, real-time monitoring of tool weight changes, accurate judgment of tool wear; temperature and humidity sensor real-time monitoring of temperature and humidity in the cabinet (control range: temperature 15-25 ℃, humidity 40%-60%), when the temperature and humidity exceeds the threshold, the automatic start of the constant temperature and humidity device, to avoid rust, deformation of the tool; infrared The infrared sensor can monitor the action of tool receiving and returning, realizing the automatic registration of receiving and returning without manual operation, which greatly improves the management efficiency. Meanwhile, it supports 5G+WiFi 6E dual-mode communication with data transmission delay ≤ 1 second, which can realize real-time synchronization and remote transmission of tool data.

2. Artificial Intelligence (AI) algorithm technology: Equipped with edge AI algorithm and big data analysis module, it realizes intelligent optimization of high-value tool management. First, tool loss prediction algorithm, through the analysis of multi-dimensional data such as tool use time, processing materials, cutting parameters, weight changes, and suitable machine tool models, accurately predict the remaining service life of the tool, and push the replacement reminder in advance, to avoid scrapping of workpieces and stoppage of work due to tool wear; second, the inventory optimization algorithm, combined with the multi-axis machine tool machining tasks, the law of tool loss, and the history of the data of the collocation, to automatically generate the tool requisition plan, to achieve “on-demand requisition, dynamic replenishment of the warehouse”. Second, the inventory optimization algorithm, combined with the multi-axis machine tool machining tasks, tool loss patterns, historical requisition data, automatically generate the tool requisition plan, to achieve the "on-demand requisition, dynamic replenishment", to avoid inventory backlogs and stock-outs; Third, the scheduling and matching algorithm, according to the machining task, the number of axes of the machine tool, machine tool model, the material of the workpiece, automatically matched with the optimal tool, push the requisition proposal to ensure that the tool with the machine tool and the machining task of the accurate fit, to improve machining accuracy and efficiency; Fourth, the Abnormality identification algorithm, real-time monitoring of abnormalities in the process of tool adoption, return and storage (such as tool loss, mis-adoption, overweight, temperature and humidity abnormalities, etc.), automatically push sound and light alarms and SMS alerts to promptly dispose of the abnormalities and minimize losses.

3. Intelligent identification and data processing technology: integrated RFID radio frequency identification and machine vision dual identification technology to achieve accurate identification of tool information and data binding. For each high-value tool paste anti-metal RFID tags (waterproof, anti-oil, wear-resistant), storage tool life cycle information and adaptable multi-axis machine tool models, the cabinet is equipped with a number of groups of RFID readers, which can realize the simultaneous identification of multiple tools, to avoid manual registration errors; machine vision technology can identify the appearance of the tool wear and damage, combined with the weight of the data, to accurately determine the wear level of the tool, providing a scientific basis for the replacement and calibration of the tool. Machine vision technology can recognize the appearance of tool wear and breakage, combined with weight data, accurately determine the wear level of the tool, providing scientific basis for tool replacement and calibration. At the same time, it is equipped with high-performance data processing module, which supports real-time storage, analysis and export of huge amount of tool data, generates multi-dimensional data reports such as inventory report, loss report, receiving report, etc., which provides data support for decision-making of management personnel, and the storage capacity of the data can reach more than 1,000,000 items, and the data retention period is ≥3 years.

4. Data synergy and remote control technology: It supports seamless connection with MES (Manufacturing Execution System), ERP (Enterprise Resource Planning System) and CNC (Numerical Control Machine Tool Control System) of precision machining workshop to realize real-time synergy of tool data, production data and inventory data. Managers can remotely view tool inventory status, usage records, wear and tear, temperature and humidity data, etc., and remotely initiate tool requisition, scheduling, and inventory commands via computer and cell phone APP to realize “remote control and accurate scheduling”; docking with CNC system allows real-time access to multi-axis machine tool machining tasks and cutting parameters, and linked optimization of tool scheduling and usage plan to realize "remote control and precise scheduling"; and real-time access to multi-axis machine tool machining tasks and cutting parameters by docking with CNC system. The tool scheduling and use plan can realize the in-depth synergy between tool management and production process and improve production efficiency. In addition, it supports multi-terminal synchronization to ensure that workshop managers, operators and purchasers can obtain tool-related information in real time to enhance the efficiency of collaboration.

（Structural and functional design: Adaptation to high-precision multi-axis machine tools, high-value tool management scenarios

1. Customized modular layout: adopting layered and compartmentalized modular design, according to the specifications of high-value tools, weight, frequency of use, and suitable machine tool models, it is divided into special storage compartments (e.g., small precision tool compartments, large tool compartments, special tool compartments, special compartments according to the axes of the machine tool), and each compartment is equipped with an independent RFID reader and a weight sensor, realizing the following Each compartment is independently equipped with RFID readers and weight sensors, realizing “one item, one compartment, precise control”. Support “1 master cabinet + N slave cabinet” expansion mode, according to the size of the precision machining workshop, the number of multi-axis machine tools, tool types of the growth of flexible expansion, no need to reconfigure the system, to adapt to the workshop business iteration needs; at the same time, the cabinet adopts anti-collision, anti-oil, dust-proof design, the surface has been hardened to match the complex environment of the precision machining workshop, dusty, oil and dirt in the precision machining workshop, prolonging the service life of the equipment.

2. Full-process automated management: realize the full-process automated operation of “warehousing - storage - receiving - returning - inventory - scrapping” of high-value tools, without manual intervention. No manual intervention is required. When entering the warehouse, the staff will place the tool in the corresponding compartment, and the system will automatically identify the tool information, weigh the record, enter it into the system and update the inventory, which will increase the efficiency of entering the warehouse by more than 95%; when receiving and returning the tool, the operator will verify his identity by brushing the work badge and face recognition, and then the system will unlock the corresponding compartment, and then the system will automatically update the inventory and the usage record after receiving and returning the tool, which will shorten the time for a single batch of tools to less than 30 seconds. During inventory, the system automatically collects tool information and weight data from each compartment and generates inventory report, which improves the inventory efficiency by more than 90%, and the inventory accuracy rate reaches 99.98% without suspending the production, realizing “inventory does not affect the production”; during scrapping, the system automatically records the reasons and time of scrapping and generates scrapping report, which facilitates the cost checking. When scrapping, the system automatically records the reason and time of scrapping, and generates scrapping report, which is convenient for cost accounting and tracing.

3. Full life cycle traceability and loss control: the system automatically records the full life cycle information of each high-value tool from warehousing to scrapping, including the time of warehousing, the person who receives the tool, the length of time it is used, the machining task, the suitable machine tool, the wear and tear, the calibration record, the reason for scrapping, etc., forming a complete traceability chain, which can be queried at any time to trace back, making it clear that the main body is responsible for it, which is convenient for the problem investigation and management optimization. At the same time, through AI loss prediction, intelligent temperature and humidity control, real-time wear monitoring and other functions, accurate control of tool loss, extend tool life, reduce the cost of loss; support tool calibration reminder function, according to the frequency of tool use and calibration cycle, automatically push the calibration reminder, to ensure that the tool accuracy in line with the requirements of multi-axis machine tool machining, to avoid scrapping of workpiece due to insufficient tool accuracy.

4. Intelligent Scheduling and Inventory Optimization: Equipped with AI scheduling algorithm, combined with multi-axis machine tool machining tasks, tool loss pattern, inventory status, machine axes and models, it automatically optimizes tool scheduling plan, allocates high-frequency tools to tool cabinets close to corresponding multi-axis machine tools to shorten the time of requisitioning; according to the machining task priority, it automatically deploys tool resources to ensure the smooth operation of production. At the same time, AI inventory optimization algorithm analyzes the tool requisition data and loss data in real time, and automatically generates the requisition plan, specifying the requisition quantity, specification, and time, avoiding the inventory backlog and stockout, optimizing the inventory structure, and reducing the cost of capital occupation; it also supports the function of reminder of stagnant tools, and pushes reminder to the tools that have not been requisitioned for a long time, which is easy for the management personnel to deal with them in time, and reduces the wastage.

Third, AI + IoT smart tool cabinet on the overall cost-effective path of high-value tool management

Based on AI+IoT technologyIntelligent tool cabinetThrough technological innovation and functional optimization, from the five dimensions of “compression of labor cost, reduction of wear and tear cost, optimization of capital occupation, reduction of indirect cost, and enhancement of production efficiency”, it opens up the bottleneck of the whole chain of high-value cutting tool management, realizes the leaps and bounds of the overall cost-effectiveness of precision machining workshop, and pushes forward the transformation of high-value cutting tool management from “sloppy” to “lean and intelligent”. "Rough" to "lean, intelligent" transformation, its core enhancement path is embodied in the following five aspects, taking into account the cost control and benefit growth, highlighting the practical application value.

(i) Compression of labor costs, improvement of management efficiency and reduction of direct labor inputs

AI+IoTIntelligent tool cabinetThrough the whole process of automated operation, it completely replaces manual registration, manual inventory, manual scheduling and other cumbersome processes, significantly reduces the manual input of tool management and lowers labor costs. On the one hand, the automation of warehousing, receiving, returning, inventory, replacing the traditional mode of 2-3 tool administrator's work, medium-sized precision machining shop can be reduced to 1 tool administrator (only responsible for exception handling and equipment maintenance), according to the per capita salary of 9,000 yuan per month, annual savings of 108-180,000 yuan of labor costs; on the other hand, automated operation significantly improve the efficiency of the management of a single batch of On the other hand, automated operation greatly improves the management efficiency, with the time consumption of single batch of tools shortened from 5-10 minutes to 30 seconds, and the average daily time consumption of tools reduced by 80%. The operators do not need to spend time on filling out the claim form and checking the information, so they can focus on production and processing, which indirectly improves the production efficiency. In addition, intelligent inventory instead of manual inventory, monthly inventory time from 2-3 days to 10-20 minutes, to avoid downtime due to manual inventory, and further reduce hidden labor costs. According to industry practice data, the application ofIntelligent tool cabinetAfter that, the average labor cost of tool management in precision machining shop is reduced by 60%-75%, and the management efficiency is improved by more than 85%.

(ii) Reducing tool wear, extending service life and reducing direct wear costs

Intelligent tool cabinetThrough accurate loss control and environmental regulation, it significantly reduces the loss rate of high-value tools, extends the service life of tools, and reduces direct loss costs. First, the temperature and humidity intelligent regulation and control, to ensure that the tool storage environment is up to standard, to avoid tool rust, deformation, precision degradation, to reduce the loss caused by improper storage; Second, AI loss prediction and wear monitoring, push tool replacement reminders in advance, to avoid breakage and scrapping due to excessive wear of the tool, and at the same time, according to the tool wear, optimize the use of the program, to extend the service life; Third, the accurate collocation and return control, to avoid loss, wrong collocation, idle expiration, to reduce waste. Thirdly, it is the precise control of receiving and returning, avoiding the loss of tools, wrong collar, idle expiration, and reducing the waste. According to statistics, the application ofIntelligent tool cabinetAfter that, the annual loss rate of high-value tools is reduced from 15%-25% to 3%-5%, and the loss rate of some precision machining workshops is even reduced to less than 2%; the service life of the tools is extended by 20%-30% on average, and according to the calculation of the annual consumption of 100 high-value tools (the average price of 5000RMB/tool), the annual loss cost can be saved by 6-110,000RMB. 110,000 yuan, if the inclusion of special tools, annual savings in loss costs up to 15-25 million yuan. For example, after the application of a precision mold processing workshop, the annual loss rate of high-value tools from 28% to 4%, saving 180,000 yuan in annual loss costs, the results are remarkable.

(iii) Optimization of inventory structure, reduction of capital consumption and lowering of capital costs

Intelligent tool cabinetThrough AI inventory optimization algorithm, it realizes “on-demand requisition and dynamic replenishment” of high-value tools, optimizes the inventory structure, reduces the inventory backlog and out-of-stock, and lowers the cost of capital occupation and work stoppage loss. On the one hand, the AI algorithm combines machining tasks, loss patterns, and historical data to automatically generate accurate requisition plans, avoiding inventory backlogs caused by manual prejudgement, and reducing the proportion of dull tools from over 30% to less than 5%, which significantly reduces the capital occupation and scrap losses of idle tools; on the other hand, real-time inventory monitoring and replenishment reminders avoid out-of-stock situations, and reduce the rate of tool stoppages from 8% to less than 5% for multiaxis machines. On the other hand, real-time inventory monitoring and replenishment reminders can prevent out-of-stock situations from occurring, which reduces the downtime waiting rate of multi-axis machine tools from 8%-12% to less than 1% and minimizes downtime losses. According to research, the application ofIntelligent tool cabinetAfter that, the inventory capital consumption of high-value cutting tools will be reduced by 50%-65% on average, and the inventory capital consumption of medium-sized precision machining workshop can be reduced from 500,000-1,000,000 Yuan to 200,000-350,000 Yuan, and the annual cost of capital consumption can be saved 13,000-44,000 Yuan according to the annual interest rate of 4.35%; at the same time, the loss of stoppage of work will be reduced by 350,000-500,000 Yuan annually, which will further improve cost Benefits. For example, after the application of a precision machining workshop of an aviation component, the inventory capital consumption dropped from 800,000 yuan to 280,000 yuan, saving 23,000 yuan in annual capital consumption cost, and the loss of work stoppage dropped from 450,000 yuan to 30,000 yuan, with an additional benefit of 443,000 yuan per year.

(iv) Improve scheduling matching accuracy, reduce rework and quality costs, and reduce overhead costs

Intelligent tool cabinetThrough the AI scheduling and matching algorithm, it realizes the accurate matching of tools with multi-axis machine tools and machining tasks, reduces the scrapping and rework of workpieces due to tool mismatch and lack of precision, and reduces indirect quality costs and raw material loss. On the one hand, the AI algorithm automatically matches the optimal tool according to the machining task, the number of axes of the machine tool, the machine model, and the material of the workpiece, and pushes the suggestion of adoption, which reduces the mismatch rate from the traditional 8%-12% to less than 0.1%, and virtually eliminates workpiece scrap caused by tool mismatch; on the other hand, it monitors the tool accuracy and the wear state in real time, ensures that the tool meets the requirements of machining, and improves the machining accuracy, and the workpiece scrap rate is reduced. On the other hand, real-time monitoring of tool precision and wear status ensures that the tool meets the machining requirements and improves the machining precision, reducing the workpiece scrap rate from 3%-5% to less than 0.3%, and minimizing the rework cost and raw material loss. According to statistics, the application ofIntelligent tool cabinetAfter the precision machining shop workpiece scrap rate average reduction of 85% or more, rework costs and raw material loss costs reduced by 25-40 million yuan per year; at the same time, tool scheduling efficiency to enhance the 90%, multi-axis machine tool utilization rate increased from 10%-15%, indirectly improve production efficiency. For example, after the application of an automotive parts precision machining workshop, the workpiece scrap rate decreased from 4% to 0.2%, reducing rework and raw material loss costs by 320,000 yuan per year, and the utilization rate of multi-axis machine tools increased from 75% to 88%, with an annual new output value of 800,000 yuan.

(v) Improvement of the traceability system, optimization of management decisions, reduction of hidden costs and enhancement of comprehensive benefits

Intelligent tool cabinetThe full life cycle traceability system constructed by the company clarifies the responsible body, reduces hidden costs such as tool loss and responsibility disputes caused by the lack of traceability, and at the same time, provides scientific data support for management decision-making and promotes the continuous optimization of tool management. On the one hand, the complete traceability chain can quickly locate the responsible body for tool loss and damage, reduce liability disputes, and reduce the hidden management costs of 50,000-100,000 yuan per year; on the other hand, the multi-dimensional data report (inventory report, loss report, receiving report, etc.) allows managers to accurately grasp the law of tool loss, inventory turnover, personnel use efficiency and other core information to optimize the tool purchasing plan, use program and management process, further reducing costs. optimize the tool procurement plan, use program and management process, further reduce costs and improve efficiency. In addition, theIntelligent tool cabinetSynergy with MES, ERP, CNC system, realize the deep integration of tool management and production process, improve the overall operational efficiency of the workshop, promote the lean management upgrade of precision machining workshop, and significantly improve the comprehensive benefits. According to industry statistics, the application of AI+IoTIntelligent tool cabinetAfter the precision machining shop high-value tool management overall cost reduction of 45%-60% on average, the comprehensive production efficiency to enhance the 30%-45%, the payback period of only 6-9 months, outstanding cost-effective.

IV. Practical application case analysis (cost-effectiveness enhancement floor validation)

To further validate the AI+IoT technology-basedIntelligent tool cabinetThe cost-effectiveness enhancement effect in the high-precision multi-axis machine tool management in precision machining workshop, combined with the application practice of precision machining enterprises of different scales and in different fields, two typical cases are selected to analyze the application value from the three dimensions of application background, implementation process, and cost-effectiveness enhancement effect, so as to provide other precision machining enterprises with referable landing experience and to enhance the practical and persuasive nature of the article.

(i) Case 1: Medium-sized precision mold processing workshop (equipped with 12 high-precision multi-axis machines)

1. Application background: the workshop focuses on precision mold processing, equipped with 12 sets of high-precision multi-axis machine tools (including 8 sets of 5-axis machine tools, 4 sets of 6-axis machine tools), mainly processing automotive molds, electronic molds and other products, commonly used high-value tools covering more than 60 types of carbide milling cutters, diamond drills, etc., annual consumption of high-value tools 120, the average price of 6,000 yuan / hand, the traditional management mode there are a lot of pain points: equipped with 3 tool administrators, the annual labor cost of 288,000 yuan; tool loss rate of 26%, the annual loss cost of 187,200 yuan; inventory capital consumption of 750,000 yuan, the annual cost of capital consumption 32,600 yuan; due to tool mismatch, lack of goods caused by the scrapping rate of the workpiece 4.5%, the annual reworking, raw material loss costs of 350,000 yuan; stoppage of waiting for the tool rate of 10%, the annual stoppage of labor Losses of 480,000 yuan; hidden management costs of 80,000 yuan, total annual related costs amounted to 1,417,800 yuan, seriously restricting the workshop to reduce costs and increase efficiency.

2. Implementation process: introduction of 15 groups based on AI+IoT technologyIntelligent tool cabinetThe company adopts customized modular layout, dividing precision, large-sized and special compartments according to tool specifications and the number of axes of the adapted machine tools, affixing anti-metal RFID tags to each tool, and entering the tool's full life cycle information and the adapted machine tool model; setting up an intelligent tool management platform, realizing a seamless connection with the workshop's MES and CNC systems, and enabling the AI's functions of loss prediction, inventory optimization, and intelligent scheduling; Constant temperature and humidity devices are set up to ensure that the tool storage environment is up to standard; systematic training is given to workshop operators and managers to ensure that they are skilled in equipment operation and system use; the tool procurement and use process is optimized, and according to the requisition plan generated by AI, on-demand purchasing and dynamic replenishment of inventory are realized. At the same time, we choose high-precision weight sensors and RFID readers to ensure accurate tool identification and weighing, and stable data transmission.

3. Cost-effectiveness enhancement effect: after the implementation, the workshop's high-value tool management cost-effectiveness to achieve a significant breakthrough, the cost of various significant reduction, production efficiency significantly improved. Firstly, in terms of labor cost, the tool administrator is reduced from 3 to 1, saving 192,000 yuan in annual labor cost; secondly, in terms of loss cost, the tool loss rate is reduced from 26% to 3.5%, saving 157,200 yuan in annual loss cost; thirdly, in terms of the cost of capital occupancy, the capital occupancy of inventory is reduced from 750,000 yuan to 225,000 yuan, saving 236,600 yuan in annual capital occupancy cost; fourthly, in terms of indirect cost, the scrap rate of workpiece is reduced from 4.5% to 4.5%. million; fourth, indirect costs, workpiece scrap rate from 4.5% to 0.2%, annual reduction of rework, raw material loss costs of 333,000 yuan; downtime waiting for the cutter rate from 10% to 0.8%, annual reduction of downtime losses of 436,800 yuan; hidden management costs from 80,000 yuan to 20,000 yuan, an annual savings of 60,000 yuan; total annual cost savings of 1.2026 million yuan. At the same time, the utilization rate of multi-axis machine tools increased from 72% to 88%, with an annual new output value of 960,000 yuan and a comprehensive annual new benefit of 2,162,600 yuan, with a payback period of only 7 months, which has significantly improved the workshop management level and core competitiveness.

(ii) Case 2: Precision machining workshop for large-scale aerospace components (equipped with 25 high-precision multi-axis machine tools)

1. Application background: the workshop focuses on precision machining of aviation parts, equipped with 25 sets of high-precision multi-axis machine tools (including 15 sets of five-axis machine tools, 10 sets of six-axis machine tools), the processing of parts with extremely high precision requirements, commonly used high-value cutting tools covering more than 80 kinds of cubic boron nitride tools, special milling cutters, etc., and the price of some of the special cutting tools reaches RMB 100,000 yuan, with the annual consumption of 200 high-value cutting tools at an average price of RMB 8,000 yuan / one. The pain points under the traditional management mode are prominent: equipped with 4 tool managers, annual labor cost of 400,000 yuan; tool loss rate of 22%, annual loss cost of 352,000 yuan; inventory capital consumption of 1.2 million yuan, annual capital consumption cost of 52,200 yuan; due to insufficient tool precision, mismatch of the workpiece caused by the scrapping rate of 3.8%, the annual reworking, raw material loss costs of 500,000 yuan; downtime Waiting tool rate of 8%, annual downtime loss of 800,000 yuan; hidden management costs of 120,000 yuan, total annual related costs amounted to 2,224,200 yuan, can not meet the demand for high-precision, high-efficiency machining of aviation parts.

2. Implementation process: introduction of 30 groups based on AI+IoT technologyIntelligent tool cabinetIt adopts the mode of “1 master cabinet + N slave cabinets” with flexible capacity expansion, divides the special storage area according to the value, specification and number of axes of the adapted machine tools, and stores the special tools individually and is equipped with an exclusive monitoring module; establishes an intelligent data analysis platform, realizes in-depth synergy with the MES, ERP, and CNC systems, and enables the prediction of the loss of AI cutting tools, Intelligent scheduling and matching, full life cycle traceability; equipped with high-precision temperature and humidity control system and anti-collision device to ensure the safety of special tool storage and stability of precision; establish a regular maintenance system for the equipment, and arrange for a person in charge ofIntelligent tool cabinetThe daily maintenance and data backup; optimize the tool calibration process, according to the calibration reminder pushed by the system, regularly calibrate the tool to ensure that it meets the machining accuracy requirements of multi-axis machine tools.

3. Cost-effectiveness enhancement effect: after the implementation, the workshop realized lean and intelligent upgrading of high-value tool management, and cost-effectiveness enhancement is remarkable. Firstly, in terms of labor cost, the tool manager is reduced from 4 to 1, saving 270,000 RMB in labor cost; secondly, in terms of loss cost, the tool loss rate is reduced from 22% to 2.8%, saving 307,200 RMB in loss cost; thirdly, in terms of capital consumption cost, the inventory capital consumption is reduced from 1.2 million RMB to 360,000 RMB, saving 36,700 RMB in capital consumption cost; Fourth, in terms of indirect costs, the workpiece scrap rate dropped from 3.8% to 0.15%, reducing rework and raw material loss costs by 482,000 RMB per year; the rate of downtime waiting for tooling dropped from 8% to 0.5%, reducing downtime losses by 760,000 RMB per year; the hidden management costs dropped from 120,000 RMB to 30,000 RMB, saving 90,000 RMB per year; and the total annual savings of 1,945,900 RMB per year. At the same time, the utilization rate of multi-axis machine tools increased from 78% to 92%, with an annual new output value of 1.8 million yuan, a comprehensive annual new benefit of 3.7459 million yuan, and a payback period of only 6.5 months, which not only meets the demand for high-precision machining of aviation parts, but also becomes the industry's benchmark for the intelligent management of high-value cutting tools.

V. AI+IoT Smart Tool Cabinet Application Notes and Industry Trends

Based on AI+IoT technologyIntelligent tool cabinetHigh-value tool management in precision machining workshop has significant cost-effectiveness enhancement value, combined with the complex scene of precision machining workshop and industry application practice, enterprises need to pay attention to the relevant matters in the application process, in order to give full play to its functional advantages; at the same time, combined with the trend of intelligent transformation of high-end manufacturing industry, the rational planning of the application of the strategy, to help enterprises to achieve long-term cost optimization and benefit growth, and further enhance the high-value Tool management level.

(i) Application considerations

1. Adaptation to workshop scenarios and the characteristics of tools and machine tools: Precision machining workshops have a wide variety of tools and specifications, and there are big differences in the requirements for tool adaptation for different axes and models of multi-axis machine tools. Enterprises should make reasonable choices according to the size of their own workshops, the number of multi-axis machines, the number of axes of the machines, the type of tools (ordinary high-value tools, special tools), and the machining needs.Intelligent tool cabinetFor example, special tools should be equipped with exclusive storage compartments and monitoring modules to ensure storage safety and precision stability. For example, special tools need to be equipped with exclusive storage compartments and monitoring modules to ensure storage safety and accuracy stability; high-frequency tools should be placed in the tool cabinet near the corresponding multi-axis machine tool to improve the efficiency of receiving; at the same time, combined with the workshop dust, oil and other environmental characteristics, choose the oil, dust and collision-proof equipment to ensure the long-term stability of equipment operation.

2. Standardize the entry of tool information and label management: the accuracy of tool information is the basis of intelligent control, enterprises in the entry of tool information, need to ensure that specifications, models, unit price, storage time, calibration cycle, service life, adaptable machine tool models and other information is accurate, and regularly update the tool information (eg, tool loss, scrapping, calibration, and timely update of the system data); to strengthen the management of RFID tags, regularly check the integrity of the label to ensure that the label information is consistent with the actual information and system data to avoid the cost-effectiveness of the impact of errors. Strengthen RFID tag management, regularly check the integrity of the tags, timely replacement of damaged, detached, worn out tags, to ensure that the tag information is consistent with the actual information of the tool and the system data, to avoid control loopholes due to incorrect information, which affects the improvement of cost-effectiveness.

3. Strengthening personnel training and equipment maintenance:Intelligent tool cabinetThe operation, system use, data interpretation requires certain professional knowledge, enterprises should strengthen the training of workshop operators, managers, equipment maintenance personnel to ensure that they are proficient in equipment operation, system data view, exception handling, label maintenance and other skills, to avoid improper operation leading to equipment failure, data errors, affecting tool management efficiency and cost control effects; at the same time, the establishment of regular equipment maintenance At the same time, establish a regular maintenance system for the equipment, regularly clean the equipment, check the accuracy of the sensors, maintain the communication module and constant temperature and humidity device, back up the system data, choose professional equipment suppliers, ensure the quality of the equipment and after-sales service, and promptly solve the problems of identification deviation, data jamming, failure and other problems in the process of the equipment operation, so as to ensure the continuous development of tool management.

4. Promoting deep system synergies and process optimization: enterprises are introducingIntelligent tool cabinetWhen, should give priority to the selection of products that can be seamlessly docked with the existing MES, ERP, CNC systems, to break the data silos, to achieve real-time synergies of tool data, production data, inventory data, and to promote the deep integration of tool management with the production process, procurement process; at the same time, according to theIntelligent tool cabinetThe results of data analysis to optimize the tool procurement plan, the use of the program, the calibration process and management process, give full play to the advantages of data-driven to further reduce costs, improve efficiency, to avoid idle equipment and waste of resources.

(ii) Trends in industry development

1. The level of intelligence continues to escalate: with the iteration of artificial intelligence, big data, digital twins, and edge computing technologies, theIntelligent tool cabinetA higher level of intelligence will be realized. Through AI algorithms to accurately predict tool wear trends, optimize scheduling solutions and inventory plans, further reducing manual intervention; combined with digital twin technology, build tool management virtual simulation model, real-time monitoring of the entire life cycle of the tool and offline simulation, advance prediction of abnormal problems, improve the accuracy of management and control; integration of machine vision and laser detection technology, to achieve a more accurate monitoring of tool wear and accuracy, and further Extend the service life of the tool and reduce the cost of loss.

2. Increasing integration: in the future.Intelligent tool cabinetIt will be deeply integrated with high-precision multi-axis machine tools, AGV trolleys, intelligent calibration equipment, etc., to build a whole-process automated tool management and production synergy system, realizing the tool “automatic warehousing-automatic storage-automatic claiming-automatic handling-automatic calibration-automatic scrapping”. automatic calibration - automatic scrapping", completely get rid of artificial dependence, and further improve management efficiency and production efficiency; at the same time, with the supply chain upstream and downstream systems (supplier management system, tool recycling system) in-depth synergy, to achieve the closed-loop management of the whole chain of tool purchasing, use, recycling, optimize the supply chain efficiency and reduce procurement costs. optimize supply chain efficiency and reduce procurement costs.

3. Customization and flexible development: different fields and different sizes of precision machining shops, tool management needs vary greatly, and in the future.Intelligent tool cabinetIt will develop in the direction of customization and flexibilization. Suppliers will design personalized equipment layouts, functional modules and management systems according to the specific machining needs, tool types, workshop layout and multi-axis machine configurations of the enterprises, so as to meet the tool management needs of different scenarios; the modular design will be further optimized to support rapid expansion, functional upgrades and layout adjustments, so as to meet the dynamic changes in workshop operations, and at the same time, low-power, energy-saving components will be adopted to realize green and energy-saving At the same time, low-power consumption and energy-saving components are adopted to realize green and energy-saving operation, which is in line with the requirements of the “dual-carbon” target.

4. Market scale continues to expand: with the acceleration of the transformation of high-end manufacturing to precision and intelligence, more and more precision machining enterprises are aware of the AI+IoTIntelligent tool cabinetThe market demand will continue to grow due to the cost-effective advantages in high-value tool management. According to industry forecasts, the market size of China's smart tool management equipment market is expected to reach 3.5 billion yuan in 2026, of which AI+IoT technology-basedIntelligent tool cabinetAccounting for more than 75%, the annual compound growth rate of up to 60% during 2022-2026, the share of domestic substitution continues to expand, the concentration of the industry continues to improve, its application in the precision machining shop will be more widely used, and become the core equipment for intelligent management of high-value cutting tools.

VI. Conclusion

In the high-end manufacturing precision, intelligent transformation of the background, high-precision multi-axis machine tools, high-value tool management as a precision machining workshop cost reduction and efficiency of the key links, the traditional sloppy management model has not been able to adapt to the modern precision machining, “high precision, high efficiency, low cost” of the development needs of the constraints on the enhancement of the core competitiveness of enterprises, the Bottleneck. Based on AI+IoT technologyIntelligent tool cabinetWith the Internet of Things perception, AI algorithms, intelligent identification, data collaboration and other core technologies, it accurately matches the management needs of high-value cutting tools of “high-value, high-precision, high-loss, strong control”, and adapts to the use of different axes and multi-axis machine tools, through compression of labor costs, reduction of cost of loss, optimization of capital occupation, and reduction of indirect costs, By compressing labor cost, reducing wear cost, optimizing capital consumption, reducing indirect cost, and improving production efficiency, the company realizes a leapfrog improvement in the overall cost-effectiveness of high-value tool management in the precision machining workshop, effectively cracks the core pain point of the traditional management mode, and pushes the transformation of high-value tool management from “sloppy” to “lean and intelligent”.

From the point of view of practical application cases, whether it is a medium-sized precision mold processing workshop or a large aviation parts precision processing workshop, the introduction of AI + Internet of ThingsIntelligent tool cabinetAfter the implementation of the system, it has realized a significant compression of costs and a significant increase in production efficiency, with an outstanding return on investment, which can effectively meet the high-value tool management needs of precision machining enterprises in different fields, and improve the operational efficiency of the workshop, machining accuracy and market competitiveness. With the continuous iteration of technology and the continuous growth of industry demand, theIntelligent tool cabinetIt will develop in the direction of higher intelligence, integration, customization and greening, further integrating new technologies such as digital twin, machine vision, etc., realizing in-depth synergy with the precision machining production process, becoming the core support for high-end precision machining workshop to reduce costs and increase efficiency, and promoting the high-end manufacturing industry to achieve high-quality development.

For precision machining enterprises, should be combined with their own workshop size, the number of multi-axis machine tools, the number of machine axes, tool types and machining needs, the reasonable introduction of AI + Internet of thingsIntelligent tool cabinetIn addition, it standardizes the application process, strengthens personnel training and equipment maintenance, and gives full play to its cost-effectiveness enhancement advantages; at the same time, it keeps up with the development trend of the industry, promotes the in-depth fusion of tool management with digital and intelligent technologies, optimizes the whole life cycle management system of high-value tools, continues to reduce costs and increase efficiency, and seizes the first opportunity in the competition of high-end manufacturing industry and realizes sustainable development.