In modern production environments, most processes run automatically. To ensure that employees still have an overview of the tools in use and their current position, researchers at Fraunhofer IIS have developed a sensor-based tracking system. To this end, cost-effective inertial and magnetic field sensors are installed on the tool or in its housing. Bluetooth or Wi-Fi is used to forward the results to a central interface, where they are compared with preset parameters. If the values do not match, this can be displayed in the central office or via an LED on the device itself. Locating a tool relative to a workpiece within a given working area is initially performed without needing to set up a separate infrastructure. The locating system is very resistant to other sources of interference and is combined with radiolocation systems within the production environment in order to perform global positioning.

Fraunhofer IIS, together with the BMW Group, presented a project for developing and testing an intelligent screwdriver for assembly use at the Hannover Messe trade fair. A special attachment module directly connected to the IT system receives a job order, uses sensor data to check that the order has been fulfilled, and signals this fact. This allows production employees to always know whether the order has been completed correctly and in full. At the moment, preparation is under way for a test launch on BMW’s production line in Regensburg. This could form the basis for possible expansions of the intelligent tool. In addition to networking, the innovative software from Fraunhofer IIS can also offer analysis of the screwing process, determination of tool movements, and position detection.

Additional fields of application for tool tracking could include monitoring, geofencing, and the documentation of work processes.