Smart Systems

Fraunhofer IWU and Fraunhofer IIS: New generation of the ingenious smartTOOL tool holder

September 4, 2025. smartTOOL enables comprehensive process monitoring with complete transparency about 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 sensor integration close to the point of impact. The next generation of the versatile tool holder is now in the starting blocks: with even more powerful electronics and sensors for monitoring process forces and vibrations in all spatial directions and therefore for each individual tool cutting edge – integrated into an even more robust and compact design.

The new generation smartTOOL harmonizes with almost any chuck geometry. Photo: Fraunhofer IWU

Numerous improvements

The initial focus in the further development of the tool holder was on sensor technology. Extensive empirical values from use in many machining applications showed which sensors could be dispensed with and where “sharpening” was required in terms of more sensitive sensors. The result of the extensive revision is an even more compact mechanical design that takes up 25 percent less installation space and can be combined with almost any chuck geometry. Newly developed antennas also ensure increased performance in terms of data transmission rates.

The electronic hardware has also been redeveloped 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 make a more important contribution to component quality assurance than ever before.

The new generation also retains many proven features.

Deployed directly at the point of action

The smart tool holder measures vibrations, process forces and temperatures directly on the tool. The collected data is transmitted wirelessly to an evaluation unit and analyzed. This means that even minimal changes, such as tool wear or slight vibrations, can be detected at an early stage. This not only enables real-time monitoring, but also the optimization and automation of production processes.

Autonomous energy supply and flexibility

The patented energy harvesting solution has also been adopted. It supplies smartTOOL with power permanently and wirelessly – without any external power supply. All that is needed is a small stator component mounted on the machine’s spindle housing. This innovative technology does not restrict the automated tool change or the workspace. As the electronics are located in a compact segment between the chuck and spindle interface, the tool holder can be used flexibly on almost any machine.

Combinable with the flexible automation solution “Edge Cloud Continuum for Production” ECC4P

smartTOOL is tailor-made for milling and drilling processes and, like the products smartGRIND (grinding processes) and smartNOTCH (forming processes), can be integrated into ECC4P. 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 medium-sized manufacturing companies

Premiere at EMO Hannover 2025

The new smartTOOL is celebrating its trade fair premiere at the joint stand of the Fraunhofer Cluster of Excellence Cognitive Internet Technologies (CCIT). In Hall 6, Stand B18, CCIT will be presenting intelligent production technologies based on cognitive internet technologies. One focus is on efficient data acquisition and processing to optimize production processes – as with the smartTOOL.

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