Case Study Tailored RFID Solution Enhances Precision in Steel Manufacturing

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Elatec GmbH

FAULHABER Drive Systems

Taiwan Machine Tool & Accessory Builders' Association (TMBA)

Wuxi InfiMotion Technology Co., Ltd.

In the world of precision steel manufacturing, tailored solutions are the key to success. When a leading European manufacturer needed a robust reader for an RFID-assisted production system that could withstand the demands of the factory floor, United Access Ltd. stepped up. Discover how innovation and collaboration in the industry are setting new standards.

A leading manufacturer of high-precision, cold-rolled strip steel products depends on RFID authentication to ensure the accurate configuration of machine controls, calling up the exact parameters needed for each part and device. High-precision machining devices are measured at a calibration station, and the individual parameters are stored on a low-frequency (LF) RFID tag on the tool. In production, these data are read dynamically, and the parameters of the machine control system are individually adapted to the tool. The RFID-based machine setup system enables a high degree of workforce automation and reliable tracking of work equipment, enhancing productivity and quality control.
To hold up to the rigors of the factory floor, the reader needed to be able to withstand high temperatures and exposure to aggressive solvents and lubricants. Highly customized software, hardware and communication protocols were required to integrate the reader with machine controls. Read range and reliability were also challenging in an environment full of metal, requiring a customized antenna of several meters. 

Custom RFID Reader Elevates Industrial Efficiency and Integration

ELATEC worked with United Access Ltd., an Austrian system integrator specializing in RFID solutions, to develop a customized reader suitable for an industrial environment. The solution was built around an ELATEC LF OEM reader that supports virtually any 125 kHz transponder technology (since replaced by the TWN4 MultiTech Nano M). United Access Ltd. developed the customized hardware, software and antenna to support the client’s needs. 

The result is a robust industrial reader suitable for use in even the harshest environments. The reader is encased in a sturdy housing that supports RS485, RS232 or USB interfaces. The reader is designed for DIN rail mounting. In this use case up to seven readers can be combined with different station IDs to a single industrial computer via TCP/IP-RS485 converter. The command interface is highly customizable for different applications. In general, up to 32 readers can be combined in a series using jumpers to assign station IDs, allowing easy centralized control of several machine stations. 

United Access developed and implemented a customized communication protocol in collaboration with the plant manufacturer to ensure seamless integration with the industrial computer and Beckhoff machine control software. The solution also required custom reader firmware. LF RFID provides a reliable signal even in metallic environments. The ELATEC reader module supports a wide variety of LF tags, including EM, Q5, ATA and Hitag. A custom external antenna (7-12 m. long) enables reliable reads and extended read range even surrounded by metal components and machines. 

The resulting solution enables accurate reads of LF tags on tools and devices for production automation. Precise measurement data is written to and stored on the LF tag at the measuring station. When the tag is read, the parameters are sent by the machine controls, enabling machine settings to be set dynamically based on precise measurements. This improves efficiency and quality control by eliminating the need to manually enter machine parameters. With robust design and seamless integration, the custom industrial reader supports smart factory solutions in any environment. 

Machine Operator Authentication - Why knowing "who" matters

Secure and reliable machine authentication provides manufacturers with essential data for process and workforce optimization. Learn why "who" matters in machine operation and how authentication enhances quality control, cost efficiency and safety.
Learn more about: 

• The missing link in manufacturing data: Why operator identity is key to optimizing production.

• Benefits of machine authentication: Improving security, quality, and efficiency.

• Workforce Tracking & Optimization: Insights into labor costs, efficiency.

• Implementing machine authentication: Using RFID badges or mobile devices.

• Best practices for deployment: Key factors for seamless integration.

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