Early tool connectivity implementations were reliant on Bluetooth for cloud data access and sharing, however, this requires a manual connection to a gateway, like a smartphone. The reliance on workers to establish a safe and secure connection presents practical challenges.
So what have been the recent advancements in technology that address these limitations, offering direct and seamless connectivity options that bypass external dependencies and enable workers to remain focused on their jobs?
Direct connectivity of tools to networks and cloud services offers a myriad of benefits, including enhanced productivity and streamlined asset management. For power tools used in construction sites, this means real-time access to data relating to tool maintenance, location, and usage patterns, thereby enabling cost control and operational transparency.
Furthermore, tool Original Equipment Manufacturers (OEMs) can leverage direct connectivity for in-depth tool function analysis, supporting the development of next-generation tools with improved designs and functionalities.
The role of advanced connectivity technologies
The transition from Bluetooth to advanced connectivity technologies such as cellular communication, Wi-Fi sniffing, and high-precision Global Navigation Satellite System (GNSS) is crucial for enabling precise tool location and real-time monitoring.
These technologies offer other distinct advantages in various operational scenarios, ranging from locating where workers are in the event of an emergency, which improves overall safety, to efficient task management and resource allocation. However, the choice of technology is dictated by the specific requirements of the construction site or assembly plant, with considerations for indoor and outdoor positioning accuracy and the need for high-precision positioning in certain applications.
Beyond location services, the implementation of connected tools with advanced connectivity facilitates accurate measurement and analysis to enhance quality control, maintenance and measurement processes. This is particularly relevant in manufacturing and construction industries, where accurate data collection and analysis of connected tool usage can significantly enhance operational efficiency and resource planning.
Figure 1: The connection flow for a power tool connecting to the cloud
Enhancing site operations
Connected test and measurement instruments on building sites, which can be configured and controlled locally, allow for faster and more accurate analysis and results in the field. This simplifies subsequent design processes and documentation.
Connected assembly tools are designed to accurately parameterize the workstation according to the job at hand and record the tightening processes. These tools require the ability to gather and analyse process data throughout the assembly lifecycle program, as well as ensure safety-critical tightening connections comply with VDI/VDE 2862 standards. This analysis also helps companies evaluate quality control and traceability.
Companies that integrate direct connectivity into their assembly plants can increase production efficiencies and flexibility, minimise errors, improve quality control, and obtain important insights into manufacturing processes. Moreover, direct connectivity supports the development of smart and adaptive manufacturing environments, enabling more efficient resource planning and process optimisation.
Addressing challenges and looking ahead
However, the widespread adoption of connected tools raises concerns regarding privacy and data security. It is imperative to establish robust privacy policies and security measures to safeguard employee confidentiality and ensure secure data transmission.
Cellular technology, in particular, offers enhanced security features such as encryption, authentication, and secure firmware updates, contributing to the safe and reliable transmission of data from connected tools to the cloud. This approach not only enhances productivity, safety, and sustainability but also reduces total solution costs and minimises power consumption.
Cellular and Wi-Fi technologies can solve two fundamental aspects for a company: finding the location of a connected tool and getting its data reliably and quickly. These technologies' principal function is to complete these daily duties while increasing productivity, sustainability, and safety. Bluetooth, on the other hand, continues to be the preferred technology for short-distance connectivity.
u-blox has developed a portfolio of solutions that can meet the needs of a construction or assembly site in a variety of ways.
Investments in own IP (indoor/outdoor location, cellular silicon, 5G-NR RedCap), long-term availability, customised features, seamless integration of cellular modules, SIM cards, IPD coverage for Wi-Fi, and enterprise services all help to provide stable and fast communications within these facilities. They also cut overall solution costs and power usage.
u-blox has also established a comprehensive IPR protection strategy for cellular modules, which lowers business risk.
Looking ahead, the landscape of assembly plants is no longer seen as just in the automotive sector but is evolving into construction, driven by digitalization and the increasing reliance on battery-powered, connected tools, where an increasing number of parts are pre-built in plants.
The shift towards technologies that enable direct connectivity and precise location is fundamental to creating more efficient, flexible, and interconnected work environments.
As the industry continues to embrace these advancements, connected tools will become indispensable assets, ensuring the optimal functioning and health of construction and assembly operations into all industrial segments.
Author details: Ludger Boeggering, Senior Principal, Application Marketing EMEA, Energy and Industry 4.0, u-blox
