1.Application Challenges
Choosing the right tooling for a stamping process is critical to the safety and efficiency of production. Once a die is mismatched, the early stages of the stroke can cause the die to crash, which not only leads to tool and machine damage, but also triggers unplanned downtime, which can sometimes last up to several weeks.
Currently, the operation of identifying the dies and loading the information into the press control software relies heavily on manual operations, where mistakes are inevitable. Common marking methods such as painted or printed serial numbers can become obscured by wear and tear from use, increasing the risk of operational error. Even if staff can read these serial numbers clearly, they may make mistakes when entering them due to manual errors.
The use of bar code scanning based on optical principles of reading technology, from self-adhesive labels to print directly on the mold block or laser-etched Data Matrix code, although to a certain extent to reduce human error, but its durability is still unstable, especially in the case of stains build-up or long detection distance between the scanner and the bar code, this limitation is even more obvious.
In contrast, RFID solutions, perform better in terms of security and readability.

2. Target
The advantages of RFID are not only reflected in the stamping application, it has shown obvious advantages in the field of mold storage. The layout of the mold warehouse can be flexibly adjusted according to user needs, whether it is scattered parts or neat racking system. At any given time, there may be tens to hundreds of dies, some of which are used more frequently, on a weekly basis, while others may be used only once every few years.
To improve stamping productivity, we must ensure that the dies are positioned accurately and quickly. With RFID technology, locating a die is as easy as viewing the information on a computer or cell phone, simply verify the ID using a handheld reader and transfer the die to the press. With ID scanning, we can detect and correct misalignment problems in a timely manner.
Therefore, by marking the molds and confirming the scanning with RFID readers, we can effectively prevent incorrect mold selection or misalignment problems and ensure smooth stamping production.
3.Solution
RFID products have significant advantages, which overcome the limitations of manual identification and traditional optical identification technology.
The RFID system consists of three parts: scanner, ID tag and controller, forming an efficient and automated identification system that not only reads the information from the electronic tag quickly, but also writes the job data into the tag, enabling immediate updating and continuous availability of information. For example, key data such as mold usage, operator job history, and mold-specific setup instructions can be accurately recorded and stored in the tag. In addition, many RFID tags can be flush embedded in metal, ensuring that they are not easily damaged during storage and retrieval.

Utilizing RFID technology for mold confirmation allows for 100% contactless operation. Compared to optical sensor reading methods, RFID reading requires more relaxed positional alignment of the target, thanks to the wide antenna coverage used to read or update tag information. This wide detection area is particularly useful on large stamping presses, especially when the upper and lower dies are stored separately. Failure to properly pair the upper and lower dies during setup can lead to serious die collisions. A single ultra-high frequency (UHF) system can read both the tags mounted on the upper and lower dies before startup, ensuring that they are correctly matched and thus avoiding potential safety risks.

RFID Readers and Tags
Technical Characteristics
Operating frequency: 13.56 MHz
Compliant with ISO 15693
Protection class: IP67/68
ID tags can be embedded flush in metal with a UHF read range of up to 4 meters.
Mounting holes for simple tag installation
Indicator lights on the read/write device provide feedback on the status of the device.
UHF system supports multi-tag reading
4. Product Advantages
The advantages of RFID go far beyond the initial error-proofing application. It has many other important functions, and stamping applications are also an area where the Internet of Things (IIoT) comes into play.
With the die identification feature, we can easily track how long a die has been in use, eliminating the need to manually determine the condition of the die. Preventive maintenance can be automatically triggered, thus avoiding the problem of lower quality production parts due to untimely tool refurbishment.
By combining RFID scanners with sensors, we can get a high-definition view of how the mold is actually being used. Many RFID systems can easily connect to a company’s Manufacturing Execution System (MES)/Enterprise Resource Planning (ERP)/Supervisory Control and Data Acquisition (SCADA) software via standard IIoT communication protocols, such as MQTT, OPC UA, or REST API. This facilitates the transition from traditional manual and spreadsheet performance analysis methods to real-time, error-free status updates. Whether it’s the number of parts produced, the number of maintenance hours remaining, mold locations, availability status, or monthly mold collision rates, all the data you deem important can be viewed anytime, anywhere.
With these advanced features, RFID technology provides powerful visibility and control in the press shop. From preventive maintenance to real-time data monitoring, RFID is helping organizations improve productivity, reduce costs and minimize errors to stay ahead in a competitive marketplace.
5.Product Features
Highlights
Eliminate Human Error with Automatic Die Recognition
Adopting RFID on the press shop floor is one way to reliably improve IIoT efficiency
Reliably eliminates die damage due to die selection and misalignment
Important operational information, such as die usage, can be written to RFID tags.
About Pepperl+Fuchs
Pepperl+Fuchs – Driver and Innovator of the Automation of the Future
Pepperl+Fuchs, headquartered in Mannheim, Germany, offers its customers in the factory automation and process industries around the world a wide range of products for both traditional and future-oriented automation applications thanks to its continuous research and development of innovative technologies. At the same time, Pepperl+Fuchs continues to promote the development of forward-looking technologies, paving the way for its customers to meet the challenges of the upcoming Industry 4.0.
Automation is our world.
Perfect solutions are our goal!

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