Enterprise software
The drawing die is becoming the smartest sensor on the line
Every meter of wire passes through the drawing die. No other component on the line experiences the interaction between the wire, lubricant, and tooling so directly. Yet in many plants, dies are still managed primarily as consumables: installed, operated until a scheduled replacement or quality issue, and then discarded. Valuable information generated during the drawing process is lost.
Berlin-based industrial AI company Ailoys aims to capture the information at its source. Proprietary acoustic sensors positioned close to the die detect high-frequency signals generated during deformation. An edge AI device installed in the existing machine’s electrical cabinet analyzes these signals in real time, learning the normal acoustic signature associated with each combination of die, wire, and drawing speed.
When the signature changes, the system can identify deviations before the result in visible wire defects or excessive tool wear.
Listening to the deformation zone
The acoustic signature of a drawing die reflects three critical factors: tool condition, material condition, and lubrication. By distinguishing between these signals, the Ailoys system translates process data into actionable information for operators and machine controls. This can include recommendations for drawing speed adjustments, lubrication checks, die wear alerts, and replacement timing.
One particularly valuable application is wire break prevention. Working with a European equipment manufacturer, Ailoys identified material conditions associated with impending wire breaks and integrated its monitoring system with the machine's programmable logic controller (PLC). Instead of operating continuously at a conservative speed to accommodate occasional material irregularities, the line automatically slows down when an affected wire section approaches the die. Once that section has passed, the machine returns to its optimized drawing speed.
In the reported application, this approach enabled up to 30% higher production speed and 12% less die wear on an existing drawing line, without replacing the machine. The principle is straightforward: the entire production line no longer needs to operate at a speed dictated by the most problematic section of wire.
A drawing die with its own digital record
Vassena Filiere was the first die manufacturer to adopt the approach. Together, the companies have developed what they describe as one of the first drawing dies with integrated AI capabilities. Each Vassena die carries a QR code connecting to a digital record containing its geometry, including its reduction angle, bearing length, and inlet configuration.
Operational data collected during wire drawing is associated with this record, allowing the die manufacturer to analyze how specific geometries perform under actual production conditions. This creates a feedback loop between die design and field performance. Instead of relying primarily on the inspection of returned, worn dies, manufacturers can use operating data to support future tooling improvements.
For wire drawing plants, the same digital infrastructure could enable a die-as-a-service model. Under this approach, the supplier maintains die inventory at the customer's facility, remotely monitors wear, and coordinates replacements. Customers could move from purchasing and stocking large quantities of dies toward a performance-based tooling service.
From process monitoring to automatic machine control
The next step is to connect acoustic monitoring directly with machine operation. At wire Düsseldorf 2026, Kieselstein International presented the first wire drawing machines designed around the Ailoys Edge device. These machines use process information generated by the system to automatically adjust lubrication parameters.
This integration extends the technology beyond condition monitoring. Instead of simply detecting unfavorable drawing conditions, the machine can respond by adjusting the process. For die manufacturers and wire producers, this opens the possibility of maintaining more consistent lubrication conditions, limiting unnecessary tool wear, and improving process stability.
As Sergei Altynbaev, Founder and CEO of Ailoys GmbH, explains:
"The die is the only tool that touches every metre of wire, so that is where we listen. The signal is processed and the decision is made on our edge AI device at the machine, in milliseconds. There is no cloud in the loop: the data never leaves the plant, and the line reacts while the wire is still in the die."
Want to see how it works on your line? Click here to contact Ailoys’ team and request a demo.
Image credits: Ailoys
