smartNOTCH: The embedded forming measurement system

Machine downtime incurs immense costs. Robust sensors installed in the T-slots of the presses can minimize this downtime.

Agility and efficiency in resource utilization are essential for successful manufacturing companies in the metal forming industry. Factors such as time, cost, quality, and flexibility play a crucial role in this regard. Detailed knowledge of processes and equipment across all operating conditions is a crucial factor in this regard, yielding numerous positive effects. Not only is there less scrap, but machine downtime is reduced, and root cause analysis is accelerated. With this information, it is possible to make the tooling-in process and product ramp-ups more knowledge-based and thus more efficient.

At Fraunhofer IWU, a holistic approach is taken to machine and process monitoring. The focus is on comprehensive data acquisition using as few robust sensors as possible, which are easy to retrofit. Decentralized sensors such as the smartNOTCH capture process variables and, using an intelligent evaluation algorithm, provide data for process and quality monitoring during the forming operation. Without affecting the forming process or the machine’s performance, the die clamping stations of presses can become valuable data sources for cognitive manufacturing.

Small sensor – big potential!

The smartNOTCH measurement concept is amazingly simple. The small sensors can be installed directly into the T-slots in a single step and are available for various slot sizes. This makes it possible to collect data at multiple points on the press table or ram, including directly beneath the forming die. Inline and robust.

The basis is the detection of the smallest deformations of the press table and ram during the forming process. For this purpose, the sensors are equipped with several highly sensitive measuring systems that, when necessary, detect elastic deformations with high dynamic response and precision. To keep setup costs low while maximizing the system’s robustness, the sensors communicate via radio from the table or ram side to the evaluation unit through a gateway. Unlike conventional systems, the compact design of the sensors – which is specifically tailored to the application – does not affect the press’s performance. This allows, for example, the machine’s tool mounting space to continue to be fully utilized.

Trend analyses help identify errors more quickly – and take action

The information collected from multiple sources can be analyzed individually or in correlation and linked to other data sources. Trend analyses can be performed during the production process, and process irregularities that lead to changes in process forces or their distribution can be reliably detected. This enables a rapid response when necessary – if desired, directly from cycle to cycle.

smartNOTCH enables knowledge-based tool development

In tool development, a tremendous amount of effort goes into running-in forming tools. During this process, the forming tool is adapted to the elastic properties of the press in order to deliver optimal quality. smartNOTCH can provide information on the elastic deflection of the press during the running-in process. This information can be used to reduce the effort required for running-in and to objectify the acceptance process upon delivery of the forming tools.

Everything is customized – and so is smartNOTCH

Consistently high quality can only be achieved when the process, tool, and machine are perfectly coordinated. This customization is the strength of successful companies in the metal forming industry. To ensure that inline monitoring is also optimally tailored, researchers at Fraunhofer IWU have developed a calibration routine. This allows the smartNOTCH to be adapted to the press’s characteristics.

The system, developed by Fraunhofer IWU within the Cluster of Excellence Cognitive Internet Technologies (CCIT), is currently undergoing industrial testing and validation for various application scenarios.

Whether smartNOTCH is suitable for your application can be efficiently tested. Using an evaluation kit, information can be collected and evaluated either for a short period alongside production or throughout an entire production run. If smartNOTCH delivers the expected benefits, the sensors simply remain in the press.