Stamping hardware forming optimization method and system

Abstract

The invention relates to the technical field of stamping hardware forming, in particular to a stamping hardware forming optimization method and system.The method comprises the following steps that instantaneous contact information of a plate and a mold in the initial stamping stage is obtained; according to the instantaneous contact information, the forming potential degree of the plate under the current working condition is evaluated; and adjusting the punching stroke or the material flow path in a subsequent execution stage of the current punching cycle according to the evaluation result. And the forming quality and stability of the stamped hardware can be improved.

Description

Technical Field

[0001] This invention relates to the technical field of stamping hardware forming, and specifically to an optimized method and system for stamping hardware forming. Background Technology

[0002] In industrial production, the forming process of stamped hardware parts is a crucial link in the manufacturing process, which places extremely high demands on the precision of parts, production efficiency, and product quality. To ensure forming quality, existing technologies typically use preset operating parameters such as stamping stroke, stamping force, and material feed rate, along with a basic feedback mechanism, to achieve stable production.

[0003] However, in actual mass production, even if obvious defects are solved through experience optimization in the early stages, unpredictable hidden problems may still occasionally occur in subsequent mass production, such as uneven surface texture, slight local dents, or springback hovering at the tolerance edge. Summary of the Invention

[0004] The purpose of this invention is to address the aforementioned shortcomings by proposing an optimized method and system for forming stamped hardware parts.

[0005] The present invention adopts the following technical solution:

[0006] An optimization method for forming stamped hardware parts includes the following steps: obtaining instantaneous contact information between the sheet metal and the die at the initial stage of stamping; evaluating the forming potential of the sheet metal under the current working conditions based on the instantaneous contact information; and adjusting the stamping stroke or material flow path in the subsequent execution stage of the current stamping cycle based on the evaluation results.

[0007] This technical solution enables real-time sensing, intelligent evaluation, and adaptive adjustment of the stamping process, effectively addressing various dynamic changes during the stamping process. This significantly improves the forming quality and stability of stamped hardware parts, solving hidden defect problems that are difficult to address using traditional methods.

[0008] Furthermore, the steps for assessing the forming potential of the sheet metal under current operating conditions include: applying a transient stimulus to the stamping equipment; capturing the transient local response of the sheet metal to the transient stimulus; extracting response feature quantities sensitive to the transient stimulus; obtaining a dynamic reference pattern based on historical process data and / or simulation modeling; and assessing the forming potential of the sheet metal under current operating conditions based on the comparison of response feature quantities and dynamic reference patterns, as well as the correlation between different response feature quantities.

[0009] Furthermore, the steps for adjusting the stamping stroke include: real-time monitoring of the instantaneous response speed and displacement accuracy of the actuators of the stamping equipment; dynamic adjustment of the control parameters of the servo drive system based on the instantaneous response speed and displacement accuracy to compensate for inconsistent responses or accuracy drift of the actuators; calculation of the plastic flow trend and springback characteristics of the material in the subsequent deformation stage of the current stamping cycle based on real-time operating parameters; dynamic correction of the stamping stroke depth, slide speed curve, and servo blank holder force distribution scheme based on the plastic flow trend and springback characteristics of the material in the subsequent deformation stage of the current stamping cycle; real-time monitoring of the micro-vibration modes and temperature changes in the key stress areas of the die; identification of potential wear risks caused by local stress concentration or abnormal friction based on the micro-vibration modes and temperature changes; and introduction of a local unloading or slow-release stage in the stamping stroke adjustment based on the potential wear risks.

[0010] Furthermore, the steps for adjusting the material flow path include: continuously acquiring the instantaneous deformation state and local stress conditions of the sheet metal within the mold cavity; calculating the local strain rate and stress distribution of the sheet metal in real time based on the instantaneous deformation state and local stress conditions; dynamically predicting the plastic flow trend and springback characteristics of the sheet metal in subsequent deformation trends based on the local strain rate and stress distribution; dynamically adjusting the distribution ratio of the blank holder force in different regions based on the plastic flow trend and springback characteristics of the sheet metal in subsequent deformation trends, and correcting the material flow path in combination with local friction conditions and forming limit constraints; during the correction process, adjusting the distribution ratio of the blank holder force in different regions, the weight and application area of ​​local friction conditions and forming limit constraints based on the geometric characteristics of the mold cavity and the current deformation degree of the sheet metal.

[0011] Furthermore, the dynamic correction step further includes a coordination and optimization step for forming targets, specifically including: acquiring the instantaneous forming state of different regions of the stamped part in real time; identifying the degree of deviation of the forming targets in different regions of the stamped part based on the instantaneous forming state, and determining the priority of the forming targets in different regions of the stamped part; dynamically adjusting the weight and range of the region allocation parameters in the distribution scheme of the stamping stroke depth, the slide speed curve, and the servo blank holder force according to the forming target priority; and calculating and generating coordinated correction instructions based on the weight and range of the parameters to balance the conflict of forming targets in different regions of the stamped part.

[0012] Furthermore, the steps for real-time acquisition of the instantaneous forming state of different regions of the stamped part include: acquiring local contact pressure, micro-strain, and ultrasonic transmission signals in complex geometric regions of the stamped part using micro-sensors integrated on the surface of the mold cavity; during high-speed stamping, employing a multi-channel synchronous data acquisition system, combined with a timestamp calibration mechanism, to synchronize the data of the instantaneous forming state of different regions of the stamped part in time; and for oil stains, scratches, or reflective properties inherent in the material itself on the surface of the stamped part, utilizing multispectral imaging technology, combined with polarized light filtering and image enhancement processing, to perform multispectral imaging of the stamped part surface, followed by polarized light filtering and image enhancement processing to filter out interference and obtain high signal-to-noise ratio data. Surface smoothness and edge contour information; by establishing a data fusion mechanism, the high signal-to-noise ratio surface smoothness and edge contour information obtained from local contact pressure, micro-strain, ultrasonic transmission signals, and multispectral imaging technology are combined with real-time environmental vibration monitoring data to distinguish two types of anomalies: one type is the anomaly of the instantaneous forming state caused by material microstructure inhomogeneity, local stress concentration, or mold wear; the other type is the signal fluctuation caused by the noise of the micro-sensor itself or environmental vibration. For stamped parts with multi-layer structures or composite materials, high-frequency ultrasonic phased array scanning technology is used to penetrate the surface material of stamped parts with multi-layer structures or composite materials to obtain the instantaneous thickness changes of internal layers and the interlayer bonding state.

[0013] Further, the steps for acquiring local contact pressure, micro-strain, and ultrasonic transmission signals include: within the confined space corresponding to the complex geometric region of the stamped part inside the mold, different types of micro-sensors are interleaved and implanted in the micro-array channels pre-set on the surface of the mold cavity. These micro-sensors include piezoelectric thin-film sensors, fiber Bragg grating sensors, and micro-ultrasonic transducers. The piezoelectric thin-film sensors are used to acquire local contact pressure signals, the fiber Bragg grating sensors are used to acquire micro-strain signals, and the micro-ultrasonic transducers are used to acquire ultrasonic transmission signals. By optimizing the spatial arrangement of the micro-sensors in the micro-array channels, different types of micro-sensors form complementary coverage in the local area, thereby improving the density and coverage of data acquisition. Time-division multiplexing or frequency-division multiplexing technology is used to synchronously acquire local contact pressure, micro-strain, and ultrasonic transmission signals. Multi-scale spatial interpolation and fusion processing are performed on the local contact pressure, micro-strain, and ultrasonic transmission signals to compensate for local data loss and generate a comprehensive data field reflecting the instantaneous forming state of the complex geometric region.

[0014] Furthermore, the steps for time synchronization of data on the instantaneous forming state of different areas of the stamped part include: pre-setting multiple reference points with known physical distances on the mold or stamped part; synchronously measuring the instantaneous position of the reference points using laser ranging or a vision system during the stamping process; calculating and compensating for the acquisition and transmission delays of data acquisition channels corresponding to various sensors used for acquiring local contact pressure, micro-strain, ultrasonic transmission signals, high signal-to-noise ratio surface flatness and edge contour information obtained by multispectral imaging technology, and real-time environmental vibration monitoring data, based on the instantaneous position of the reference points, thereby achieving time synchronization of data on the instantaneous forming state of different areas of the stamped part; deploying multiple time synchronization modules; and integrating the outputs of multiple time synchronization modules. The system incorporates a hardware-level signal preprocessing unit in the data acquisition channel to denoise and filter the raw signals from various sensors, thereby improving the accuracy of timestamp extraction. During system startup or operational mode switching, a rapid time synchronization calibration process is triggered, which includes acquiring short-term high-frequency data and establishing initial time synchronization based on this data. During normal system operation, an adaptive filtering time synchronization algorithm is used to adjust the synchronization based on the initial time synchronization results. A self-calibration module is integrated; this module periodically sends known timing test signals to the data acquisition channels corresponding to various sensors and adjusts the internal clock or timestamp calibration parameters based on the response timing deviations of the data acquisition channels corresponding to various sensors.

[0015] Furthermore, the step of presetting multiple reference points with known physical distances on the mold or stamping part includes: applying a layer of plastic polymer material to the surface of the mold or stamping part; and using microfluidics or microimprinting technology to form micro-cavity structures with specific geometric shapes, sizes and array arrangements as reference points in the polymer material layer.

[0016] This application also discloses a stamping hardware forming optimization system, applied to the above-mentioned stamping hardware forming optimization method. The system includes: an information acquisition module for acquiring instantaneous contact information between the sheet metal and the die in the initial stage of stamping; a potential assessment module for assessing the forming potential of the sheet metal under the current working conditions based on the instantaneous contact information; and a parameter adjustment module for adjusting the stamping stroke or material flow path in the subsequent execution stage of the current stamping cycle based on the assessment results.

[0017] This technical solution provides an intelligent system that integrates information acquisition, potential assessment, and parameter adjustment, enabling closed-loop control and optimization of the stamping process. It effectively solves the problems of dynamic changes and hidden defects that are difficult to deal with in traditional stamping production, and significantly improves production efficiency and product quality.

[0018] This application significantly improves the forming quality and stability of stamped hardware parts, thereby maintaining high forming quality under complex and dynamically changing production conditions, and has remarkable and excellent technical effects.

[0019] To further understand the features and technical content of the present invention, please refer to the following detailed description and drawings of the present invention. However, the drawings provided are for reference and illustration only and are not intended to limit the present invention. Attached Figure Description

[0020] Figure 1 This is a flowchart of an optimized method for forming stamped hardware parts according to the present invention;

[0021] Figure 2 This is a schematic diagram of the structure of an optimized forming system for stamped hardware parts according to the present invention. Detailed Implementation

[0022] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can understand the advantages and effects of the present invention from the content disclosed in this specification. The present invention can be implemented or applied through other different specific embodiments, and various details in this specification can also be modified and changed based on different viewpoints and applications without departing from the spirit of the present invention. Furthermore, the accompanying drawings of the present invention are for simple illustrative purposes only and are not depictions of actual dimensions; this is stated in advance. The following embodiments will further describe the relevant technical content of the present invention in detail, but the disclosed content is not intended to limit the scope of protection of the present invention.

[0023] This embodiment provides an optimized method and system for forming stamped hardware parts, combined with... Figure 1 and Figure 2 As shown.

[0024] refer to Figure 1 An optimized method for forming stamped hardware parts, the method comprising the following steps:

[0025] Obtain instantaneous contact information between the sheet metal and the die during the initial stamping stage;

[0026] Based on instantaneous contact information, assess the forming potential of the sheet material under the current working conditions;

[0027] Based on the evaluation results, the stamping stroke or material flow path is adjusted in the subsequent execution phase of the current stamping cycle.

[0028] The term "initial stamping sheet" as used in this application refers to a metal sheet that has not yet undergone significant plastic deformation at the beginning of the stamping process. "Die" refers to the tool used to stamp and form the sheet metal, typically consisting of an upper die and a lower die. "Instantaneous contact information" refers to real-time physical state data of the contact area between the sheet metal and the die during the stamping process, such as contact pressure, contact area, and coefficient of friction. "Forming potential" refers to the ability or tendency of the sheet metal to continue plastic deformation and ultimately form a qualified stamped part under the current stamping conditions; it reflects the sheet metal's ability to resist defects (such as cracking, wrinkling, excessive springback, etc.) in its current state. "Stamping stroke" refers to the distance the slide of the stamping equipment moves from the top dead center to the bottom dead center; its depth, speed curve, and other parameters directly affect the deformation process of the sheet metal. "Material flow path" refers to the microscopic or macroscopic movement trajectory and direction of the material when it undergoes plastic deformation within the die cavity; it is affected by factors such as blank holder force, die geometry, and friction conditions.

[0029] In the optimization method for forming stamped hardware parts, the first step is to obtain the instantaneous contact information between the sheet metal and the die during the initial stage of stamping. This step can be achieved in several ways. For example, a pressure sensor array can be integrated into the die cavity surface to monitor the contact pressure distribution between the sheet metal and the die in real time. These pressure sensors can be piezoelectric sensors, which acquire pressure data by measuring the change in charge generated by the piezoelectric material under force; or they can be resistance strain gauge sensors, which calculate the pressure by measuring the change in resistance value with strain. Another approach is to use an optical measurement system, such as a high-speed camera combined with image processing technology, to capture the morphological changes of the contact area between the sheet metal and the die during the initial stage of stamping, and indirectly obtain contact information, such as the trend of contact area changes, by analyzing the image data. In addition, acoustic sensors can be used to monitor the sound wave signals generated when the sheet metal and the die contact during the initial stage of stamping, and the contact state can be determined by analyzing the frequency and amplitude characteristics of the sound waves.

[0030] After acquiring instantaneous contact information, the next step is to assess the forming potential of the sheet material under the current working conditions based on this information. There are various methods for assessing forming potential. One approach is to establish an expert system based on empirical rules. This system pre-defines a series of rules, such as "if the contact pressure is too high in a certain area, the forming potential decreases," or "if the contact area change rate is abnormal, there is a risk of wrinkling." The system matches the corresponding rules based on the real-time instantaneous contact information, thus providing a qualitative or semi-quantitative assessment of the forming potential. Another approach is to use a simulation method based on a physical model. By establishing a finite element model of the sheet material's plastic deformation, the real-time instantaneous contact information is used as the model's boundary conditions or input parameters for rapid simulation calculations. This predicts the stress and strain distribution of the sheet material in subsequent deformation stages, and the forming potential is assessed based on these predictions. For example, if the simulation predicts that the local strain exceeds the material's forming limit, the forming potential is considered low. Furthermore, machine learning models can also be used for assessment. By collecting a large amount of historical stamping data, including instantaneous contact information, final forming quality, and corresponding forming potential labels, a machine learning model (such as support vector machine, neural network, etc.) is trained to predict the current forming potential based on new instantaneous contact information.

[0031] Based on the evaluation results, adjustments to the stamping stroke or material flow path are needed in the subsequent execution phases of the current stamping cycle. Adjusting the stamping stroke can be achieved in the following ways. For example, if the evaluation results indicate low sheet metal forming potential and a potential risk of cracking, the deformation rate can be slowed down by adjusting the slider speed curve of the stamping equipment. This can be achieved by modifying the control commands of the servo drive system, such as reducing the slider speed at specific deformation stages. Another approach is to adjust the depth of the stamping stroke. If the evaluation results indicate that the sheet metal may have excessive springback, the depth of the stamping stroke can be increased to allow the sheet metal to undergo more sufficient plastic deformation within the die cavity, thereby compensating for the springback. This can be achieved by adjusting the bottom dead center position of the stamping equipment.

[0032] Adjusting the material flow path can be achieved in several ways. For example, if an assessment indicates a risk of wrinkling in a certain area of ​​the sheet metal, the material flow path can be altered by adjusting the distribution ratio of the blank holder force in different areas. This can be achieved by setting multiple independent blank holder force control units on the die blank holder ring, each capable of applying a different blank holder force independently. By increasing the blank holder force in the wrinkling area, excessive material inflow can be suppressed, thus preventing wrinkling. Another approach is to adjust local friction conditions. For example, by coating the die surface with lubricants of different friction coefficients, or by locally heating / cooling the die surface, the friction between the sheet metal and the die can be altered, thereby guiding the material to flow in the desired direction. Furthermore, forming constraints can be adjusted. For instance, adjustable limit blocks can be installed within the die cavity; by changing the position or shape of these limit blocks, the flow direction of the material can be restricted or guided, thereby optimizing the material flow path.

[0033] Specifically, when the stamping equipment starts working, the information acquisition module acquires real-time information on the instantaneous contact between the sheet metal and the die during the initial stamping stage. This information may include key parameters such as contact pressure, contact area, and coefficient of friction. Subsequently, the potential assessment module evaluates the forming potential of the sheet metal under the current working conditions based on this instantaneous contact information and a preset assessment model or algorithm. For example, if the assessment results show abnormal contact pressure or excessively rapid change in contact area, it may indicate a risk of cracking or wrinkling in that area, indicating a low forming potential. Based on the assessment results from the potential assessment module, the parameter adjustment module dynamically adjusts the stamping stroke or material flow path in subsequent execution stages of the current stamping cycle. For example, if the assessment results indicate a risk of cracking, the parameter adjustment module may instruct the stamping equipment to reduce the buffer pressure speed or adjust the depth of the stamping stroke to reduce local stress concentration. If the assessment results indicate a risk of wrinkling, the parameter adjustment module may adjust the distribution ratio of the blank holder force in different areas to suppress excessive material inflow. Through this closed-loop real-time feedback and adjustment mechanism, the method of this application can effectively cope with various dynamic changes in the stamping process and ensure the forming quality of the stamped parts.

[0034] This application further proposes a method for evaluating the molding potential of sheet metal under current operating conditions, the steps of which include:

[0035] Apply instantaneous stimulation to the stamping equipment;

[0036] Capture the instantaneous local response of the board material to instantaneous stimuli;

[0037] Extract response features that are sensitive to transient stimuli;

[0038] Dynamic reference patterns are obtained based on historical process data and / or simulation modeling.

[0039] The forming potential of the sheet material under the current working conditions is evaluated by comparing the response characteristics and the dynamic reference mode, as well as the correlation between different response characteristics.

[0040] Specifically, applying instantaneous stimulation to stamping equipment can be understood as applying a brief, controllable energy input to the sheet metal or mold during the stamping process through non-contact or micro-contact methods, such as micro-pulse lasers, high-frequency sound waves, micro-currents, or local micro-vibrations. The purpose is to stimulate the instantaneous elastic or plastic response of the sheet metal under the current stress state, in order to reveal subtle changes in its internal structure and mechanical properties.

[0041] Capturing the instantaneous local response of a material to a transient stimulus involves using highly sensitive sensors, such as piezoelectric sensors, fiber optic sensors, or high-speed camera systems, to monitor in real time the rapid changes in physical quantities such as surface vibration, strain, temperature, or acoustic emission of the material after it has been subjected to a transient stimulus. The aim is to obtain dynamic behavior data of the material under micro-disturbances, which can reflect the current state of the material and its potential deformation trends.

[0042] In practical applications, extracting response features sensitive to transient stimuli specifically refers to identifying and quantifying parameters closely related to sheet metal forming performance from captured transient local response data using signal processing and feature extraction algorithms. These parameters include response amplitude, frequency, attenuation rate, phase difference, or energy spectral density. The aim is to transform complex raw response data into concise and meaningful indicators for subsequent analysis and comparison.

[0043] Furthermore, obtaining a dynamic reference pattern based on historical process data and / or simulation modeling can be understood as establishing a dynamic response pattern of the ideal forming state of sheet metal under different stamping conditions through statistical analysis of process data from a large number of successfully stamped hardware parts, or through numerical simulation methods such as finite element simulation. The purpose is to provide a benchmark for measuring the degree of deviation of the current sheet metal response.

[0044] The evaluation of the sheet metal's forming potential under current operating conditions involves comparing the response characteristics with the dynamic reference pattern and analyzing the correlations between different response characteristics. This includes comparing the response characteristics extracted from the current stamping cycle with a preset dynamic reference pattern, and simultaneously analyzing the interrelationships between different response characteristics, such as their correlation, synergistic changes, or abnormal patterns. The aim is to comprehensively determine whether the sheet metal is in an ideal forming state, whether there is localized stress concentration, uneven material hardening, or potential cracking risk, thereby obtaining an evaluation result of the sheet metal's forming potential under current operating conditions.

[0045] In some preferred embodiments, assuming that when stamping a hardware part with complex bending and drawing regions, to accurately assess the forming potential of the sheet metal in the drawing region, a very short-duration (e.g., microsecond-level) ultrasonic pulse can be applied to the drawing region of the sheet metal as an instantaneous stimulus when the stamping slide descends to a specific position, using a micro-piezoelectric actuator integrated on the surface of the die cavity. Simultaneously, an array of micro-ultrasonic receivers arranged on the back of the sheet metal or inside the die captures the instantaneous transmission or reflection response of the sheet metal to this ultrasonic pulse. From these response signals, response characteristics such as ultrasonic propagation velocity, attenuation coefficient, frequency shift, and local acoustic impedance can be extracted. These characteristics are highly sensitive to the material's density, elastic modulus, internal defects, and stress state. For example, a dynamic reference model of the ultrasonic response characteristics of an ideally formed sheet metal at different drawing depths can be established using historical stamping data and finite element simulation. During the actual stamping process, the real-time extracted response characteristics are compared with this dynamic reference model. If a region is found to have a significantly reduced ultrasonic propagation speed, an increased attenuation coefficient, and a large deviation from the reference mode, and this is combined with the phase difference analysis of signals between different receivers, it can be determined that the region may have the risk of excessive material thinning, local stress concentration, or microscopic damage, indicating that its molding potential is low.

[0046] The steps for adjusting the stamping stroke include:

[0047] Real-time monitoring of the instantaneous response speed and displacement accuracy of the actuators in the stamping equipment;

[0048] Based on instantaneous response speed and displacement accuracy, the control parameters of the servo drive system are dynamically adjusted to compensate for inconsistent response or accuracy drift of the actuators.

[0049] Based on real-time operating parameters, calculate the plastic flow trend and springback characteristics of the material in the subsequent deformation stage of the current stamping cycle;

[0050] Based on the plastic flow trend and springback characteristics of the material in the subsequent deformation stage of the current stamping cycle, the depth of the stamping stroke, the slide speed curve, and the distribution scheme of the servo blank holder force are dynamically modified.

[0051] Real-time monitoring of micro-vibration modes and temperature changes in key stress areas of the mold;

[0052] Based on micro-vibration modes and temperature changes, identify potential wear risks caused by localized stress concentration or abnormal friction;

[0053] Based on potential wear risks, a partial unloading or slow-release phase is introduced into the stamping stroke adjustment.

[0054] Specifically, real-time monitoring of the instantaneous response speed and displacement accuracy of the actuators in a stamping equipment refers to continuously acquiring the actual speed and position data of the actuators, such as the press slide, during their movement using high-precision sensors (e.g., laser displacement sensors, encoders). This data is used to evaluate the dynamic performance of the actuators, such as their response time to control commands, the smoothness of acceleration / deceleration, and the accuracy of final positioning.

[0055] The dynamic adjustment of the servo drive system's control parameters based on instantaneous response speed and displacement accuracy can be understood as modifying the PID (proportional-integral-derivative) control parameters, feedforward control parameters, or other advanced control algorithm parameters of the servo motor in real time based on the monitored performance deviations of the actuators. Its purpose is to compensate for changes in the response characteristics of the actuators caused by factors such as mechanical wear, temperature variations, or load fluctuations, ensuring the accuracy and stability of the slider's motion trajectory.

[0056] In practical applications, real-time operating parameters specifically refer to various measurable physical quantities during the stamping process, such as sheet thickness, material hardness, lubrication conditions, and ambient temperature. These parameters affect the mechanical behavior of the material. Calculating the plastic flow trend and springback characteristics of the material in the subsequent deformation stages of the current stamping cycle involves predicting, based on these real-time operating parameters and combined with methods such as material constitutive models and finite element analysis, how the sheet will undergo plastic deformation (such as tension, bending, and shear) in subsequent stamping stages, as well as the amount and direction of springback that may occur after unloading. The purpose is to provide a theoretical basis for accurately adjusting the stamping stroke.

[0057] Furthermore, the dynamic correction scheme for the depth of the stamping stroke, the slider speed curve, and the distribution of the servo blank holder force refers to the real-time adjustment of the final bottom dead center position of the stamping stroke, the slider's movement speed at different stages, and the pressure applied by the servo blank holder in different areas, based on the predicted plastic flow trend and springback characteristics of the material. Its purpose is to optimize material flow within the mold cavity, reduce defects such as wrinkling and cracking, and precisely control the geometry and dimensional accuracy of the final part.

[0058] Furthermore, real-time monitoring of the micro-vibration modes and temperature changes in key stress areas of the mold refers to continuously acquiring the local dynamic response and thermal state of the mold during the stamping process by installing sensors such as miniature accelerometers, strain gauges, and thermocouples inside or on the surface of the mold. Micro-vibration modes can reflect the instantaneous contact state and frictional characteristics between the mold and the sheet metal, while temperature changes may indicate local energy dissipation and the accumulation of frictional heat.

[0059] Therefore, identifying potential wear risks caused by localized stress concentration or abnormal friction based on microscopic vibration modes and temperature changes refers to analyzing monitoring data, such as abnormal vibration frequency or amplitude, or sudden increases in localized temperature, to determine whether the mold shows early signs of wear due to high stress concentration or excessive friction. The aim is to provide early warning of mold failure risks.

[0060] As a preferred implementation, introducing a partial unloading or slow-release stage in the stamping stroke adjustment based on potential wear risk means that when potential wear risk is identified, the stamping stroke is finely adjusted without affecting the forming quality. For example, the stamping force is slightly reduced or the slide speed is lowered in a specific area or at a specific time point to reduce the local load on the mold and extend the mold life.

[0061] In some preferred embodiments, it is assumed that during the production of automotive body panels, slight deviations in the actual displacement accuracy of the slider may occur due to batch variations in sheet metal or mechanical wear caused by prolonged operation of the stamping press. Traditional methods may fail to detect and correct this in a timely manner, resulting in slight understretching or overstretching in localized areas of the stamped part, thereby affecting subsequent assembly accuracy.

[0062] The solution proposed in this application monitors the instantaneous response speed and displacement accuracy of the actuators of the stamping equipment in real time. For example, it continuously acquires the real-time position and speed data of the slider through a high-precision encoder and laser displacement sensor mounted on the slider. Once a deviation between the actual displacement and the theoretical displacement of the slider is detected, the control parameters of the servo drive system are immediately and dynamically adjusted. For example, by modifying the gain parameters of the PID controller, the slider can more accurately follow the preset motion trajectory, thereby compensating for the accuracy drift caused by mechanical wear.

[0063] Meanwhile, during the stamping process, if real-time operating parameters (such as sheet temperature and lubricant viscosity) change, causing slight alterations to the material's plastic flow tendency and springback characteristics, this application will calculate the material's plastic flow tendency and springback characteristics in subsequent deformation stages based on these real-time parameters and using a pre-established material constitutive model and simulation data. For example, if it is predicted that the springback amount in a certain area may be too large, the system will dynamically adjust the depth of the stamping stroke to slightly increase it, or adjust the distribution ratio of the servo blank holder force in that area to more effectively suppress springback.

[0064] Furthermore, in critical stress areas such as the radius (R-angle) of the die, micro-strain gauges and thermocouples are integrated to monitor the die's micro-vibration modes and temperature changes in real time. If an abnormal increase in vibration frequency or a sudden rise in temperature is detected in a certain radius area, it may indicate localized stress concentration or abnormal friction, posing a potential risk of wear. In this case, the system will introduce a local unloading or mitigation phase during the stamping stroke adjustment. For example, when the slider reaches this area, the slider speed is briefly reduced or the blank holder force is finely adjusted to alleviate the instantaneous load in that area, thereby effectively preventing premature die wear, extending die life, and ensuring the surface quality and dimensional stability of the stamped parts.

[0065] This application further proposes steps for adjusting the material flow path, including:

[0066] Continuously acquire the instantaneous deformation state and local stress state of the sheet metal within the mold cavity;

[0067] Based on the instantaneous deformation state and local stress conditions, the local strain rate and stress distribution of the plate are calculated in real time.

[0068] Based on local strain rate and stress distribution, the plastic flow trend and springback characteristics of the plate in subsequent deformation are dynamically predicted.

[0069] Based on the plastic flow trend and springback characteristics of the sheet in the subsequent deformation trend, the distribution ratio of the blank holder force in different areas is dynamically adjusted, and the material flow path is modified in combination with local friction conditions and forming limit constraints.

[0070] During the correction process, the distribution ratio of blank holder force in different areas, local friction conditions, weight of forming limit constraint and area of ​​action are adjusted according to the geometric characteristics of the mold cavity and the current deformation degree of the sheet metal.

[0071] Specifically, continuously acquiring the instantaneous deformation state and local stress conditions of the sheet metal within the mold cavity refers to integrating various sensors, such as strain sensors, pressure sensors, or displacement sensors, onto the mold cavity surface to monitor the geometric changes, thickness distribution, and contact pressure between the sheet metal and the mold during the stamping process in real time. These sensors can provide accurate data on the current degree of deformation and the load borne by the sheet metal. Calculating the local strain rate and stress distribution of the sheet metal in real time based on the instantaneous deformation state and local stress conditions can be understood as using a finite element analysis model or a data-driven machine learning model, taking the real-time data acquired by the sensors as input, to quickly solve for or predict the strain rate and stress field inside the sheet metal. The local strain rate reflects the rate of material deformation, while the stress distribution reveals the internal stress state of the material; both are key indicators for judging the plastic flow behavior of materials. In practical applications, based on local strain rate and stress distribution, the plastic flow trend and springback characteristics of sheet metal in subsequent deformation are dynamically predicted. Specifically, this is based on the material's constitutive model and real-time calculated strain rate and stress data, combined with the kinematic parameters of the stamping equipment, to predict how the sheet metal will continue to deform in the following stamping stroke, including its plastic flow direction and degree, and the amount of elastic springback after unloading. This prediction provides forward-looking guidance for subsequent adjustments. Furthermore, based on the plastic flow trend and springback characteristics of the sheet metal in subsequent deformation, the distribution ratio of the blank holder force in different regions is dynamically adjusted, and combined with local friction conditions and forming constraint, the material flow path is corrected. The purpose is to guide the material flow by actively controlling external conditions. The distribution ratio of the blank holder force in different regions can be achieved through a multi-point servo blank holder system, local friction conditions can be adjusted through the local application of a coating or lubricant on the die surface, and forming constraint can be controlled through adjustable limit blocks or die gaps. The dynamic adjustment of these parameters works together to ensure that the material flows along the expected path and avoids defects. During the correction process, the distribution ratio of blank holder force in different regions, local friction conditions, and the weight and application area of ​​forming constraint are adjusted based on the geometric characteristics of the mold cavity and the current degree of deformation of the sheet metal. The aim is to achieve refined and adaptive material flow control. For example, in areas with sharp bending or deep drawing, it may be necessary to increase the blank holder force or adjust friction conditions to suppress wrinkling; while in areas where material needs to flow rapidly, it may be necessary to reduce the blank holder force or optimize lubrication. The adjustment of weights and application areas ensures that the control strategy can flexibly adapt to the complex geometry of the stamped part and its real-time deformation state.

[0072] In some preferred embodiments, it is assumed that a car body side panel with deep drawing and complex curved surface features needs to be stamped. In the initial stage of stamping, distributed pressure sensors and strain gauges integrated on the die cavity surface continuously acquire the instantaneous contact pressure and local strain of the sheet metal in different areas. For example, in the recessed area of ​​the door handle, due to the deep drawing of the material, its deformation state and local stress conditions are very complex. Based on this real-time data, the system uses a pre-trained machine learning model to quickly calculate the local strain rate and stress distribution in this area, and predicts the plastic flow direction and springback that may occur in subsequent stamping strokes. If the prediction results indicate a risk of wrinkling or cracking in this area, the system immediately and dynamically adjusts the servo blank holder force distribution ratio in that area. For example, increasing the blank holder force in areas prone to wrinkling to suppress material inflow, while appropriately reducing the blank holder force in areas where material flow is required. Simultaneously, the system can also change local friction conditions by locally heating or cooling the die surface, or correct the material flow path by fine-tuning the position of the movable limit block. For example, in the edge region of the side panel, if excessive material springback is predicted, the system may briefly increase the blank holder force in that area before the stamping process ends to compensate for the springback effect. Throughout the correction process, the system dynamically adjusts the weights and areas of application of these control parameters based on the real-time deformation of the side panel and the geometry of the mold cavity, ensuring that the material remains in an optimal flow state throughout the forming process, ultimately resulting in high-quality automotive body side panels.

[0073] This application further proposes that the above-mentioned dynamic correction steps include a coordinated optimization step for the forming target, specifically including:

[0074] Real-time acquisition of the instantaneous forming state of different areas of the stamped part;

[0075] Based on the instantaneous forming state, identify the degree of deviation of the forming target in different areas of the stamped part, and determine the priority of the forming target in different areas of the stamped part;

[0076] Based on the priority of forming targets, dynamically adjust the weight and range of the area allocation parameters in the stamping stroke depth, slide speed curve, and servo blank holder force distribution scheme;

[0077] Based on weights and scope of application, a coordinated correction instruction is calculated and generated to balance the forming target conflicts in different areas of the stamped part.

[0078] Specifically, real-time acquisition of the instantaneous forming state of different areas of a stamped part refers to continuously acquiring key parameters such as deformation, stress, thickness, and surface quality of the stamped part at different locations during the stamping process using various sensors and monitoring technologies. These parameters reflect the forming status of each part of the stamped part at the current moment. For example, micro-sensors integrated on the surface of the mold cavity can be used to acquire local contact pressure, micro-strain, and ultrasonic transmission signals, or multispectral imaging technology can be used to acquire surface flatness and edge contour information.

[0079] This process involves identifying the degree of deviation from the forming target in different areas of the stamped part based on the instantaneous forming state, and determining the priority of the forming target for different areas. This can be understood as comparing the real-time acquired forming state with a preset ideal forming target to quantify the degree of deviation in each area. For example, the thickness of one area may be lower than the design requirement, while another area may show slight wrinkling. Based on this, priorities are set for the forming targets of different areas according to product design requirements, subsequent process requirements, or defect sensitivity. For example, for critical structural areas, the dimensional accuracy and strength requirements may be higher than those for non-critical areas, therefore their forming target priority is higher.

[0080] In practical applications, the weights and ranges of regional allocation parameters in the stamping stroke depth, slide speed curve, and servo blank holder force distribution scheme are dynamically adjusted according to the priority of the forming target. Specifically, during the adjustment of control parameters such as stamping stroke depth, slide speed, and servo blank holder force, the adjustment is no longer uniform, but rather refined based on the priority and deviation of each region, adjusting the influence weights and ranges of these parameters in different regions. For example, for high-priority regions with large deviations, a greater adjustment weight can be assigned, allowing them to dominate in correction commands while limiting their negative impact on low-priority regions.

[0081] Furthermore, based on weights and scope of application, a coordinated correction instruction is calculated and generated to balance the forming target conflicts in different regions of the stamped part. This involves using an optimization algorithm or control strategy to comprehensively consider the forming targets, deviations, priorities, and the weights and scope of adjustment parameters in all regions to calculate a globally optimal or suboptimal correction instruction. This instruction aims to maximize the satisfaction of all high-priority targets while minimizing the negative impact on other targets, thereby achieving a dynamic balance and conflict resolution between the forming targets in different regions.

[0082] In some preferred embodiments, it is assumed that a car body structural component with a deep-drawn region, a curved region, and a flat region needs to be stamped. During the stamping process, the deep-drawn region may face the risk of excessive material stretching leading to thinning or even cracking, while the curved region may experience excessive springback or wrinkling, and the flat region has extremely high requirements for surface flatness.

[0083] Without optimization of the forming target, reducing the blank holder force to prevent cracking in the deep drawing region may cause wrinkling in the bending region; conversely, increasing the blank holder force to prevent wrinkling in the bending region may exacerbate the thinning of the deep drawing region.

[0084] The solution proposed in this application addresses this issue in the following ways:

[0085] First, the instantaneous forming state of different regions of the stamped part is acquired in real time. For example, in the deep drawing region, micro-sensors monitor material thickness changes and local strain; in the bending region, springback angle and surface ripples are monitored; and in the planar region, surface flatness and local stress are monitored.

[0086] Secondly, based on these instantaneous forming states, the degree of deviation from the forming target in each region is identified. For example, the thickness in the deep-drawing region is close to the minimum allowable value, the springback in the bending region exceeds the tolerance, and slight ripples appear in the planar region. At the same time, the forming target priority is determined; for example, the risk of cracking in the deep-drawing region has the highest priority, followed by the springback in the bending region, and finally the surface flatness of the planar region.

[0087] Next, based on these priorities, the weights and ranges of the regional allocation parameters in the stamping stroke depth, slide speed curve, and servo blank holder force distribution scheme are dynamically adjusted. For example, for deep drawing regions, a higher weight is given in blank holder force adjustment to prioritize avoiding cracking; for curved regions, springback may be controlled by adjusting local segments of the slide speed curve; and for planar regions, flatness may be optimized by fine-tuning the blank holder force distribution.

[0088] Finally, based on these weights and scopes of action, the coordinated correction instructions are calculated and generated. These instructions might manifest as follows: at specific stages of the stamping stroke, the blank holder force in the deep drawing region is precisely controlled within a low but safe range to allow material flow; simultaneously, the blank holder force in the bending region is moderately increased, and springback is suppressed through localized slider deceleration; while the blank holder force in the planar region is finely adjusted to ensure uniform contact and surface quality. Through this coordinated optimization, the system can effectively balance the conflicting forming objectives of different regions, ensuring that the entire automotive body structural component achieves high-quality forming while meeting stringent requirements.

[0089] Specifically, the steps for obtaining the instantaneous forming state of different regions of the stamped part in real time include:

[0090] In complex geometric areas of stamped parts, micro-sensors integrated into the mold cavity surface acquire local contact pressure, micro-strain, and ultrasonic transmission signals. During high-speed stamping, a multi-channel synchronous data acquisition system, combined with a timestamp calibration mechanism, synchronizes the data of the instantaneous forming state of different areas of the stamped part. For oil stains, scratches, or the reflective properties of the material itself on the surface of the stamped part, multispectral imaging technology, combined with polarized light filtering and image enhancement processing, is used to perform multispectral imaging of the stamped part surface, followed by polarized light filtering and image enhancement processing to remove interference and obtain high signal-to-noise ratio surface smoothness and edge contour information. A data fusion mechanism is established to combine high signal-to-noise ratio surface flatness and edge contour information obtained from local contact pressure, micro-strain, ultrasonic transmission signals, and multispectral imaging technology with real-time environmental vibration monitoring data to distinguish two types of anomalies: one type is the anomaly of the instantaneous forming state caused by material microstructure inhomogeneity, local stress concentration, or mold wear; the other type is the signal fluctuation caused by the noise of the micro-sensor itself or environmental vibration. For stamped parts with multi-layered structures or composite materials, high-frequency ultrasonic phased array scanning technology is used to penetrate the surface material of stamped parts with multi-layered structures or composite materials to obtain the instantaneous thickness changes of internal layers and the interlayer bonding state.

[0091] Specifically, micro-sensors can include piezoelectric thin-film sensors, fiber Bragg grating sensors, and micro-ultrasonic transducers, which are cleverly integrated into the surface of the mold cavity to capture key physical quantities in real time in complex geometric areas of the stamped part in a non-invasive or micro-invasive manner. Local contact pressure signals reflect the instantaneous force distribution between the mold and the sheet metal, while micro-strain signals reveal the degree and direction of material deformation at the microscopic level, and ultrasonic transmission signals can provide indirect information about the internal structure or thickness changes of the material. These sensors can be arranged in an array according to the geometric complexity and forming requirements of the stamped part to achieve dense monitoring of key areas. In high-speed stamping environments, data acquisition and transmission from various sensors may experience time delays and asynchrony issues. Multi-channel synchronous data acquisition systems are used to simultaneously receive signals from different sensors and ensure strict consistency of all acquired data in the time dimension through a high-precision clock source and timestamp calibration mechanism. This is crucial for accurately analyzing the instantaneous forming state, as any time deviation can lead to misjudgment of the deformation process. The surface of stamped parts may contain oil stains, scratches, or reflective properties of the material itself, which can severely interfere with the detection of surface quality by traditional vision systems. Multispectral imaging technology, by acquiring images at different wavelengths, can effectively distinguish the material itself from surface defects or contaminants. Combined with polarized light filtering, surface reflections can be further suppressed, improving image contrast. Image enhancement processing is used to optimize image quality, such as through denoising and sharpening, ultimately obtaining high signal-to-noise ratio surface smoothness and edge contour information, thereby accurately assessing the surface quality and geometric accuracy of stamped parts. Data acquired by various sensors have different physical meanings and noise characteristics. The data fusion mechanism aims to integrate local contact pressure, micro-strain, ultrasonic transmission signals, and surface information acquired by multispectral imaging, combined with real-time environmental vibration monitoring data. Through advanced signal processing and pattern recognition algorithms, this mechanism can intelligently distinguish between two types of anomalies: one type is the instantaneous forming state anomalies truly caused by process problems such as material microstructure inhomogeneity, local stress concentration, or mold wear. These anomalies directly reflect defects or potential risks in the stamping process. The other type is signal fluctuations caused by external factors such as the noise of the micro-sensor itself or environmental vibrations. These fluctuations do not represent actual forming problems and need to be effectively filtered out to avoid misjudgment. For stamped parts with multi-layered structures or composite materials, the forming state of their internal layers is crucial to the performance of the final product. High-frequency ultrasonic phased array scanning technology can emit and receive high-frequency ultrasonic beams and, by precisely controlling the direction and focus of the beams, penetrate the surface material to perform non-destructive testing of the internal layers. This allows for the acquisition of instantaneous thickness changes and interlayer bonding states of the internal layers, thereby comprehensively evaluating the internal forming quality of composite material stamped parts and promptly detecting defects such as delamination and voids.

[0092] Specifically, the steps described above for obtaining local contact pressure, micro-strain, and ultrasonic transmission signals can be implemented in the following manner.

[0093] In the confined space of the complex geometric region of the stamped part inside the mold, different types of micro sensors are staggered in the micro array channels preset on the surface of the mold cavity. The micro sensors include piezoelectric thin film sensors, fiber Bragg grating sensors and micro ultrasonic transducers. The piezoelectric thin film sensors are used to acquire local contact pressure signals, the fiber Bragg grating sensors are used to acquire micro strain signals, and the micro ultrasonic transducers are used to acquire ultrasonic transmission signals.

[0094] By optimizing the spatial arrangement of microsensors in the microarray channels, different types of microsensors can form complementary coverage in local areas, thereby improving the density and coverage of data acquisition.

[0095] By employing time-division multiplexing or frequency-division multiplexing technology, local contact pressure, micro-strain, and ultrasonic transmission signals are simultaneously acquired.

[0096] By performing multi-scale spatial interpolation and fusion processing on local contact pressure, micro-strain, and ultrasonic transmission signals, local data loss is compensated, and a comprehensive data field reflecting the instantaneous forming state of complex geometric regions is generated.

[0097] Among them, micro-array channels refer to tiny channels or grooves pre-designed and machined on the surface of a mold cavity, with their size and shape precisely controlled to accommodate the implantation of micro-sensors. These channels are typically designed not to affect the overall strength of the mold or the forming quality of the stamped parts. Piezoelectric thin-film sensors are thin-film devices that convert mechanical pressure into electrical signals; they have a fast response speed and are suitable for capturing instantaneous contact pressure. Fiber Bragg grating sensors utilize the reflection characteristics of gratings in optical fibers to reflect light of specific wavelengths, measuring the microscopic strain of materials by monitoring changes in the reflected wavelength, and have the advantage of resistance to electromagnetic interference. Micro-ultrasonic transducers can emit and receive ultrasonic waves, obtaining information such as material thickness changes, internal defects, or interlayer bonding states by analyzing the propagation characteristics of ultrasonic waves in materials (such as transmission time and attenuation). The interleaving of different types of micro-sensors aims to utilize the advantages of each sensor to achieve comprehensive monitoring of multiple physical quantities within a limited space.

[0098] Furthermore, optimizing the spatial arrangement of microsensors within the microarray channels means precisely planning the positions of different sensor types based on the characteristics of complex geometric regions in the stamped part, such as large curvature variations, high stress concentration risks, or complex material flow. For example, in areas prone to wrinkling or cracking, the density of fiber Bragg grating sensors can be increased; in areas with drastic changes in blank holder force, piezoelectric thin film sensors can be densely arranged. This optimized arrangement allows different sensor types to complement each other in local areas, thereby improving the precision and coverage of data acquisition for the instantaneous forming state.

[0099] Furthermore, employing time-division multiplexing (TDM) or frequency-division multiplexing (FDM) techniques to synchronously acquire local contact pressure, micro-strain, and ultrasonic transmission signals ensures temporal consistency of data from multiple sensors sharing the same data transmission channel. TDM allocates specific time slices to each sensor for data transmission in turn, while FDM assigns a different carrier frequency to each sensor. Both techniques effectively avoid data ambiguity and ensure that data from different physical quantities can be accurately correlated to the same time point during high-speed stamping, providing a reliable foundation for subsequent analysis.

[0100] Furthermore, multi-scale spatial interpolation and fusion processing of local contact pressure, microstrain, and ultrasonic transmission signals aims to overcome the limitations of the limited number of sensors and the lack of localized data. Multi-scale spatial interpolation technology can predict physical quantities in sensor-free areas using mathematical models based on data from known sensor points, thereby generating a continuous spatial data field. Fusion processing integrates data from different types of sensors. For example, combining local contact pressure data with microstrain data allows for a more accurate assessment of the material's plastic deformation behavior; combining ultrasonic transmission signals with surface strain data provides a more comprehensive understanding of the material's internal structural changes and surface morphology. This results in the generation of a comprehensive data field reflecting the instantaneous forming state of complex geometric regions, containing richer and more complete information.

[0101] This application further proposes steps for time synchronization of data on the instantaneous forming state of different regions of a stamped part, including:

[0102] Pre-set multiple reference points with known physical distances on the mold or stamping part;

[0103] During the stamping process, the instantaneous position of the reference point is simultaneously measured using laser ranging or a vision system;

[0104] Based on the instantaneous position of the reference point, the acquisition and transmission delay of the data acquisition channels of various sensors used to collect local contact pressure, micro-strain, ultrasonic transmission signals, high signal-to-noise ratio surface flatness and edge contour information obtained by multispectral imaging technology, as well as real-time environmental vibration monitoring data, are calculated and compensated, thereby achieving time synchronization of data on the instantaneous forming state of different areas of the stamping part.

[0105] Deploy multiple time synchronization modules;

[0106] Integrate the outputs of multiple time synchronization modules;

[0107] A hardware-level signal preprocessing unit is introduced into the data acquisition channel;

[0108] The raw signals from various sensors are denoised and filtered to improve the accuracy of timestamp extraction.

[0109] When the system starts up or the operating condition changes, a fast time synchronization calibration process is triggered. The fast time synchronization calibration process includes collecting short-time high-frequency data and establishing initial time synchronization based on the short-time high-frequency data.

[0110] During the normal operation phase of the system, an adaptive filtering time synchronization algorithm is used to make adjustments based on the initial time synchronization results.

[0111] Integrated self-calibration module;

[0112] The self-calibration module periodically sends test signals with known timing to the data acquisition channels corresponding to various sensors, and adjusts the internal clock or timestamp calibration parameters according to the response timing deviation of the data acquisition channels corresponding to various sensors.

[0113] Specifically, multiple reference points with known physical distances are pre-set on the mold or stamped part. These reference points serve as spatial and temporal benchmarks for subsequent displacement measurement and time calibration. For example, these reference points can be specific geometric marks on the surface of the mold cavity or microstructures formed on the surface of the stamped part through specific processes. During the stamping process, the instantaneous position of the reference points is simultaneously measured using laser ranging or a vision system to obtain high-precision real-time displacement information. Laser ranging systems can provide high-frequency, high-precision distance data, while vision systems can provide multi-dimensional position and attitude information. The combination of the two can comprehensively capture the dynamic changes of the reference points. Based on the instantaneous position of the reference points, the acquisition and transmission delays of the data acquisition channels corresponding to various sensors used to collect local contact pressure, micro-strain, ultrasonic transmission signals, high signal-to-noise ratio surface flatness and edge contour information obtained by multispectral imaging technology, and real-time environmental vibration monitoring data can be calculated and compensated. This means that the system can deduce and correct the time deviation between data streams from different sensors based on the synchronicity of actual physical motion, thereby achieving time synchronization of data on the instantaneous forming state of different areas of the stamped part.

[0114] To further enhance the robustness and accuracy of synchronization, multiple time synchronization modules can be deployed. These modules can employ different synchronization strategies or algorithms, such as hardware clock synchronization, network time protocol synchronization, or event-triggered synchronization. By fusing the outputs of multiple time synchronization modules, redundant information can be used for cross-validation and error correction, thereby improving the overall reliability of synchronization. Introducing a hardware-level signal preprocessing unit into the data acquisition channel aims to denoise and filter the raw signals from various sensors before the data enters the main processing system. For example, analog low-pass filters can be used to remove high-frequency noise, or digital filters can be used for signal smoothing.

[0115] During system startup or operating condition switching, a rapid time synchronization calibration process is triggered. This process includes acquiring short-term high-frequency data and establishing initial time synchronization based on this data. This rapid calibration mechanism ensures that the system quickly reaches a basic synchronization level under new operating conditions. During normal system operation, an adaptive filtering time synchronization algorithm is used for adjustment based on the initial time synchronization results. The adaptive filtering algorithm can dynamically adjust synchronization parameters according to the characteristics of the real-time data stream, such as Kalman filtering or extended Kalman filtering, to cope with nonlinear changes and random interference that may occur during the stamping process, thereby maintaining high-precision continuous synchronization. In addition, a self-calibration module is integrated. This self-calibration module periodically sends test signals with known timing to the data acquisition channels corresponding to various sensors, and adjusts the internal clock or timestamp calibration parameters according to the response timing deviation of the data acquisition channels corresponding to various sensors.

[0116] The solution presented in this application effectively addresses the challenge of time synchronization for data from multiple heterogeneous sensors because it constructs a multi-layered, multi-dimensional synchronization calibration system. First, by pre-setting reference points with known physical distances on the mold or stamped part, and using laser ranging or a vision system to synchronously measure the instantaneous positions of these reference points, an external, high-precision physical motion benchmark is provided for the entire system. Because physical motion is continuous and measurable, the system can use this benchmark to inversely calculate and compensate for the inherent acquisition and transmission delays of different sensor data acquisition channels. This physical event-based synchronization mechanism fundamentally solves the problem of misalignment of data streams from different sensors on the time axis. Second, by deploying multiple time synchronization modules and fusing their outputs, this application introduces redundancy and diversity in the synchronization strategy. Different modules may be adept at handling different types of delays or noise; their fused output provides a more robust and accurate synchronization result, effectively reducing the errors that may arise from a single synchronization method. Furthermore, the introduction of a hardware-level signal preprocessing unit ensures the quality of the original signal, providing high-quality input data for subsequent timestamp extraction and synchronization algorithms, avoiding synchronization errors caused by signal noise. The combination of a rapid time synchronization calibration process and an adaptive filtering time synchronization algorithm ensures the system's dynamic adaptability during startup and operation. Rapid calibration ensures the accuracy of initial synchronization, while adaptive filtering enables the system to continuously track and adjust to cope with complex dynamic changes during the stamping process. Finally, the integration of a self-calibration module, by periodically sending test signals and analyzing response deviations, enables continuous optimization and correction of the system's internal clock and calibration parameters. This proactive, closed-loop calibration mechanism ensures that the time synchronization accuracy does not decrease due to environmental changes or component aging during long-term operation, thereby maintaining the accuracy and reliability of the entire stamping hardware forming optimization method.

[0117] In some preferred embodiments, it is assumed that during the stamping process of an automotive body panel, multiple sensors need to be deployed in the complex curved surface areas of the mold cavity and the edge areas of the stamped part. These include piezoelectric film sensors for measuring local contact pressure, fiber Bragg grating sensors for measuring micro-strain, miniature ultrasonic transducers for acquiring ultrasonic transmission signals, and high-speed cameras for multispectral imaging. To achieve precise time synchronization of these sensor data, tiny reference points with known geometric dimensions are first preset at several key locations in the mold cavity and specific non-deformable areas of the stamped part. During the stamping process, these reference points are synchronously monitored by a laser rangefinder and a high-frame-rate vision system mounted outside the stamping equipment, acquiring their three-dimensional instantaneous positions in real time. When the stamping cycle begins, the system triggers a rapid time synchronization calibration process. In this process, all sensors are activated simultaneously and acquire a short period of high-frequency data. By analyzing the timestamps of specific events (e.g., the initial contact moment of the stamping slide) in this data, a preliminary global time synchronization reference is established. During the subsequent normal stamping operation, the system continuously utilizes instantaneous position data of reference points acquired by laser ranging and the vision system, combined with a pre-calibrated sensor acquisition and transmission delay model, to perform real-time time compensation on the data streams of various sensors. For example, if the data transmission delay of a certain piezoelectric film sensor is known to be 50 microseconds, the timestamp of its acquired data will be adjusted forward by 50 microseconds to align with the actual physical event occurrence time. Simultaneously, a hardware-level signal preprocessing unit is integrated into the data acquisition channel. For instance, before the piezoelectric film sensor signal enters the data acquisition card, it passes through an analog low-pass filter to filter out high-frequency noise, ensuring signal clarity and thus improving the timestamp extraction accuracy. Furthermore, the system deploys two time synchronization modules: one based on hardware clock synchronization and the other based on an event-triggered synchronization algorithm. The outputs of these two modules are fused using a weighted average to improve synchronization robustness. To ensure long-term operational accuracy, the system also integrates a self-calibration module. This module automatically sends a preset, precisely timed test pulse signal to all sensors every certain number of stamping cycles (e.g., every 1000 stamping cycles). The system records the response time of each sensor upon receiving the test signal and compares it with a preset timing sequence. If a persistent timing deviation is detected in the data acquisition channel of a certain sensor, the self-calibration module automatically adjusts its internal clock or timestamp calibration parameters to correct this deviation. Through this series of sophisticated time synchronization mechanisms, it ensures that all multi-source heterogeneous sensor data can be time-aligned with extremely high precision in a high-speed, dynamic stamping environment, providing a reliable data foundation for subsequent forming potential assessment and parameter adjustment.

[0118] The steps described above for presetting multiple reference points with known physical distances on the mold or stamping part include:

[0119] Apply a layer of malleable polymer material to the surface of the mold or stamped part;

[0120] In the polymer material layer, micro-cavity structures with specific geometries, sizes and array arrangements are formed as reference points using microfluidics or microimprinting techniques.

[0121] Specifically, the malleable polymer material layer refers to a polymer material with good flexibility, wear resistance, and good adhesion to the surface of the mold or stamped part, such as polyurethane, silicone rubber, or specific photosensitive resins. This material layer is applied to the surface of the mold or stamped part as a substrate to support and protect reference points, aiming to provide a stable reference plane that is not easily affected by the stamping process. Microfluidics or microimprinting technology can be understood as a high-precision, highly repeatable microstructure manufacturing process. Microfluidics typically involves precisely controlling fluid flow in microchannels to form structures, while microimprinting technology replicates intricate structures on the material surface by imprinting a mold with a pre-defined pattern onto a malleable material. Both technologies can precisely form microcavity structures with specific geometries, sizes, and array arrangements within the malleable polymer material layer. These microcavity structures are designed with well-defined geometric features, such as circular, square, or cross-shaped, and are typically in the micrometer to sub-millimeter range in size. They are arranged in a predetermined array pattern to provide clear, identifiable, and physically accurate reference points for subsequent laser ranging or vision systems.

[0122] In some preferred embodiments, for stamping dies of automotive body panels, the surface of the die cavity can be cleaned first, in specific areas such as curved transition zones or deep-drawing areas. Subsequently, a layer of photocurable polymer material with a thickness of approximately 50-100 micrometers is uniformly applied by spraying or scraping. Next, a pre-fabricated silicone or nickel metal microimprinting die is precisely imprinted onto the uncured polymer material layer. This microimprinting die is etched with, for example, square grooves with a side length of 100 micrometers, arranged in a grid pattern with a center-to-center distance of 200 micrometers. After imprinting, the polymer material layer is cured by ultraviolet light irradiation, forming a micro-cavity structure with precise geometry and array arrangement. These micro-cavity structures serve as reference points at known physical distances, and during the stamping process, they can be tracked and imaged in real time by a vision system composed of high-speed cameras, thus providing a high-precision positional reference for the time synchronization of the instantaneous forming state data of the stamped part.

[0123] refer to Figure 2 This application provides a stamping hardware forming optimization system, applied to the above-mentioned stamping hardware forming optimization method. The system includes:

[0124] The information acquisition module is used to acquire instantaneous contact information between the sheet metal and the die during the initial stamping stage;

[0125] The potential assessment module evaluates the forming potential of the sheet material under the current working conditions based on instantaneous contact information.

[0126] The parameter adjustment module adjusts the stamping stroke or material flow path in the subsequent execution phase of the current stamping cycle based on the evaluation results.

[0127] The information acquisition module is used to acquire instantaneous contact information between the sheet metal and the die during the initial stamping stage. Specifically, this module can integrate various sensors, such as pressure sensors, displacement sensors, and vision sensors, to monitor key parameters such as pressure distribution, contact area, and contact time when the sheet metal contacts the die surface after entering the die cavity. These sensors can be placed in critical areas of the die or at appropriate locations on the stamping equipment to ensure high accuracy and real-time performance of the acquired data.

[0128] The potential assessment module evaluates the forming potential of the sheet metal under current operating conditions based on instantaneous contact information. This module can incorporate advanced algorithmic models, such as simulation models based on finite element analysis (FEA), machine learning models, or expert systems, to perform in-depth analysis of the instantaneous contact information provided by the information acquisition module. By comparing real-time data with preset forming standards or historical success case data, this module can predict the risk of defects such as cracking, wrinkling, and springback in the sheet metal during the current stamping cycle and quantify its forming potential.

[0129] Based on the evaluation results, the parameter adjustment module adjusts the stamping stroke or material flow path in the subsequent execution phases of the current stamping cycle. In practical applications, this module can communicate with the servo drive system, hydraulic blank holder system, and other actuators of the stamping equipment. Based on the output of the potential assessment module, the parameter adjustment module can generate precise control commands, such as adjusting the speed curve of the stamping slide, the stamping depth, the magnitude of the blank holder force and its distribution ratio in different areas, or correcting the material flow direction through local friction control to avoid potential forming defects.

[0130] Specifically, the information acquisition module, acting as the system's perception layer, captures the instantaneous contact information between the sheet metal and the die in the initial stages of stamping in real time and accurately, providing a data foundation for subsequent decision-making. The potential assessment module, acting as the system's decision-making layer, uses intelligent algorithms based on this real-time data to quickly and accurately assess the forming potential of the sheet metal and identify potential forming risks. The parameter adjustment module, acting as the system's execution layer, dynamically adjusts the stamping stroke or material flow path in later stages of the stamping cycle based on the assessment results, thereby correcting deviations in real time during the stamping process and preventing defects. It is precisely this mechanism of real-time perception, intelligent assessment, and precise execution that enables the aforementioned optimized forming method for stamped hardware parts to be applied efficiently and stably in actual production, overcoming the limitations of traditional stamping processes that struggle to dynamically adapt to changes in materials and working conditions.

[0131] The content disclosed above is only a preferred and feasible embodiment of the present invention, and is not intended to limit the scope of protection of the present invention. Therefore, all equivalent technical changes made based on the content of the present invention specification and drawings are included within the scope of protection of the present invention. Furthermore, the elements therein can be updated as technology develops.

Claims

1. An optimized method for forming stamped hardware parts, characterized in that, The method includes the following steps: Obtain instantaneous contact information between the sheet metal and the die during the initial stamping stage; Based on instantaneous contact information, assess the forming potential of the sheet material under the current working conditions; Based on the evaluation results, the stamping stroke or material flow path is adjusted in the subsequent execution phase of the current stamping cycle.

2. The method for optimizing the forming of stamped hardware parts as described in claim 1, characterized in that, The steps for assessing the forming potential of sheet metal under current operating conditions include: Apply instantaneous stimulation to the stamping equipment; Capture the instantaneous local response of the board material to instantaneous stimuli; Extract response features that are sensitive to transient stimuli; Dynamic reference patterns are obtained based on historical process data and / or simulation modeling. The forming potential of the sheet material under the current working conditions is evaluated by comparing the response characteristics and the dynamic reference mode, as well as the correlation between different response characteristics.

3. The optimized forming method for stamped hardware parts as described in claim 1, characterized in that, The steps for adjusting the stamping stroke include: Real-time monitoring of the instantaneous response speed and displacement accuracy of the actuators in the stamping equipment; Based on instantaneous response speed and displacement accuracy, the control parameters of the servo drive system are dynamically adjusted to compensate for inconsistent response or accuracy drift of the actuators. Based on real-time operating parameters, calculate the plastic flow trend and springback characteristics of the material in the subsequent deformation stage of the current stamping cycle; Based on the plastic flow trend and springback characteristics of the material in the subsequent deformation stage of the current stamping cycle, the depth of the stamping stroke, the slide speed curve, and the distribution scheme of the servo blank holder force are dynamically modified. Real-time monitoring of micro-vibration modes and temperature changes in key stress areas of the mold; Based on micro-vibration modes and temperature changes, identify potential wear risks caused by localized stress concentration or abnormal friction; Based on potential wear risks, a partial unloading or slow-release phase is introduced into the stamping stroke adjustment.

4. The optimized forming method for stamped hardware parts as described in claim 1, characterized in that, The steps for adjusting the material flow path include: Continuously acquire the instantaneous deformation state and local stress state of the sheet metal within the mold cavity; Based on the instantaneous deformation state and local stress conditions, the local strain rate and stress distribution of the plate are calculated in real time. Based on local strain rate and stress distribution, the plastic flow trend and springback characteristics of the plate in subsequent deformation are dynamically predicted. Based on the plastic flow trend and springback characteristics of the sheet in the subsequent deformation trend, the distribution ratio of the blank holder force in different areas is dynamically adjusted, and the material flow path is modified in combination with local friction conditions and forming limit constraints. During the correction process, the distribution ratio of blank holder force in different areas, local friction conditions, weight of forming limit constraint and area of ​​action are adjusted according to the geometric characteristics of the mold cavity and the current deformation degree of the sheet metal.

5. The optimized forming method for stamped hardware parts as described in claim 3, characterized in that, The dynamic correction process further includes a coordination and optimization step for the shaped target, specifically including: Real-time acquisition of the instantaneous forming state of different areas of the stamped part; Based on the instantaneous forming state, identify the degree of deviation of the forming target in different areas of the stamped part, and determine the priority of the forming target in different areas of the stamped part; Based on the priority of forming targets, dynamically adjust the weight and range of the area allocation parameters in the stamping stroke depth, slide speed curve, and servo blank holder force distribution scheme; Based on weights and scope of application, a coordinated correction instruction is calculated and generated to balance the forming target conflicts in different areas of the stamped part.

6. The method for optimizing the forming of stamped hardware parts as described in claim 5, characterized in that, The steps for obtaining the instantaneous forming state of different areas of a stamped part in real time include: In complex geometric regions of stamped parts, micro-sensors integrated on the surface of the mold cavity are used to acquire local contact pressure, micro-strain, and ultrasonic transmission signals. During high-speed stamping, a multi-channel synchronous data acquisition system is used, combined with a timestamp calibration mechanism, to synchronize the data of the instantaneous forming state of different areas of the stamped part in time. To address issues such as oil stains, scratches, or reflective properties inherent in the material on the surface of stamped parts, multispectral imaging technology is employed, combined with polarized light filtering and image enhancement processing, to perform multispectral imaging on the surface of the stamped parts. Polarized light filtering and image enhancement processing are then applied to filter out interference and obtain surface flatness and edge contour information with a high signal-to-noise ratio. By establishing a data fusion mechanism, the high signal-to-noise ratio surface flatness and edge contour information obtained from local contact pressure, micro-strain, ultrasonic transmission signals and multispectral imaging technology are combined with real-time environmental vibration monitoring data to distinguish two types of anomalies: one is the anomaly of instantaneous forming state caused by material microstructure inhomogeneity, local stress concentration or mold wear, and the other is the signal fluctuation caused by the noise of the micro-sensor itself or environmental vibration. For stamped parts with multi-layered structures or composite materials, high-frequency ultrasonic phased array scanning technology is used to penetrate the surface material of the stamped parts with multi-layered structures or composite materials to obtain the instantaneous thickness changes of the internal layers and the interlayer bonding state.

7. The optimized forming method for stamped hardware parts as described in claim 6, characterized in that, The steps for obtaining local contact pressure, microstrain, and ultrasonic transmission signals include: In the confined space of the complex geometric region of the stamped part inside the mold, different types of micro sensors are staggered in the micro array channels preset on the surface of the mold cavity. The micro sensors include piezoelectric thin film sensors, fiber Bragg grating sensors and micro ultrasonic transducers. The piezoelectric thin film sensors are used to acquire local contact pressure signals, the fiber Bragg grating sensors are used to acquire micro strain signals, and the micro ultrasonic transducers are used to acquire ultrasonic transmission signals. By optimizing the spatial arrangement of microsensors in the microarray channels, different types of microsensors can form complementary coverage in local areas, thereby improving the density and coverage of data acquisition. By employing time-division multiplexing or frequency-division multiplexing technology, local contact pressure, micro-strain, and ultrasonic transmission signals are simultaneously acquired. By performing multi-scale spatial interpolation and fusion processing on local contact pressure, micro-strain, and ultrasonic transmission signals, local data loss is compensated, and a comprehensive data field reflecting the instantaneous forming state of complex geometric regions is generated.

8. The method for optimizing the forming of stamped hardware parts as described in claim 6, characterized in that, The steps for time synchronization of data on the instantaneous forming state of different regions of a stamped part include: Pre-set multiple reference points with known physical distances on the mold or stamping part; During the stamping process, the instantaneous position of the reference point is simultaneously measured using laser ranging or a vision system; Based on the instantaneous position of the reference point, the acquisition and transmission delay of the data acquisition channels of various sensors used to collect local contact pressure, micro-strain, ultrasonic transmission signals, high signal-to-noise ratio surface flatness and edge contour information obtained by multispectral imaging technology, as well as real-time environmental vibration monitoring data, are calculated and compensated, thereby achieving time synchronization of data on the instantaneous forming state of different areas of the stamping part. Deploy multiple time synchronization modules; Integrate the outputs of multiple time synchronization modules; A hardware-level signal preprocessing unit is introduced into the data acquisition channel; The raw signals from various sensors are denoised and filtered to improve the accuracy of timestamp extraction. When the system starts up or the operating condition changes, a fast time synchronization calibration process is triggered. The fast time synchronization calibration process includes collecting short-time high-frequency data and establishing initial time synchronization based on the short-time high-frequency data. During the normal operation phase of the system, an adaptive filtering time synchronization algorithm is used to make adjustments based on the initial time synchronization results. Integrated self-calibration module; The self-calibration module periodically sends test signals with known timing to the data acquisition channels corresponding to various sensors, and adjusts the internal clock or timestamp calibration parameters according to the response timing deviation of the data acquisition channels corresponding to various sensors.

9. The method for optimizing the forming of stamped hardware parts as described in claim 8, characterized in that, The steps for presetting multiple reference points with known physical distances on a mold or stamping part include: Apply a layer of malleable polymer material to the surface of the mold or stamped part; In the polymer material layer, micro-cavity structures with specific geometries, sizes and array arrangements are formed as reference points using microfluidics or microimprinting techniques.

10. A stamping hardware forming optimization system, applied to the stamping hardware forming optimization method described in claim 1, characterized in that, The system includes: The information acquisition module is used to acquire instantaneous contact information between the sheet metal and the die during the initial stamping stage; The potential assessment module evaluates the forming potential of the sheet material under the current working conditions based on instantaneous contact information. The parameter adjustment module adjusts the stamping stroke or material flow path in the subsequent execution phase of the current stamping cycle based on the evaluation results.

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