A method for tracing forged parts throughout the entire production process, specifically from the forging process through sandblasting and heat treatment to mechanical processing.

Abstract

The present invention relates to a tracking method for tracking forged parts throughout an entire production process, particularly from a forging process to mechanical processing via sandblasting and heat treatment, wherein the tracking method comprises: a detection step for detecting process parameters of a forging process; a marking step for marking a first identification code on a workpiece manufactured in a forging process using a mechanical or thermal intrusion method; a storage step for storing the detected process parameters of the forging process together with the first identification code of the manufactured workpiece in a database; a read-output step for reading and outputting the identification code of the workpiece manufactured in a previous process step; a detection step for detecting process parameters during subsequent process steps of the production process; and a storage step for storing process parameters of subsequent process steps in a database for the read-out identification code, provided that the readability of the first identification code of the workpiece is maintained through subsequent process steps of the production process. If the readability of the first identification code of the workpiece is not maintained through subsequent process steps of the production process, a marking step of marking an additional identification code on the workpiece manufactured in a subsequent process step using a surface imprinting method; and a storage step of storing process parameters of the subsequent process step along with the additional identification code, along with process parameters of the previous process steps and the first identification code, in a database.

Description

Technology Field

[0001] The present invention relates to a tracing method for tracing forged parts throughout the entire production process, particularly from the forging process to mechanical processing via sandblasting and heat treatment. Background Technology

[0002] Traceability of workpieces is desirable from numerous perspectives. For instance, if a quality issue arises with a single workpiece, other workpieces manufactured under similar conditions can be identified for inspection, selection, or replacement. This is desirable, for instance, for parts in the automotive industry, because if a problem occurs with a single part, it is not necessary to replace all parts in the same production batch, which can sometimes lead to complex recalls; instead, only parts manufactured under similar conditions need to be replaced. However, to achieve this, parts (forged parts) must be traceable throughout the entire production process. In this case, access to process parameters at individual steps of the production process also falls under the scope of workpiece traceability.

[0003] Traceability of forged parts throughout the entire production process requires general identification marking of the workpieces, extending from the forging process through sandblasting and heat treatment to mechanical processing and the final use of the finished forged parts. However, in conjunction with the requirements for the finished forged parts, the prevailing environmental conditions and concomitant circumstances during the forging process hinder the standard identification marking of workpieces from the forging process through sandblasting and heat treatment to mechanical processing and the final use of the finished forged parts. During and immediately after the forging process, extremely high thermal loads exist due to high temperatures of the workpieces and corresponding thermal radiation. Furthermore, the workpieces exhibit surface scale formations after the forging process that impede direct access to the workpiece surfaces. In addition, contaminants such as graphite generated through spray agents are still present. In subsequent process steps, the scale-forming portion is removed by a method for mechanically and / or thermally removing the material, such as sandblasting or shot blasting, and the surface of the workpiece is processed through heat treatments such as case hardening, carbonitriding, or hardening and tempering, which results in high mechanical stress. General identification markings must be maintained under these conditions, but at the same time, requirements for the final workpiece (forged part) prevent the use of identification markings that have a negative effect on the mechanical properties of the workpiece. Thus, damage to the surface of the workpiece [notch effect], deterioration of corrosion resistance, or negative effects on the assembly process are eliminated.

[0004] Furthermore, individual process steps of the overall production process are typically not executed immediately and sequentially; instead, workpieces are temporarily stored, for example, between individual process steps. Additionally, multiple workpieces are processed in parallel at some process steps, which applies, for instance, to abrasive blasting or heat treatment. Consequently, general optical tracking of workpieces throughout the entire production process is impossible. The problem to be solved

[0005] Therefore, the objective of the present invention is to provide a tracking method for tracking forged parts throughout the entire production process, particularly from the forging process through sandblasting and heat treatment to mechanical processing, which satisfies all the aforementioned requirements. means of solving the problem

[0006] The above problem is solved according to the present invention through a tracking method for tracking forged parts throughout the entire production process, particularly from the forging process to mechanical processing via sandblasting and heat treatment, comprising the following steps.

[0007] A detection step for detecting process parameters of a forging process;

[0008] A marking step of marking a first identifier on a workpiece manufactured in a forging process using a mechanical or thermal penetrant method;

[0009] A storage step of storing detected process parameters of the forging process along with a first identification code of the manufactured workpiece in a database;

[0010] A read output step for reading and outputting the identification code of a workpiece manufactured in a previous process step;

[0011] A detection step for detecting process parameters during subsequent process steps of a production process;

[0012] If the readability of the first identification code of the workpiece is maintained through subsequent process steps of the production process, a storage step of storing process parameters of subsequent process steps for the read-out identification code in a database;

[0013] A marking step for marking an additional identification code on a workpiece manufactured in a subsequent process step using a surface inscription method when the readability of the first identification code of the workpiece is not maintained through subsequent process steps of the production process; and

[0014] A storage step for storing process parameters of subsequent process steps in a database, along with process parameters of previous process steps and a first identification code, along with additional identification codes.

[0015] According to the method of the present invention, relevant process parameters are detected at every process step of the method for manufacturing a forged part. This is performed, for example, through process automation of each production process. In order to allow the detected process parameters to be assigned to the workpiece being manufactured at any time along the process chain or subsequent use, a first identification code is assigned to the workpiece manufactured by the forging process by a mechanical or thermal intrusion method. The first identification code and the detected process parameters are stored in a database for future tracking. Based on the first identification code, the process parameters of the forging process can be retrieved from the database at a later point in time.

[0016] A detection step for detecting process parameters of a forging process may include, according to the present invention, a detection step for detecting parameters before, during, and after the forging process. Before the forging process, for example, raw material data may be detected; during the forging process, parameters of the forging process such as force, temperature, etc. may be detected; and after the forging process, parameters of the manufactured workpiece such as dimensions may be detected.

[0017] A mechanical or thermal penetration method for generating a first identification mark has the advantage that a brittle scale layer is automatically removed from the area of ​​the first identification mark as a result, because said scale layer is peeled off. In addition, unexpected contaminants do not negatively affect the first identification mark, because said first identification mark is generated within the surface of the workpiece through mechanical penetration. Since the workpiece still maintains a very high temperature of up to 1250°C after the forging process, the mechanical means for generating the first identification mark can penetrate into the surface of the workpiece more simply. Furthermore, the mechanical means for generating the first identification mark can be formed through simple mechanical devices that withstand thermal and mechanical loads after the forging process. In addition, as an alternative to the mechanical penetration method, a thermal penetration method can also be used to generate the first identification mark. The thermal penetration method is based, for example, on a laser for generating the first identification mark.

[0018] A first identification code formed through a mechanical or thermal intrusion method is maintained in subsequent process steps of abrasive blasting and heat treatment, thereby allowing process parameters detected in said process steps to be stored in a database along with process parameters of the forging process for the first identification code.

[0019] For example, during subsequent mechanical processing of the workpiece, such as turning, milling, or grinding, the first identification code is removed and can no longer be read for tracking the processed workpiece. Therefore, subsequently, an additional identification code is assigned to the workpiece processed in the process step, and the additional identification code is generated by a surface imprinting method. Process parameters detected during the relevant process step are assigned to the corresponding first identification code of the workpiece in the database along with the additional identification code. Accordingly, the corresponding first identification code is retrieved from the database via the additional identification code, the workpiece can be tracked throughout the entire production process, and access to all process parameters of all process steps, correspondingly stored in the database, is also possible.

[0020] In addition, theoretically, during additional processing of the workpiece, if the previous additional identification code is not maintained during such additional processing, a new identification code may be provided by a surface engraving method.

[0021] According to a preferred variant of the present invention, a first identification code is generated in an area of ​​the workpiece manufactured in the forging process and in an area that is removed in one of the subsequent process steps. In this case, the area containing the first identification code is mechanically removed, for example, through subsequent processing. By subsequently removing the first identification code, the first identification code generated by a mechanical or thermal intrusion method does not have any adverse effect on the workpiece (forged part) manufactured in the entire production process.

[0022] According to another preferred variant of the present invention, additional identification codes are provided in an area of ​​the workpiece that is exposed to a small load during use. Preferably, additional identification codes are provided in an area of ​​the workpiece that is not exposed to any load during use. Accordingly, the additional identification codes of the workpiece do not have any adverse effects on the characteristics of the workpiece. By ensuring that a small load is applied or no load is applied to the area containing the additional identification codes, the legibility of the additional identification codes is maintained, which is equally desirable for future traceability.

[0023] However, if the location where a workpiece is used or mounted, including its own additional identification code, is documented, the subsequent readability of the additional identification code is not strictly necessary for traceability.

[0024] In another variation according to the present invention, quality data is detected at least partially along with process parameters in process steps, and such quality data is stored in a database along with a first identification code and / or additional identification codes. The quality data is determined, for example, within the category of automatic and / or manual quality inspection and / or final check. Where possible, automatic determination is preferred. Through the determination and storage of quality data, the stored quality data can be utilized for individual process steps or, in some cases, subsequent additional processing or assembly. In other words, quality standards can also be checked and guaranteed. Furthermore, in some cases, it is not necessary to perform an incoming inspection of the workpieces.

[0025] According to one variation of the present invention, a first identification code is generated in an area of ​​a workpiece that is not deformed through a forging process or has already secured its final shape through a forging process. In the said area of ​​the workpiece, the first identification code can theoretically be generated before or during the forging process, because the forging process does not have any effect on (and no longer has any effect on) the said area, and thus the first identification code is maintained in a readable state.

[0026] According to a suitable variation of the present invention, the first identification code is generated by a dot-printing method or a stamping method.

[0027] In a preferred variant, the stamping die [e.g., pins] is made of hot-formed tool steel, carbide metal, etc., and / or includes an active cooling device. In this way, the effective life of the pins for the dot printing method or pin marking method is extended.

[0028] According to another preferred variation of the present invention, a generating device for generating a first identification code includes passive and / or active thermal protection devices. The passive thermal protection device is, for example, a thermal insulator, and the active thermal protection device is, for example, a cooling device. In this way, the negative thermal effects of the forging process or the forged workpiece on the generating device for generating the first identification code are reduced, thereby extending the effective life of the generating device and reducing failures.

[0029] According to a suitable variation of the present invention, additional identification codes are generated by a laser or through a printing method. The printing method generates identification codes on the surface of the workpiece and thus does not affect the mechanical properties of the workpiece. However, printed additional identification codes are typically less resistant than additional identification codes integrated within the surface. A laser generates additional identification codes within the surface of the workpiece and thus theoretically can affect the mechanical properties of the workpiece. However, the identification codes are generated only on the top layer, thereby significantly reducing the effect. Additional identification codes generated by a laser are typically more resistant than printed additional identification codes.

[0030] In a variation according to the present invention, the first identification code and / or additional identification code comprises, in particular, a data matrix code, QR code, barcode, one or more numbers and / or digits, or other symbols or signs for specifying part numbers or drawing numbers, supplier identifiers, order numbers, etc.

[0031] According to one variant of the present invention, when a workpiece is divided in one of the subsequent manufacturing steps, a plurality of first identification codes are assigned to the workpiece, and the plurality of first identification codes are preferably arranged so that each divided workpiece includes the first identification code. If the division of the workpiece is performed at the end of the production process, each individual part may be assigned one additional identification code by a surface imprinting method, and each process data and the first identification code may be used together.

[0032] According to a variation of the present invention, the detected process parameters include set values ​​and actual values ​​of equipment automation such as forging processes or other process steps, machine data, process data, measurement protocols, and carbon emissions; preferably, process temperature, workpiece temperature; particularly at different points in time, process time; clock control time; spray time; dwell time; process force; forming force; reaction force; machine data; motor power consumption of the main drive unit and auxiliary drive unit; amount of swell of the press body; unplanned process results; die failure, particularly crack formation; forging of end piece; double loader; etc. As process parameters, carbon emissions include carbon emissions occurring in particular at each process step.

[0033] In a preferred variant according to the present invention, process parameters are stored in a database with a first identifier and / or an additional identifier when they exceed and / or fall below preset limits or thresholds. In other words, the storage of all process parameters of the production process is not mandatory; only process parameters that exceed preset thresholds or limits are stored. In this way, the amount of data to be stored is clearly reduced.

[0034] According to a highly desirable variant, the method according to the present invention comprises an analysis step of analyzing process data stored in a database to identify defective or defective products based on, in particular, defective or defective products to be discovered later; and a comparison of process data in a database with process data of defective or defective products; and an identification step of identifying a corresponding product based on a first identification code and / or additional identification code.

[0035] According to a suitable variation of the present invention, the process step in which the first identification code is maintained includes sandblasting of the workpiece; shot blasting; and heat treatment such as surface hardening, carburizing, nitriding, hardening, and quenching.

[0036] In a modified example according to the present invention, the process step in which the first identification code is not maintained includes mechanical processing of a workpiece, such as turning, milling, grinding, etc.

[0037] According to a suitable variation of the present invention, a first identification code is generated through one or more marking units positioned before, within, or after the forging device. Through placement immediately before, within, or after the forging device, process parameters of the forging process can be clearly assigned to the first identification code provided immediately thereafter, prior to, or in parallel with. There is no risk of reversal between the forging device and the marking units. If this is not possible, clear assignment must be ensured, for example, through optical or logical tracking of workpieces between the forging device and the marking units. If the forging process proceeds faster than the generation of the first identification code, multiple marking units are preferably assigned to a single forging device to ensure that the production process throughput is not reduced by the generation of the first identification code. In such cases, the assignment of workpieces to individual marking units must be ensured along with the relevant process parameters.

[0038] In the following, the present invention is described in more detail based on the embodiment illustrated in FIG. 1. Brief explanation of the drawing

[0039] FIG. 1 is a flowchart illustrating an embodiment of a method according to the present invention for tracking forged parts throughout the entire production process, particularly from the forging process to mechanical processing via sandblasting and heat treatment. Specific details for implementing the invention

[0040] FIG. 1 shows a flowchart of one embodiment of a method according to the present invention for tracking forged parts throughout the entire production process, particularly from the forging process to mechanical processing via sandblasting and heat treatment.

[0041] According to the flowchart of the method according to the present invention in FIG. 1, the production process begins with a forging process. The process parameters of the forging process are detected according to the present invention.

[0042] After or during the forging process, a first identification code is assigned to the workpiece produced in the forging process. The first identification code is generated by a mechanical or thermal intrusion method, in particular by a dot printing method or a stamping method. Corresponding stamping means, such as pins, are particularly composed of hot-formed tool steel, hard metal, etc. Additionally, the stamping means or pins may include an active cooling device. In this way, the effective life of the stamping means or pins is extended.

[0043] To more sufficiently protect the generating device for generating the first identification code from the temperature of the forging process and / or the workpiece, the generating device preferably includes passive and / or active thermal protection devices. Such thermal protection devices may be, for example, thermal insulators or cooling devices.

[0044] The first identification mark is generated specifically in an area of ​​the workpiece manufactured in the forging process and in an area that is mechanically removed in one of the subsequent process steps. In this way, the generated first identification mark does not have a negative impact on the workpiece / product manufactured in the entire production process.

[0045] If the first identification code is generated during the forging process, this is performed in an area of ​​the workpiece that is not deformed by the forging process or has already acquired its final shape through the forging process. In this way, it is ensured that the forging process does not degrade the readability of the first identification code.

[0046] If the forging process proceeds faster than the generation of the first identification code, a plurality of generating devices for generating the first identification code may be provided to ensure that the generation of the first identification code does not negatively affect the throughput of the manufacturing method. At least one generating device for generating the first identification code is preferably positioned in front of, within, or behind the forging device.

[0047] After a first identification code is assigned to the workpiece, the detected process parameters of the forging process are stored in a database along with the first identification code of the manufactured workpiece.

[0048] In subsequent process steps, the identification code of the workpiece manufactured in the previous process step, for example, the first identification code of the workpiece manufactured in the forging process, is read and output. In addition, process parameters are also detected in the subsequent process steps.

[0049] Basically, in subsequent process steps, it is distinguished whether the readability of the identification code of the workpiece manufactured in the previous process step is maintained through the subsequent process step or not.

[0050] If the readability of the identification code of the workpiece manufactured in the previous process step is maintained, the order between the read-output step, which reads and outputs the workpiece identification code, and the detection step, which detects the process parameters of the subsequent process step, is not critical and can be freely selected. In this case, the detected process parameters of the subsequent (actual) process step are stored in a database for the detected and read-out identification code. Subsequently, the next process step is performed.

[0051] Process steps in which the legibility of the first identification code is maintained include, in particular, sandblasting of the workpiece; shot blasting; and heat treatments such as surface hardening, carburizing, nitriding, hardening, and quenching.

[0052] In contrast, if the readability of the identification code of the workpiece manufactured in the previous process step is not maintained, the identification code of the workpiece manufactured in the previous process step is first read and output, and then the process parameters of the immediately following (actual) process step are detected, because in this case, the readability of the identification code of the workpiece generated in the previous process step is lost. In such a case, the workpiece is identified and marked with an additional identification code by a surface engraving method.

[0053] Subsequently, the detected process parameters are stored in a database along with additional identification codes for the identification code of the workpiece manufactured in the previous process step, in particular for the first identification code associated with the corresponding workpiece.

[0054] In this case, additional identification codes are provided, particularly in areas of the workpiece that are exposed to small loads or are not exposed to loads when the workpiece is used.

[0055] Surface engraving methods are based, for example, on laser engraving or printing methods.

[0056] Process steps in which the identification code of the workpiece manufactured in a previous process step is not retained include, in particular, mechanical processing of the workpiece, such as turning, milling, and grinding.

[0057] Subsequently, additional process steps may be performed, or the production process is terminated.

[0058] The detected process parameters of the forging process and / or subsequent process steps include set values ​​and actual values ​​of the equipment automation, such as the forging process or subsequent process step, machine data, process data, measurement protocols, and carbon emissions. Additionally, the process parameters preferably include process temperature and workpiece temperature, and particularly at different points in time, process time; clock control time; spray time; dwell time; process force; forming force; reaction force; machine data; motor power consumption of the main drive and auxiliary drive; expansion amount of the press body; unplanned process results; die failure, particularly crack formation; forging of end piece; double loader; etc. In a suitable manner, carbon emissions generated at each process step are detected as process parameters for the process step.

[0059] Along with process parameters, according to a variation of the present invention, quality data may also be detected at least partially in the process steps, and such quality data is stored in a database along with a first identification code and / or additional identification code.

[0060] The first identification code and / or additional identification codes include a data matrix code, QR code, barcode, one or more numbers and / or digits, or other symbols or signs, particularly for specifying part numbers or drawing numbers, supplier identifiers, order numbers, etc. Since the first identification code is generated through a mechanical intrusion method, the first identification code consists of a simple string of numbers, or a string of alphabetic characters and numbers, or a dot matrix. Conversely, additional identification marks generated by a surface imprinting method may be composed more complexly and may include additional information, for example, in the form of a QR code.

[0061] According to one variant of the present invention, when a workpiece is divided in one of the subsequent manufacturing steps, a plurality of first identification codes are assigned to the workpiece, and the plurality of first identification codes are preferably arranged so that each divided workpiece includes the first identification code. If the division of the workpiece is performed at the end of the production process, each individual part may be assigned one additional identification code by a surface imprinting method, and each process data and the first identification code may be used together.

[0062] In a preferred variant according to the present invention, process parameters are stored in a database with a first identifier and / or an additional identifier when they exceed and / or fall below preset limits or thresholds. In other words, the storage of all process parameters of the production process is not mandatory; only process parameters that exceed preset thresholds or limits are stored. In this way, the amount of data to be stored is clearly reduced.

[0063] According to a highly desirable variant, the method according to the present invention comprises an analysis step of analyzing process data stored in a database to identify defective or defective products based on, in particular, defective or defective products to be discovered later; and a comparison of process data in a database with process data of defective or defective products; and an identification step of identifying a corresponding product based on a first identification code and / or additional identification code.

Claims

Claim 1 A method for tracking forged parts for tracking forged parts throughout an entire production process, from the forging process to sandblasting and heat treatment to mechanical processing, wherein the tracking method comprises: a detection step for detecting process parameters of the forging process; a marking step for marking a first identification code on a workpiece manufactured in the forging process using a mechanical or thermal intrusion method; a storage step for storing the detected process parameters of the forging process along with the first identification code of the manufactured workpiece in a database; a read-output step for reading and outputting the identification code of the workpiece manufactured in a previous process step; a detection step for detecting process parameters during subsequent process steps of the production process; and a storage step for storing process parameters of subsequent process steps in a database for the read-out identification code, provided that the readability of the first identification code of the workpiece is maintained through subsequent process steps of the production process. A method for tracking forged parts, comprising: a marking step of marking an additional identification code on a workpiece manufactured in a subsequent process step using a surface imprinting method when the readability of a first identification code of a workpiece is not maintained through subsequent process steps of a production process; and a storage step of storing process parameters of a subsequent process step along with an additional identification code, along with process parameters of previous process steps and a first identification code, in a database; wherein the first identification code is generated in an area of ​​a workpiece manufactured in a forging process and an area that is removed in one of the subsequent process steps. Claim 2 delete Claim 3 A method for tracking forged parts according to claim 1, wherein the additional identification code is provided in an area of ​​the workpiece exposed to a small load when the workpiece is used. Claim 4 A method for tracking forged parts according to claim 1 or 3, wherein quality data is also detected at least partially in process steps simultaneously with the process parameters, and the quality data is stored in a database together with the first identification code and / or the additional identification code. Claim 5 A method for tracking forged parts according to claim 1 or 3, wherein the first identification code is generated in an area of ​​a workpiece that is not deformed through the forging process or has already secured its own final shape through the forging process. Claim 6 A method for tracking forged parts according to claim 1 or 3, wherein the first identification code is generated by a dot printing method or a pin marking method. Claim 7 A method for tracking forged parts according to claim 6, wherein the pins are composed of at least one of hot-formed tool steel and hard carbide metal, and / or include an active cooling device. Claim 8 A method for tracking forged parts according to claim 1 or 3, wherein the generating device for generating the first identification code includes a passive and / or active thermal protection device. Claim 9 A method for tracking forged parts according to claim 1 or 3, wherein the additional identification code is generated by a laser or through a printing method. Claim 10 A method for tracking forged parts according to claim 1 or 3, wherein the first identification code and / or the additional identification code comprises at least one of a data matrix code, a QR code, a barcode, one or more numbers and one or more digits for specifying identification information including at least one of a part number, a drawing number, a supplier identifier, and an order number. Claim 11 A method for tracking forged parts according to claim 1 or 3, wherein when the workpiece is divided in one of the subsequent manufacturing steps, a plurality of first identification codes are assigned to the workpiece, and the plurality of first identification codes are arranged such that each divided workpiece includes the first identification code. Claim 12 A method for tracking forged parts according to claim 1 or 3, wherein the detected process parameters include at least one of set values ​​and actual values ​​of equipment automation of a forging process or other process steps, machine data, process data, and measurement protocols. Claim 13 A method for tracking forged parts according to claim 1 or 3, characterized in that the process parameters are stored in a database together with the first identification code and / or the additional identification code when they exceed and / or fall below preset limits or thresholds. Claim 14 A method for tracking forged parts according to claim 1 or 3, wherein the tracking method comprises: an analysis step of analyzing process data stored in a database to identify incomplete or defective products based on incomplete or defective products subsequently discovered; and a comparison of process data in a database with process data of incomplete or defective products; and an identification step of identifying a corresponding product based on a first identification code and / or additional identification code. Claim 15 A method for tracking forged parts according to claim 1 or 3, wherein the process step in which the first identification code is maintained comprises sandblasting of the workpiece; shot blasting; and heat treatment including at least one of surface hardening, carburizing, nitriding, hardening, and quenching. Claim 16 A method for tracking forged parts according to claim 1 or 3, wherein the process step in which the first identification code is not maintained comprises mechanical processing of a workpiece including at least one of turning, milling, and grinding. Claim 17 A method for tracking forged parts according to claim 1 or 3, wherein the first identification code is generated through one or more marking units disposed in front of, within, or behind the forging device.

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