Press molding process monitoring service method using sensor module

Abstract

The present invention relates to a press forming process monitoring service method and system using a sensor module, which installs a mold counter, a shot counter, or a sensor module, etc., in a mold to measure the number of mold openings and closings, cycle time, and vibration signals of a manufacturing production process, transmits the measured signals to store and analyze the measured data in real time on a server / cloud server, and provides manufacturing production process information in real time to an online app platform without restrictions on the location of the mold and / or the location and distance of the manager.

Description

Technology Field

[0001] The present invention relates to a method and system for a press forming process monitoring service using a sensor module, and more specifically, to a method and system for a press forming process monitoring service using a sensor module that measures the number of mold openings and closings, cycle time, and vibration signals of a press forming product production process by installing a mold counter, a shot counter, or a sensor module in a mold, transmits the measured signals in real time to a server / cloud server, stores them in a database, and analyzes them to provide real-time production process information of the product to an online app platform without restrictions on the location of the mold and / or the location and distance of the manager. Background Technology

[0002] The business models of the manufacturing industry, which were previously organized and operated on a small-scale regional basis, have recently evolved into large-scale, country-to-country global business chains in line with the establishment of global networks and the globalization of related markets.

[0003] Consequently, the relationship between the OEM, the entity responsible for production, and the supplier, the executor of production, has shifted from a small-scale, regional relationship to a global one; as a result, there are limitations to managing the manufacturing chain using traditional production management methods in the form of spreadsheets, which were managed through worker records and input.

[0004] Conventional technology, which relies on workers passively checking and sharing process and production status periodically, is not suitable for managing value chains of expanded scale due to time constraints and makes systematic management impossible; consequently, there are cases where timely measures cannot be taken when problems or abnormal situations occur.

[0005] In addition, manual production management by workers within the OEM's value chain involves uncertainty regarding human factors, which has led to data instability and caused a decline in mutual data reliability, resulting in a problem where efficient production management cannot be achieved.

[0006] The present invention provides a press molded product quality management service method and system equipped with a mold counter and magnetic and vibration sensors for quality control, which enhances accuracy and reliability by analyzing and managing the quality of molded products in a double or triple manner, and provides process information for the production of press molded products in real time via a high-speed online app platform regardless of the location and distance between the mold and the manager.

[0007] While there is an advantage in obtaining accurate process information by directly measuring factors such as the stamping force applied to the product during the press forming process, there are significant difficulties in applying this technology to general industrial sites due to the high cost of implementation. This is because the measurement sensors and systems need to measure the high levels of pressure generated during the press forming process and require the miniaturization of the sensors.

[0008] Furthermore, in order to consistently receive parts or products of various shapes and sizes on time with uniform quality, multiple production bases may be established in multiple countries, and it is crucial to efficiently manage the quality and production volume of products supplied from each base.

[0009] When production bases are located in multiple countries, there is a problem in that established rules and values ​​are modified and applied differently to reduce production costs, such as by increasing the stamping speed of the press forming process, which lowers product uniformity and quality, thereby reducing product reliability and durability.

[0010] The present invention relates to a press-formed product quality analysis monitoring system using a sensor module that can be easily applied to existing or new molds to efficiently solve the various problems mentioned above, and can efficiently manage the quality and production volume of press (stamping) formed products. Prior art literature

[0011] Korean Registered Patent Publication No. 10-2266747 Japanese Patent Publication No. 5551243 (B2) Japanese Published Patent Publication No. 2018-128876 (A) The problem to be solved

[0012] The problem that the present invention aims to solve is to provide a press-formed product quality management service method that installs a sensor module on one side of a press mold to measure the number of mold openings and closings and the mold vibration signal, arranges the measured signals according to a predetermined procedure using a control algorithm mounted on a control PCB embedded in the sensing unit, transmits the data to a transmitting / receiving terminal via Bluetooth communication, transmits the data in real-time to a server / cloud server via Internet WiFi communication to store the data, and then analyzes the quality of the product using a statistical algorithm and / or AI / ML algorithm mounted on the server based on the stored data to provide desired services to individuals and / or companies.

[0013] Another problem that the present invention aims to solve is to provide a quality control service method for press-formed products that can determine whether the press forming process is being performed normally by measuring at least one vibration signal among the press holder contact time, punch contact and press start time, press end time, mold opening start time, and material and product ejection time from the vibration signal of the mold measured by an acceleration sensor or vibration sensor fixedly installed on a punch plate, and monitoring at least one vibration signal among each measured vibration signal.

[0014] Another problem that the present invention aims to solve is to provide a press-molded product quality control service method comprising the step of analyzing mold opening / closing signal and vibration signal data among data stored in a server, measuring at least one signal among mold opening / closing time, press holder contact time, punch contact and press start time, press end time, mold opening start time, and material and product ejection time, analyzing at least one of the generation interval and amplitude of each generated signal, and displaying or providing guidance on a screen as a defective product on a monitor linked to the server for molded products that deviate from at least one set range.

[0015] Another problem that the present invention aims to solve is to provide a quality management service method for press-formed products, which involves installing an AI / ML algorithm for detecting abnormal conditions of a mold or press-forming machine on a server, labeling various abnormalities of the mold or press-forming machine, and learning each signal pattern; wherein, when an abnormality occurs in the vibration signal data pattern in advance, the method compares the change pattern of vibration signal data measured by an acceleration sensor or vibration sensor collected in real time with the labeled and learned signal pattern to determine the maintenance timing or potential problems of the mold or press-forming machine.

[0016] Another problem that the present invention aims to solve is to provide a quality control service method for press-formed products that improves the accuracy of vibration signal measurement, wherein the sensing part of the sensor module is fixedly installed on one of a punch plate or a stripper plate that can detect vibration signals relatively easily, and the magnetic part is fixedly installed on a lower mold or die with relatively small vibration, and the sensing part has a control PCB and a measurement PCB embedded therein, and the control PCB is equipped with a Hall sensor, a liquid crystal display, an MCU, and a memory equipped with a control algorithm and is fixedly installed on the upper part inside the sensor module case, and the measurement PCB is equipped with a vibration measuring sensor and is installed in close contact with the lower part of the sensor module case to accurately measure vibration signals.

[0017] Another problem that the present invention aims to solve is to provide a press-formed product quality management service method that incorporates statistical algorithms and AI / ML algorithms into a management server, a server, or a cloud server, analyzes the quality of a molded product based on data stored in the server, and displays results obtained from at least one of a mold ID, a molded product, a Hall sensor, and an accelerometer to an individual or company by displaying them on a desired screen.

[0018] Another problem that the present invention aims to solve is to provide a press-formed product quality analysis monitoring system that uses a magnetic sensor as a shot counter and utilizes the amplitude of vibration signals measured by an acceleration sensor or a vibration sensor and the intervals between signals for quality control, while simultaneously recording and storing the acquisition time of each data information when detecting the signal measured by the magnetic sensor and the vibration signal from the acceleration sensor or the vibration sensor, and analyzing each signal and time interval to produce better products through detailed product control. means of solving the problem

[0019] The means for solving the problem of the present invention is to provide a press forming process monitoring service method using a sensor module comprising the steps of: downloading a predetermined program provided by an app to access a server and receive a service; clicking an information input button provided by the app, and then inputting information for receiving a service, including a mold, product, and company name linked to a plurality of sensor modules installed in a mold requiring information input, and storing it in a memory or database; transmitting a signal measured from the input and stored plurality of sensor modules to a control PCB embedded in a sensing unit; preprocessing the data using an algorithm mounted on the control PCB that measures the signal; transmitting the preprocessed data to a transmitting and receiving terminal via wireless communication; and storing the transmitted data on a server via communication including Internet WiFi.

[0020] As a means of solving another problem of the present invention, the present invention provides a press forming process monitoring service method using a sensor module, comprising the steps of installing a sensor for counting the number of times a mold is opened and closed and a sensor for detecting vibration of a press mold for quality control of a press-formed product, and monitoring a vibration signal to manage a press-formed product.

[0021] As a means of solving another problem of the present invention, a sensor for detecting vibration of a press mold is provided, wherein an acceleration sensor or a vibration sensor capable of measuring vibration of the mold is embedded in a sensing part, and at least one vibration signal among the press holder contact time, punch contact and press start time, press end time, mold opening start time, and material and product ejection time is measured from the vibration signal measured by the acceleration sensor or vibration sensor embedded in the sensing part, and at least one vibration signal among each measured vibration signal is monitored to determine whether the press molding process is being performed normally. The present invention provides a press molding process monitoring service method using a sensor module comprising the step of

[0022] As a means of solving another problem of the present invention, a control PCB embedded in a sensing unit is equipped with a firmware program for operating an MCU and a sensor module, and to increase the processing speed of data measured by a sensor on a measuring PCB and to reduce storage capacity, the control PCB is edited into a single data array in a time series through a firmware algorithm and transmits and receives data via wireless communication including Bluetooth to transmit and receive data to a transmitting and receiving terminal.

[0023] As a means of solving another problem of the present invention, the sensing part of the sensor module is fixedly installed on one of a punch plate and a stripper plate where vibration signals are easily detected, and a magnetic part is fixedly installed on a lower mold or die where vibration is relatively small; a control PCB and a measurement PCB are embedded in the sensing part, and the control PCB is equipped with a Hall sensor, a liquid crystal display, a memory equipped with an MCU and a control algorithm, and a wireless communication part including Bluetooth is installed and fixedly installed on the upper part of the sensing part case, and the measurement PCB is equipped with a vibration measuring sensor and is installed in close contact with the lower part of the sensing part case to accurately measure vibration signals, thereby providing a press forming process monitoring service method using a sensor module.

[0024] A means for solving another problem of the present invention is to provide a press forming process monitoring service method using a sensor module, comprising the steps of: recording and storing data measured from a sensing unit on a server through a transmitting and receiving terminal; and displaying an analyzed screen based on at least one piece of information or data among a mold ID, part ID, sensor module ID, molded product, Hall sensor, and vibration sensor, equipped with a statistical algorithm and an AI / ML algorithm, and based on the data stored on the server, so as to enable an individual or company to manage products produced from a mold.

[0025] Another means of solving another problem of the present invention is to provide a press forming process monitoring service method using a sensor module, comprising the step of measuring at least one of the mold opening time and mold closing time measured by a magnetic sensor in real time, and if at least one of the time intervals of the mold opening time and mold closing time deviates from the range of a set time interval, determining that there is an abnormality in the quality of the press-formed product and displaying it as a defective product on a monitor or displaying an abnormality notice on a screen.

[0026] As a means of solving another problem of the present invention, a control unit is fixedly installed inside a sensing unit, and the control unit includes the step of setting a time interval for measuring signals from an acceleration sensor, a vibration sensor, and a magnetic sensor; performing a usage analysis for each mold of the company, performing an analysis based on days when the target production volume was met, days when it was not met, and days when the mold was not operated, displaying the total production ratio, and providing a screen that shows the additional time during which product production was possible for each mold in addition to the actual product production time.

[0027] As a means of solving another problem of the present invention, a press forming process monitoring service method using a sensor module is provided, comprising the steps of: displaying on a screen a part ID, part name, and current production status of a part being produced at a company among a plurality of service target companies or individuals; and displaying a screen that allows checking production information of the part when the part ID is clicked.

[0028] A means for solving another problem of the present invention is to provide a press forming process monitoring service method using a sensor module, comprising the steps of: displaying on a screen the press mold ID and the current status of the press mold that produce multiple parts of a company among a plurality of service target companies or individuals; and, when the press mold ID is clicked, displaying a screen that allows checking production information of the corresponding part produced by the press mold.

[0029] As a means of solving another problem of the present invention, a method for a press forming process monitoring service using a sensor module is provided, comprising the step of displaying a screen that allows an analysis report on the number of shots, cycle time, uptime, and vibration signal to be viewed on a screen of the press mold, and allows data stored in memory or a database to be searched and viewed by month, week, day, and hour.

[0030] A means for solving another problem of the present invention is to provide a press forming process monitoring service method using a sensor module, comprising the steps of: downloading a predetermined program provided by an app platform and registering as a member by following a predetermined procedure provided by the program; being assigned a unique ID to use the service upon registration; and accessing a press forming process monitoring management service app using the assigned unique ID to check the production volume of the company's products and whether production is proceeding normally through various monitoring screens.

[0031] Another means of solving another problem of the present invention is to provide a press forming process monitoring service method using a sensor module, wherein the data measured by a sensor embedded in a sensing unit is changed and set at a frequency for measuring the temperature and vibration signals of the mold through a memory equipped with an MCU and a firmware program, and the signal measurement frequency set in the firmware program is changed and set considering the number of sensing units, the number of service target companies, the data storage capacity, and the processing speed of the amount of data.

[0032] A means for solving another problem of the present invention is to provide a press forming process monitoring service method using a sensor module, comprising the steps of: installing an AI / ML algorithm for detecting abnormal conditions of a mold or press forming machine on a server or management server; labeling cases where at least one of a punch plate, a lower mold receiving pressure applied by the punch plate, and a die is partially or wholly damaged; learning each signal pattern; and comparing data of vibration signals measured by an acceleration sensor or vibration sensor collected in real time with the various patterns learned through labeling to determine at least one of damage to the mold or press forming machine, the timing of maintenance, and potential problems.

[0033] A means for solving another problem of the present invention is to provide a press forming process monitoring service method using a sensor module, comprising the steps of: a battery that supplies electrical energy to an electronic component embedded in a sensor module is fixedly installed in a battery fixing part located between a measurement PCB and a control PCB; a silicone member for fixing the battery is fixedly installed on the upper part of the battery so as not to separate the battery from the battery fixing part; and an insulating plate is fixedly installed in the battery fixing part to minimize heat transfer to the battery so as not to exceed the operating temperature limit of the battery.

[0034] As a means of solving another problem of the present invention, a liquid crystal display for displaying sensor module information is fixedly installed on the upper part of the sensing unit case, and a step of displaying one of the following on the liquid crystal display for displaying information of the sensing unit by operating a button for operating the sensor module is provided. Effects of the invention

[0035] The present invention has an enhanced effect of efficiently analyzing and managing the production process in real time by installing a sensor module on one side of a press mold to measure the number of mold openings and closings and the mold vibration signal, arranging the measured signals according to a predetermined procedure using a control algorithm mounted on a control PCB embedded in the sensing unit, transmitting the data to a transmitting / receiving terminal via Bluetooth communication, transmitting the data in real time to a server / cloud server via Internet WiFi communication for storage, and then using a statistical algorithm and / or AI / ML algorithm mounted on the server based on the stored data.

[0036] Another advantage of the present invention is that it is possible to determine in real time whether the press forming process is being performed normally by measuring at least one vibration signal among the press holder contact time, punch contact and press start time, press end time, mold opening start time, and material and product ejection time from the vibration signal of the mold measured by an acceleration sensor or vibration sensor fixedly installed on the punch plate, and monitoring at least one vibration signal among each measured vibration signal.

[0037] Another effect of the present invention is to analyze mold opening / closing signal and vibration signal data among the data stored in a server, measure at least one signal among mold opening / closing time, press holder contact time, punch contact and press start time, press end time, mold opening start time, and material and product ejection time, and analyze at least one of the generation interval and amplitude of each generated signal, thereby providing an enhanced effect of displaying or providing guidance on the presence or absence of abnormalities on a monitor linked to the server for molded products that deviate from at least one set range.

[0038] Another advantage of the present invention is that by installing an AI / ML algorithm for detecting abnormal conditions of a mold or press forming machine on a server, labeling various abnormalities of the mold or press forming machine, and learning each signal pattern, when an abnormality occurs in the vibration signal data pattern in advance, the vibration signal data measured by the acceleration sensor or vibration sensor collected in real time is compared with the labeled and learned signal pattern to determine the maintenance timing or potential problems of the mold or press forming machine.

[0039] Another advantage of the present invention is that it is possible to install statistical algorithms and AI / ML algorithms on a management server, a server, or a cloud server, analyze the quality of molded products based on data stored on the server, and display results obtained from at least one of mold ID, molded product, Hall sensor, and accelerometer sensor in real time on a screen to an individual or company. Brief explanation of the drawing

[0040] FIG. 1 illustrates one cycle (1 Cycle) of a press forming process according to the present invention to facilitate understanding. FIG. 2 illustrates one embodiment of a sensor module composed of a sensing part and a magnet part. FIG. 3 illustrates an exploded view showing the internal structure of the sensing part among the sensor module of FIG. 2. FIG. 4 is an exploded view of the magnet part of FIG. 2. FIG. 5 is a photograph taken of one embodiment of a press forming machine installed to perform various experiments for the present invention. FIG. 6 is a vibration signal obtained when the sensor module according to the present invention is attached to a punch plate or stripper plate on the movable side. FIG. 7 simultaneously illustrates a vibration signal with a high peak value (60 RPM) and a vibration signal with a somewhat low peak value (40 RPM). FIG. 8 is a data flow diagram showing the process of signals measured by a sensor module being transmitted to a server system / cloud (902) through a data transmission / reception terminal (901). FIG. 9 is a data flow diagram showing multiple sensor modules and data transmission / reception terminals connected and interacting at a manufacturing production site. FIG. 10 is a flow diagram showing the process from data collection using a sensor module to the display of collected data and analysis information on an app platform. FIG. 11 shows the usage status of all molds owned by the company. Specific details for implementing the invention

[0041] We will examine the specific details for implementing the present invention.

[0042] The present invention relates to a method and system for a press forming process monitoring service using a sensor module, wherein a mold counter, a shot counter, or a sensor module is installed in a mold to measure the number of mold openings and closings, cycle time, and vibration signals of a manufacturing production process, and the measured signals are transmitted in real time to a server / cloud server, stored in a database, and analyzed, thereby providing manufacturing production process information in real time to an online app platform without restrictions on the location and distance of the mold and / or manager.

[0043] Let us examine specific embodiments of the present invention.

[0044] <Example>

[0045] A specific embodiment according to the present invention will be examined based on the drawings.

[0046] The press molded product quality management service method according to the present invention, which can analyze and monitor the molded product production process, can be applied to all manufacturing industrial fields that use molds as the main production agent, such as injection molding and press molding, and can provide services to individuals and / or companies who wish to receive services through an app platform.

[0047] In order to receive the service according to the present invention, the step of downloading a predetermined program from an app platform provided by the server of the present invention and registering as a member by following a predetermined procedure provided by the program is included.

[0048] The method may include a step of being assigned a unique ID to use the service upon signing up, and using the assigned unique ID to access the press molded product quality management service app provided by the present invention to check various information on a monitor regarding the production volume of the company's product and whether production is proceeding normally.

[0049] The method includes the step of registering as a member to receive the service according to the present invention, clicking an information input button provided by the app to receive the service, and then inputting information such as a mold ID linked to the sensor module ID installed in the mold, a product, a part, and a company.

[0050] The step of inputting information for receiving the service of the present invention may include the step of storing and registering information by an app platform manager when a user accesses an app platform and directly inputs information about a press mold to be linked, or requests service subscription in the form of various documents or materials.

[0051] There are countless press molds, press-formed parts, press-formed products, and companies that receive or intend to receive the services of the present invention, and the method includes the step of assigning a unique ID to each of those that require identification so that they can be identified.

[0052] That is, it includes the step of acquiring data by identifying the shot cycle and / or mold vibration signals of products produced in all molds producing press-molded products, such as the mold ID, the unique ID of the sensor module attached to the mold, the transmitting / receiving terminal ID, and the company ID, and storing the acquired data in memory and / or a database, such as a management server, a server, or a cloud server.

[0053] Data stored in memory and / or a database is configured to analyze the quality of a product using statistical algorithms and / or AI (Artificial Intelligence) / ML (Machine Learning) algorithms developed in the present invention and installed on a management server, server, or cloud server, etc., in order to provide desired services to individuals and / or companies.

[0054] The 'sensor module' in the specification of the present invention is composed of a 'magnetic part' and a 'sensing part', and the sensing part accommodates a Hall sensor, a temperature sensor, an acceleration sensor, a battery, a measurement PCB, and a control PCB, etc.

[0055] In the specification of this invention, the term "App Platform" is a compound term formed by combining "App" and "Platform." "App" has the same meaning as a conventional "App" and refers to the application program provided in this invention, while "Platform" refers to the "Internet environment" where the App is provided.

[0056] Therefore, 'app' and 'app platform' are used interchangeably in specifications and should be understood as having the same meaning.

[0057] In addition, the present invention provides a system capable of providing services to customers to monitor in real time whether various press-formed products are being produced normally.

[0058] The press forming of the present invention is also referred to as stamping forming, which means the same thing.

[0059] In the specification of the present invention, 'punch plate' refers to the 'upper mold' on the movable side, and the 'die' on the fixed side may be referred to as 'die' or 'lower mold' depending on the model of the press forming machine.

[0060] The 'struffer plate' in the specification of the present invention includes a 'movable struffer plate' and a 'fixed struffer plate,' and the means and method for acquiring signals to monitor a press forming process by applying a sensor module according to the present invention are the same.

[0061] In the specification of this invention, technical configurations are described as a press forming process.

[0062] The press forming process monitoring system and service method according to the present invention involves attaching and fixing a sensor module to one side of the press mold surface to measure various vibration signals and mold opening / closing signals generated during the press forming process, storing the data in a database such as a management server and / or computer via a terminal using wired or wireless transmission / reception means, and managing the press forming process by analyzing and processing the stored data in real time.

[0063] The present invention is designed and manufactured to provide a service for monitoring press forming processes by attaching and installing sensor modules to various press forming machines installed in countries around the world using conventional wired or wireless communication means capable of real-time signal processing.

[0064] Depending on the simplicity or complexity of the molded product, a single press-formed product is produced through one or multiple press-forming processes.

[0065] In the case of a molded product manufactured through multiple press forming processes, more specifically, when a single molded product is produced through five press processes, five press forming processes are performed, and in each press process, different vibration signals can be obtained depending on the contact area, contact angle, and contact shape of the punch stripper and the die (lower mold).

[0066] First, we will examine in detail, based on the drawings, the configuration of the sensor module fixedly installed on one side of the press forming machine to monitor the press forming process.

[0067] Press forming is a process of making a desired product by pressing a molding plate (604 in FIG. 5) of a predetermined thickness, mainly made of metal material, with strong pressure to form it into the shape formed in the mold.

[0068] Figure 1 is illustrated to facilitate understanding of one cycle (1 Cycle) of the press forming process according to the present invention.

[0069] Based on Figure 1, we will briefly examine the entire process of manufacturing a molded product using a press forming machine.

[0070] In FIG. 1, the sequence for manufacturing a press-formed product includes the step and means of ‘press holder (material fixing) contact time (701 in FIG. 6)’ in which a molding plate (604, Sheet Material in FIG. 5) to be formed is first pushed between the punch plate and the die (lower mold) of the press-forming machine, and then the molding plate is pressed by moving the stripper plate (602 in FIG. 5) located below the punch plate downward to make fixed contact (Holder Contact) on the die.

[0071] The following includes the step and means of ‘punch contact and press start time (702 in FIG. 6)’ for applying pressure to the punch plate of the press forming machine toward the die (lower mold) side with punch contact and press in order to form a molding plate (604 in FIG. 5) fixed to the die (lower mold) shown on the right side of FIG. 1.

[0072] Next, as in FIGS. 1 and 5, the next step after the 'punch contact and press start time (702 in FIG. 6)' includes the step and means of moving the punch plate (601 in FIG. 5) downward to press-contact the die (lower mold, 603 in FIG. 5) for a predetermined time and ending the press forming, which is the 'press end time (703 in FIG. 6)'.

[0073] The predetermined time for maintaining contact with the above press generally means a short time of 1 second or less.

[0074] Next, as illustrated on the left side of FIG. 1, the step and means of ‘mold opening start time (704 in FIG. 6)’ for lifting the punch plate from the die to open and demold the press-molded product are included.

[0075] The following includes the step and means of the ‘material and product ejection time (705 in FIG. 6)’ generated when the punch plate is completely demolded to push the material and molded product out of the mold, at the time when the peak value (705 in FIG. 6) is generated in the vibration signal of FIG. 6.

[0076] As shown in FIG. 1, one cycle of the press forming process includes positioning the sheet material to be formed onto the upper part of the die (lower mold) at a set cycle, fixing the sheet material to the die with a stripper plate, making punch contact and applying pressure to the die with a punch plate to produce a formed product, and lifting the punch plate from the die to remove the press-formed product in order to take out the formed product.

[0077] The above 'mold opening start time (704 in FIG. 6)' and 'material and product ejection time (705 in FIG. 6)' can both be viewed as signals that occur when the mold is opened and demolded, so they can be grouped into one process (step) or one technical configuration and used for monitoring.

[0078] The present invention allows a molding plate (molding material) to be positioned on a die, and after molding with a punch plate (upper mold) while the molding plate is fixed with a stripper plate, it can be dropped to the bottom of the die or pushed out of the die and dropped downward.

[0079] The present invention monitors a molding process by acquiring vibration signals generated in a press molding process for producing various types of press molding machines and / or molded products using a sensor module.

[0080] As shown in FIGS. 1 and 5, the present invention measures vibration signals and / or mold opening / closing signals by fixing a sensor module to a punch plate (upper mold) or stripper plate to specifically monitor a given pressure, set cycle, or time when performing a press forming process.

[0081] In other words, as previously described, the present invention can detect various vibration signals, including first to fifth impact signals, occurring during one cycle using an acceleration sensor or vibration sensor embedded in a sensor module, thereby enabling continuous real-time monitoring of whether the press forming process is being performed normally.

[0082] The present invention can monitor whether the press forming process is being performed normally by detecting signals distinguishing press holder contact time, punch contact, press start time, press end time, mold opening start time, material and product ejection time, etc., from a sensor module installed in a mold to monitor the press forming process and transmitting them to a control unit.

[0083] The magnitude and period of the vibration signal measured by the acceleration sensor of the sensor module described above can be detected by acquiring peak values ​​or by acquiring signals exceeding a set value, and among these signal acquisition methods, the one that enables more accurate and easier monitoring of the press process can be selectively used.

[0084] To achieve the objective of the present invention, we examine a sensor module employed in a press forming process monitoring system designed and manufactured to monitor a press forming process.

[0085] FIG. 2 illustrates one embodiment of a sensor module composed of a sensing part and a magnetic part.

[0086] As shown in FIG. 2, the 'sensor module' in the specification of the present invention is composed of a 'magnetic part' and a 'sensing part', and the sensing part accommodates a Hall sensor, a temperature sensor, an acceleration sensor, a battery, a measuring PCB, and a control PCB.

[0087] Figure 3 shows an exploded view of the sensing part (100 in Figure 2) of the sensor module (150 in Figure 2) of Figure 2, so that the internal structure can be seen.

[0088] Figure 4 is an exploded view of the magnetic part (200) of Figure 2.

[0089] The magnet part is composed of a magnet part body (201 in FIG. 4), a magnet part cover (202 in FIG. 4), and a magnet (203 in FIG. 4), and it is preferable to make the magnet out of neodymium, which has a strong magnetic force.

[0090] More specifically, we will examine the configuration of the sensing unit (100 in FIG. 2).

[0091] Components that are described in the description of the symbols in the specification of the present invention but are not mentioned in the detailed description are depicted in the drawings to the extent that it is easy to understand what role the corresponding component plays, so a specific description is omitted.

[0092] Terms expressing location and direction, such as 'upper' and 'lower' in the specification of the present invention, are described based on the drawings and may be expressed in various ways when the drawings are modified.

[0093] The sensing unit (100 in FIG. 2) described in the specification of the present invention has a temperature sensor, an acceleration sensor, a magnetic sensor, a Hall sensor, a measuring PCB with the temperature sensor and acceleration sensor fixedly installed, a battery (107 in FIG. 3), and a control PCB with a memory equipped with an MCU and a control algorithm.

[0094] The magnetic sensor embedded in the sensing unit (100 in FIG. 2) according to the present invention is used to count the number of times the mold is opened and closed, and the acceleration sensor can be used to detect and analyze the vibration signal of the mold and monitor the press forming process in real time.

[0095] The temperature sensor embedded in the sensor module can be used selectively only when mold temperature measurement is necessary, taking into account the material and characteristics of the product being manufactured in the press forming machine.

[0096] The above magnetic sensor is primarily used as a shot counter to count the number of times a press mold is opened and closed, but it can also be used to determine that an abnormality has occurred in the work process by measuring the interval and / or period (cycle) between shots with a clock embedded in the sensing unit and determining if it is longer or shorter than the set time.

[0097] In other words, the magnetic sensor of the sensing unit can also be used as a means to evaluate quality.

[0098] The present invention embeds a clock on one side of a control PCB within a sensing unit so that the detection time of signals measured from sensors can be recorded and stored in a memory or database of a control unit and / or server, etc.

[0099] Signals measured by a Hall sensor, temperature sensor, and / or acceleration sensor are configured to be transmitted to a terminal through various communication means, including Bluetooth embedded in the sensing unit, after undergoing a predetermined data processing procedure by executing a predetermined program in a memory equipped with an MCU and a control algorithm.

[0100] Data transmitted to the terminal is stored in real-time in the memory and / or database of one or more of the relevant server, management server, and cloud server using wireless / wired communication means and / or WiFi, and by analyzing this data, it is possible to monitor whether press-formed products are being manufactured normally.

[0101] The sensor module illustrated in FIGS. 2 to 4 is one embodiment of the present invention, and the overall shape including width, length, and height can be designed and manufactured in various sizes and shapes while maintaining the overall function, taking into account the location and space to be installed on one side of a press forming machine.

[0102] The lower part of the sensing unit case (113 in FIG. 3) and the mold or stripper plate are installed so as to be in direct contact, and are securely fixed using bolts or magnets so that the contact surface can be continuously maintained firmly.

[0103] In addition, the lower part of the sensing unit case (113 in FIG. 3) and the measuring PCB (109 in FIG. 3) are also fixed in place so as to be in direct contact, and it is desirable to fix them securely using conventional fastening means such as bolts so that the contact surface can be continuously maintained.

[0104] On one side of the lower part of the sensing unit case, a button (not shown) for confirming the installation of the sensing unit may be installed facing the surface of the mold or stripper plate to confirm that the sensing unit is installed on the mold surface.

[0105] The button for confirming the installation of the sensing unit generates a signal when the sensor module is detached from or attached to the mold surface, transmits it from the control unit to a terminal via wireless communication including Bluetooth, and transmits it from the terminal to a management server, server, or cloud server via various wireless communication means including the Internet and WiFi, thereby enabling the administrator to always verify the information.

[0106] FIG. 5 is a photograph of a press forming machine installed to perform various experiments for the present invention, and is intended to explain the present invention as one embodiment to facilitate understanding.

[0107] FIG. 6 is a vibration signal obtained when a sensing unit according to the present invention is attached to a punch plate (601 in FIG. 5) or a stripper plate (602 in FIG. 5) on the movable side to perform press forming.

[0108] Compared to the lower mold or die, the punch plate (601 in FIG. 5) or stripper plate (602 in FIG. 5) makes it easy to detect vibration signals and also enables the detection of fine vibration signals.

[0109] In addition, the present invention detects signals by classifying them from the vibration signal of the mold into press holder contact time (701 in FIG. 6), punch contact and press start time (702 in FIG. 6), press end time (703 in FIG. 6), mold opening start time (704 in FIG. 6), and material and product ejection time (705 in FIG. 6) in order to monitor the press forming process, transmits these signals to a control unit, a terminal, and a server, and then analyzes these signals to monitor whether the press forming process is being performed normally.

[0110] Press holder contact time (701 in FIG. 6), punch contact and press start time (702 in FIG. 6), press end time (703 in FIG. 6), mold opening start time (704 in FIG. 6), and material and product ejection time (705 in FIG. 6) are detected from the vibration signal of the mold measured by an acceleration sensor or vibration sensor embedded in the sensor module, and at least one of these can be used as a monitoring signal.

[0111] The vibration signal in Fig. 6 is acquired by an acceleration sensor when operating at a speed of 40 RPM, and proceeds as one cycle (1 period) of 1.5 seconds.

[0112] Figure 7 simultaneously shows a vibration signal with a high peak value (60 RPM) and a vibration signal with a somewhat low peak value (40 RPM), and when operating at 60 RPM, one cycle is 1 second, and when operating at 40 RPM, one cycle is 1.5 seconds.

[0113] The vibration signal in Fig. 7 was obtained by matching the RPM speed and the injection speed of the molding plate with a mechanical press forming machine, and it can be seen that as the speed increases, the acceleration becomes somewhat larger and the amplitude of the vibration signal appears larger.

[0114] More specifically, in FIG. 7, the difference in amplitude between the vibration signal measured by the acceleration sensor at 60 RPM and the vibration signal measured at 40 RPM (801 in FIG. 7) can be observed, and the signal with the smaller amplitude is the vibration signal measured at 40 RPM.

[0115] However, if the RPM is set too high, the press holding time for forming becomes too short, making it impossible to produce normal formed products; conversely, if it is set too slowly, there is a problem with low press force and poor production speed.

[0116] In the case of press forming, wear may occur on part or the entire upper and / or die (or lower mold) because the punch plate and the die press against each other with high pressure with the forming plate (the sheet that serves as the material for the formed product) in between.

[0117] In the case of the blanking process during press forming, the punch plate (upper mold) and the die (lower mold) do not come into contact with each other. Since the forming plate is firmly fixed by a stripper plate and then formed by applying strong pressure to the punch plate instantaneously, the formed product is dropped to the bottom of the die, there may be some difference in wear of the punch plate, etc.

[0118] If wear occurs in part or all of the mold, or if the injection speed of the molding plate does not match the reciprocating period of the punch plate, a difference may occur when compared to a normal vibration signal in terms of the amplitude or the timing of signal generation of the vibration signal acquired from the acceleration sensor or vibration sensor.

[0119] If a difference in amplitude, occurrence time, etc., occurs compared to the normal vibration signal described above, it is determined that an abnormality has occurred in the molding product production process, and the system can be configured to display an abnormality message on the monitor of the relevant server and / or management server or to notify the administrator through communication means.

[0120] In FIG. 5, the sensing part and the magnetic part of the sensor module may each be installed with the sensing part on a punch plate or stripper plate and the magnetic part on a die, taking into consideration the possibility of accurately acquiring a monitoring signal and the space for easy installation, or the sensing part may be installed on a die and the magnetic part on a punch plate or stripper plate.

[0121] In the case of press forming, since the formed product is produced by the movement of the punch plate and the stripper plate, if a sensing unit is fixedly installed on the punch plate and / or the stripper plate, there is an advantage in that various vibration signals generated during the press forming process can be more easily obtained.

[0122] Of course, vibration signals can also be acquired by fixing the sensing unit to the die.

[0123] The present invention obtains press holder contact time, punch contact and press start time, press end time, mold opening start time, and material and product ejection time from vibration signals measured by an acceleration sensor or a vibration sensor, and can monitor whether the press forming process is being performed normally or abnormally by obtaining a peak value or a value greater than a set value from each of the obtained vibration signals.

[0124] A Hall sensor embedded in the sensor module of the present invention is installed on a punch plate or a stripper plate, and a magnetic part is installed on a die or in reverse. When the Hall sensor approaches the magnet and the mold is closed due to a press operation, the Hall sensor detects a '1' signal in the sense of 'ON', and when the magnet moves away from the Hall sensor and the mold is opened due to a press operation, the magnetic Hall sensor detects a '0' signal in the sense of 'OFF' and transmits a signal to the control unit of the sensor module.

[0125] The present invention can be configured to rapidly and accurately monitor a press forming process by transmitting and processing signals acquired from a magnetic Hall sensor and an accelerometer into a data array according to a predetermined rule, in order to rapidly process data measured by a sensor embedded in a sensor module.

[0126] The control unit of the monitoring sensor module according to the present invention is equipped with a wireless communication unit including Bluetooth to transmit signals obtained from a magnetic Hall sensor, an acceleration sensor, and a temperature sensor to at least one of a computer, a server, and a smartphone.

[0127] The present invention obtains press holder contact time, punch contact and press start time, press end time, mold opening start time, and material and product ejection time from vibration signals measured by an acceleration sensor or a vibration sensor, defines the time obtained by adding the 'punch contact and press start time' and the 'press end time' from each of the acquired vibration signals as the 'press process time', and analyzes these signals to monitor whether the press forming process is being performed normally.

[0128] The above 'mold opening start time (704 in FIG. 6)' and 'material and product ejection time (705 in FIG. 6)' can both be viewed as signals that occur when the mold is opened and demolded, so they can be grouped into a single step or process as a single technical configuration and defined as 'mold opening and product ejection time' to be used as monitoring information.

[0129] FIG. 8 is a data flow diagram showing the process of signals measured by a sensor module being transmitted to a server and / or cloud server (902) through a data transmission and reception terminal (901).

[0130] Figure 9 is a data flow diagram showing multiple sensor modules and data transmission / reception terminals connected and interacting at a manufacturing production site.

[0131] Figure 10 is a data flow diagram schematically illustrating the entire process from data collection using a sensor module to the display of collected data and analysis information on an app platform.

[0132] Figure 11 shows the usage status of all molds owned by the company, displayed on a monitor linked to a server according to the present invention.

[0133] FIG. 11 is a screen capture taken on a monitor to show one example of a display screen of various types provided according to the present invention.

[0134] The methods for applying pressure to the punch plate described above include a mechanical press forming method that converts rotational motion into linear reciprocating motion and a press forming method that applies pressure via linear reciprocating motion using a conventional hydraulic or pneumatic cylinder; in both methods, the press forming process can be monitored by measuring and analyzing the mold vibration signals and / or mold opening / closing signals by applying the technical configuration described above.

[0135] To manage various press-formed products produced in countries around the world, multiple sensor modules are attached to the molds, and signals measured by the sensor modules are transmitted to transmitting and receiving terminals via a control PCB. The transmitted data is then sent to a management server, a server, or a cloud server via wired or wireless communication, such as standard high-speed internet or WiFi, and stored in memory and / or a database.

[0136] Data stored in memory and / or databases can provide various services to users to efficiently monitor and manage the molding process of products through various analyses using statistical algorithms and AI / ML algorithms installed on management servers, servers, or cloud servers.

[0137] Based on the previously described contents and drawings, the contents to be described below can be easily carried out by a person with ordinary knowledge in this technical field.

[0138] The server or cloud server system is equipped with mathematical statistical tools / algorithms and / or AI / ML algorithms to enable analysis using stored data, cycle times measured during the press forming process, and mold vibration signals.

[0139] The data recorded and stored in the memory and / or database of the server or cloud server includes a step of determining, for each press-formed product, whether it is a good product produced by a normal process or a defective product produced by an abnormal process, based on data patterns learned using mathematical statistical tools / algorithms and / or AI / ML algorithms installed on the server or cloud server.

[0140] These analysis data can be viewed remotely on a monitor from anywhere in the world through a management server, server, or cloud server equipped with an app platform program designed and manufactured according to the present invention, and since the data is displayed in real time, it can be utilized for the control and management of press production processes regardless of time and place.

[0141] The present invention may include the step of displaying the results of an analysis using an analysis algorithm for vibration signals measured by an acceleration sensor or a vibration sensor among data collected through a sensor module and stored in a management server, server, or cloud server system, in various ways on an app platform in relation to quality control of press-formed products.

[0142] The present invention includes the step of converting time-series data into specific peak and time data based on an algorithm embedded in the firmware program of a sensor module, arranging the data, transmitting it to a management server, server, or cloud server system via a transmitting and receiving terminal for storage, analyzing it, and displaying it on the screen of an app platform.

[0143] The amplitude of the vibration signal measured by the acceleration sensor or vibration sensor of the sensor module can be detected by obtaining a peak value or by obtaining signals that are greater than or equal to a set value.

[0144] The signal detected in this way is transmitted from the control unit embedded in the sensor module to the terminal via wireless communication, including Bluetooth, and from the terminal to a management server, server, or cloud server via wireless communication or WiFi, and stored in memory or a database.

[0145] Data transmitted to the aforementioned management server, server, or cloud server and recorded and stored in memory or a database is classified into good products, defective products, or products with potential for abnormalities using embedded statistical algorithms and / or AI / ML algorithms, and productivity and defect rates can be analyzed.

[0146] The above statistical algorithm and / or AI / ML algorithm may include a step of managing production or predicting the timing of maintenance / repair of molds and / or press forming machines by analyzing the quality of various press forming products based on data recorded and stored in memory, while recording and storing vibration signal data measured by an acceleration sensor or vibration sensor in real time and being installed on a management server, server, cloud server, computer, etc., where a program is running.

[0147] One embodiment of the present invention constructs an AI / ML algorithm that determines in real time what type of defect has occurred by labeling various defect information, including damage to the upper mold and / or lower mold, changes in the cycle (process cycle), etc., and for learning, extracts and trains various types of signal patterns based on normalized or generalized values, and can determine in real time whether a product is good or not by comparing the learned signal patterns with the patterns of vibration signal data measured by an acceleration sensor or a vibration sensor.

[0148] One embodiment of the present invention may include the step of installing an AI / ML algorithm for detecting an abnormal state of a mold or press forming machine on a server or management server, labeling each case where at least one of a punch plate, a lower mold receiving pressure applied by the punch plate, and a die is partially or wholly damaged to learn each signal pattern, and comparing the data of vibration signals measured by an acceleration sensor or vibration sensor collected in real time with the various patterns learned through labeling to determine whether at least one of the damage to the mold or press forming machine, the timing of maintenance, and potential problems has occurred.

[0149] Based on the technical configuration described above, the scope of patent protection of the present invention is summarized.

[0150] One embodiment of the present invention provides a press-formed product quality analysis monitoring system equipped with a sensor fixedly installed on the surface of a mold to count the number of times the mold is opened and closed, and a sensor to detect vibration of the press mold for quality control of the press-formed product, and a system for monitoring to manage the press-formed product. Another embodiment of the present invention includes the step of providing a press-formed process monitoring service by installing a memory or database that stores information including information on a plurality of sensor modules installed in a plurality of molds, a mold linked to the plurality of sensor modules, a product being press-formed in the mold, and a company name, in order to provide the service to a personal or company computer requiring the press-formed process monitoring service from a management server.

[0151] In one embodiment of the present invention, a sensor for detecting vibration of a press mold has an acceleration sensor or a vibration sensor capable of measuring vibration of the mold embedded in a sensor module, and measures at least one vibration signal among the press holder contact time, punch contact and press start time, press end time, mold opening start time, and material and product ejection time from the vibration signal measured by the acceleration sensor or vibration sensor embedded in the sensor module, and can determine whether the press forming process is being performed normally by monitoring at least one vibration signal among each measured vibration signal.

[0152] In one embodiment of the present invention, the sensing part of the sensor module is fixedly installed on one of a punch plate and a stripper plate capable of easily detecting a vibration signal, and a magnetic part is fixedly installed on a lower mold or die where vibration is minimal. The sensing part has a control PCB and a measurement PCB embedded therein. The control PCB is equipped with a Hall sensor, a liquid crystal display, an MCU, and a memory equipped with a control algorithm, and is fixedly installed within the sensing part case. The measurement PCB is equipped with a sensor for measuring vibration and is preferably installed in close contact with the bottom of the sensing part case to accurately measure the vibration signal.

[0153] In one embodiment of the present invention, the vibration signal measured by the acceleration sensor or vibration sensor at the press holder contact time, punch contact time, and press start time varies according to the difference in cycle time, and if at least one of the amplitude of the vibration signal and the period of the vibration signal deviates from a set size, it can be determined that there is an abnormality in the quality of the press-formed product.

[0154] In one embodiment of the present invention, mold opening and mold closing signals are counted from a vibration signal measured by an acceleration sensor or a vibration sensor, and the signal interval between the mold opening and mold closing signals is measured in real time to determine whether it exists within a set time range, and if the result of the determination is smaller or larger than the set time range, it can be determined that there is an abnormality in the quality of the molded product.

[0155] One embodiment of the present invention measures at least one of the mold opening time and mold closing time measured by a magnetic sensor in real time, and if the time interval of at least one of the mold opening time and mold closing time deviates from the range of a set time interval, it can be determined that there is an abnormality in the quality of the press-formed product.

[0156] In one embodiment of the present invention, a control unit is fixedly installed inside a sensing unit, and the control unit controls and sets the time interval for measuring signals from an acceleration sensor, a vibration sensor, and a magnetic sensor. The signals obtained from the acceleration sensor, a vibration sensor, and a magnetic sensor are processed according to a predetermined procedure by an algorithm mounted in the control unit embedded in the sensing unit, and a wireless communication unit including Bluetooth is provided to transmit and receive the data from the control unit to at least one of a computer, a management server, a server, and a smartphone via a terminal, and can be configured to manage product quality by transmitting the data in real time worldwide via high-speed internet WiFi communication.

[0157] In one embodiment of the present invention, an AI / ML algorithm is constructed to determine in real time what type of defect has occurred by labeling various defect information, such as damage to the upper mold and / or lower mold, changes in the cycle (process cycle), etc., and for learning, signal patterns are extracted and trained based on normalized or generalized values, and based on the learned patterns, it is possible to determine whether the product is good or not by comparing it with the pattern of vibration signal data measured by an acceleration sensor or a vibration sensor.

[0158] One embodiment of the present invention detects a vibration signal by dividing it into press holder contact time, press process time, mold opening and product ejection time intervals using an acceleration sensor or vibration sensor embedded in a sensing unit, and continuously measures and stores at least one of the amplitude of the vibration signal generated during the press holder contact time, press process time, mold opening and product ejection time, and the time between each interval, and can determine whether there is an abnormality in the press-formed product by comparing and analyzing the amplitude of the measured and stored vibration signal and the time interval of occurrence.

[0159] One embodiment of the present invention may include a configuration in which an AI / ML algorithm for detecting abnormal conditions of a mold or press forming machine is installed on a server or management server, and when an abnormality occurs in the vibration signal pattern measured by an acceleration sensor or vibration sensor embedded in a sensing unit, the abnormal vibration signal generated by the press mold or press forming machine is labeled respectively, and each signal pattern is learned, and after comparing and analyzing the learned signal pattern with the vibration signal pattern that is generated and measured in various ways during the production of a press formed product, the press forming conditions are modified to normally control the press forming cycle so that a process producing defective products produces good products, or the mold is notified of damage to the mold so that the mold can be replaced.

[0160] One embodiment of the present invention is equipped with an AI / ML algorithm for detecting abnormal conditions of a mold or press forming machine on a server or management server, and considering that there is not only one molding condition for producing a good molded product, it learns the production patterns of good products under various conditions among the various molding conditions for producing good products and the vibration signal data measured by an acceleration sensor or vibration sensor accordingly, and can determine whether a product is good or not by comparing the collected vibration signal data pattern measured by the acceleration sensor with the learned pattern.

[0161] One embodiment of the present invention is equipped with an AI / ML algorithm for detecting abnormal conditions of a mold or press forming machine on a server or management server, and measures at least one vibration signal among the press holder contact time, punch contact and press start time, press end time, mold opening start time, and material and product ejection time from a vibration signal measured by an acceleration sensor or vibration sensor embedded in a sensor module, and based on at least one vibration signal among each measured vibration signal, if at least one of the punch plate, the lower mold receiving the pressure applied by the punch plate, and the die is partially or wholly damaged during the process of pressing a forming plate of a press forming target with strong pressure, the vibration signal is measured by an acceleration sensor or vibration sensor embedded in a sensing unit and used to monitor the press forming process.

[0162] One embodiment of the present invention is capable of detecting abnormal conditions of a mold or press forming machine by installing an AI / ML algorithm on a server or management server, labeling cases where at least one of a punch plate, a lower mold receiving pressure applied by the punch plate, and a die is partially or wholly damaged, learning each signal pattern, and determining at least one of the damage to the mold or press forming machine, the timing of maintenance, and possible problems by comparing the data pattern of vibration signals measured by an acceleration sensor or vibration sensor collected in real time with the various patterns learned through labeling.

[0163] Another embodiment of the present invention is such that, since the magnetic force strength of a magnet installed in a magnet part decreases inversely proportional to the cube of the distance, the distance between the magnet part and the sensing part containing a Hall sensor is fixed within a set distance, and is placed on a control PCB and fixedly installed on the upper part of the sensing part, and the magnet installed in the magnet part can be fixedly installed within a set distance range considering the position of the Hall sensor installed in the sensing part.

[0164] Another embodiment of the present invention is such that a battery supplying electrical energy to an electronic component embedded in a sensor module is fixedly installed in a battery fixing part located between a measurement PCB and a control PCB, a silicone member for fixing the battery is fixedly installed on the upper part of the battery to prevent the battery from being separated from the battery fixing part, and an insulating plate may be fixedly installed on the lower part of the battery fixing part to minimize heat transfer to the battery so as not to exceed the operating temperature limit of the battery.

[0165] In another embodiment of the present invention, a liquid crystal display for displaying sensor module information is fixedly installed on the upper part of the sensing unit case, and the liquid crystal display for displaying information of the sensing unit can be configured to display one of the following by operating a button for operating the sensor module: display of the last shot count, display of the closed state, display of the remaining battery level, display of the communication sensitivity between the terminal and the control unit, display of the installation status, and display of whether there is stored data.

[0166] Another embodiment of the present invention is to install an AI / ML algorithm for detecting abnormal conditions of a mold or press forming machine on a server or management server, measure at least one vibration signal among the press holder contact time, press process time, mold opening, and product ejection time from a vibration signal measured by an acceleration sensor or vibration sensor embedded in a sensor module, and compare the period obtained based on at least one of the measured vibration signals with the set period of the press forming process, so that when it deviates from the set period, it can be determined that the product was produced in an abnormal forming process.

[0167] Another embodiment of the present invention includes the steps of: downloading a predetermined program provided by an app to access a server and receive a service; clicking an information input button provided by the app, and then inputting information for receiving a service, including a mold, product, and company name linked to a plurality of sensor modules installed in a mold requiring information input, and storing it in a memory or database; transmitting a signal measured from the input and stored plurality of sensor modules to a control PCB embedded in a sensing unit; preprocessing the data using an algorithm mounted on the control PCB; transmitting the preprocessed data to a transmitting and receiving terminal via wireless communication, and storing the transmitted data on a server via communication including Internet WiFi.

[0168] Another embodiment of the present invention includes a sensor module equipped with a sensor for counting the number of times a mold is opened and closed, and a sensor for detecting vibration of a press mold for quality control of a press-formed product, and includes a step of monitoring a vibration signal to manage a press-formed product.

[0169] In another embodiment of the present invention, a sensor for detecting vibration of a press mold includes an acceleration sensor or a vibration sensor capable of measuring vibration of the mold embedded in a sensing part, and measures at least one vibration signal among the press holder contact time, punch contact and press start time, press end time, mold opening start time, and material and product ejection time from the vibration signal measured by the acceleration sensor or vibration sensor embedded in the sensing part, and monitors at least one vibration signal among each measured vibration signal to determine whether the press forming process is being performed normally.

[0170] In another embodiment of the present invention, a control PCB embedded in a sensing unit is equipped with a firmware program for operating an MCU and a sensor module, and the method includes a step of transmitting and receiving data via wireless communication including Bluetooth, which is edited into a single data array in a time series through a firmware algorithm to increase the processing speed of data measured by a sensor of a measurement PCB and reduce storage capacity, and transmits and receives data from the control PCB to a transmitting and receiving terminal.

[0171] In another embodiment of the present invention, the sensing part of the sensor module is fixedly installed on one of a punch plate and a stripper plate, and the magnetic part is fixedly installed on a lower mold or die. The sensing part has a control PCB and a measurement PCB embedded therein. The control PCB is equipped with a Hall sensor, a liquid crystal display, a memory equipped with an MCU and a control algorithm, and a wireless communication part including Bluetooth, and is fixedly installed on the upper part of the sensor module case. The measurement PCB is equipped with a sensor for measuring vibration and is installed in close contact with the lower part of the sensor module case to accurately measure the vibration signal.

[0172] Another embodiment of the present invention includes the steps of: recording and storing data measured from a sensing unit on a server via a transmitting and receiving terminal; and displaying an analyzed screen based on at least one piece of information or data among a mold ID, part ID, sensor module ID, molded product, Hall sensor, and vibration sensor, equipped with a statistical algorithm and an AI / ML algorithm, and analyzing the quality of a molded product based on the data stored on the server, so that an individual or company can manage products produced from a mold.

[0173] Another embodiment of the present invention includes the steps of: measuring a signal measured by a sensor embedded in a sensing unit as time-series data using an algorithm mounted on a measuring PCB; applying the algorithm in a memory equipped with an MCU embedded in a control PCB and a control algorithm to the measured data to obtain a peak value or a value greater than a set value required for production information analysis and including it in a data array; transmitting the arrayed data to a transmitting / receiving terminal via Bluetooth communication of the control PCB and storing it in at least one of a management server, a server, and a cloud server; and analyzing the generation interval of vibration signals occurring during mold opening and closing based on data stored in the server for product management, and displaying a list of defective products on a monitor or displaying an abnormality notice on the screen for press-formed products that fall outside a set range.

[0174] Another embodiment of the present invention includes the step of measuring at least one of the mold opening time and mold closing time measured by a magnetic sensor in real time, and if at least one of the time intervals of the mold opening time and mold closing time deviates from the range of a set time interval, determining that there is a defect in the quality of the press-formed product and displaying a list of defective products on a monitor or displaying a defect notification on the screen.

[0175] In another embodiment of the present invention, a control unit is fixedly installed inside a sensing unit, and the control unit includes the step of controlling and setting a time interval for measuring signals from an acceleration sensor, a vibration sensor, and a magnetic sensor; performing a usage analysis for each mold of the company, performing the analysis based on days when the target production volume was met, days when it was not met, and days when the mold was not operated, displaying the total production ratio, and providing a screen that shows the additional time during which product production was possible for each mold in addition to the actual product production time.

[0176] Another embodiment of the present invention includes the steps of displaying on a screen a part ID, part name, and current production status of a part being produced by a company among a plurality of service target companies or individuals, and, when the part ID is clicked, displaying a screen that allows checking production information of the corresponding part.

[0177] Another embodiment of the present invention includes the steps of displaying on a screen a press mold ID and the current status of a press mold that produces a plurality of parts of a company among a plurality of service target companies or individuals, and, when the press mold ID is clicked, displaying a screen that allows checking production information of the corresponding part produced by the press mold.

[0178] Another embodiment of the present invention includes the step of displaying a screen on which an analysis report regarding the number of shots, cycle time, uptime, and vibration signal can be viewed on the screen of the press mold, and collected and stored data can be searched and viewed by month, week, day, and hour.

[0179] Another embodiment of the present invention includes the steps of downloading a predetermined program provided by an app platform and registering as a member by following a predetermined procedure provided by the program, being assigned a unique ID for using the service upon registration, and accessing a press forming process monitoring management service app using the assigned unique ID to check the production volume of the company's products and whether production is proceeding normally through various monitoring screens.

[0180] Another embodiment of the present invention comprises a step of changing the frequency of measuring the temperature and vibration signals of the mold through a memory equipped with an MCU and a firmware program using data measured by a sensor embedded in a sensing unit, wherein the signal measurement frequency set in the firmware program includes a step of changing the frequency of the signal measurement frequency by taking into consideration the number of sensing units, the number of service target companies, the data storage capacity, and the processing speed of the amount of data.

[0181] Another embodiment of the present invention includes the steps of: installing an AI / ML algorithm for detecting abnormal conditions of a mold or press forming machine on a server or management server; labeling various abnormal vibration signals generated in a press mold or press forming machine, learning each signal pattern, comparing and analyzing the pattern of vibration signal data measured by an acceleration sensor or vibration sensor with the learned signal pattern, and then modifying the press forming conditions to normally control the press forming cycle so that good products are produced in a process where defective products are being produced, or providing guidance on whether defective products have occurred.

[0182] Another embodiment of the present invention includes the steps of: installing an AI / ML algorithm for detecting abnormal conditions of a mold or press forming machine on a server or management server; labeling various abnormalities of the mold or press forming machine and learning each pattern; and comparing the pattern of vibration signals measured by an acceleration sensor or vibration sensor collected in real time with the labeled and learned pattern to determine the maintenance timing or potential problems of the mold or press forming machine.

[0183] Another embodiment of the present invention includes the steps of: installing an AI / ML algorithm for detecting abnormal conditions of a mold or press forming machine on a server or a management server; measuring at least one vibration signal among the press holder contact time, punch contact and press start time, press end time, mold opening start time, and material and product ejection time from a vibration signal measured by an acceleration sensor or a vibration sensor embedded in a sensor module; and, based on at least one of the measured vibration signals, monitoring for abnormalities by measuring and analyzing a vibration signal using an acceleration sensor or a vibration sensor embedded in a sensing unit when at least one of the punch plate, the lower mold receiving the pressure applied by the punch plate, and the die is partially or wholly damaged during the process of pressing a forming plate of a press forming target with strong pressure.

[0184] Another embodiment of the present invention includes the steps of: installing an AI / ML algorithm for detecting abnormal conditions of a mold or press forming machine on a server or management server; labeling cases where at least one of a punch plate, a lower mold receiving pressure applied by the punch plate, and a die is partially or wholly damaged, and learning each signal pattern; and comparing the pattern of vibration signals measured by an acceleration sensor or vibration sensor collected in real time with the various patterns learned through labeling to determine at least one of damage to the mold or press forming machine, the timing of maintenance, and possible problems.

[0185] Another embodiment of the present invention includes the step of fixing a battery that supplies electrical energy to an electronic component embedded in a sensor module to a battery fixing part located between a measurement PCB and a control PCB, fixing a silicone member for fixing the battery to the upper part of the battery so as not to separate the battery from the battery fixing part, and fixing an insulation plate to the battery fixing part to minimize heat transfer to the battery so as not to exceed the operating temperature limit of the battery.

[0186] Another embodiment of the present invention is to enhance the reliability and accuracy of the judgment by including the steps of: measuring a mold opening / closing signal using a magnetic sensor among a magnetic sensor and a vibration sensor embedded in a sensor module, and measuring the vibration of a press mold using a vibration sensor; analyzing and determining whether a normal product was produced in a normal press forming process based on each of the measured signals; determining a normal product when both signals measured by the magnetic sensor and the vibration sensor are within a normal signal range, and determining an abnormal product when both sensors are outside the normal signal range; and analyzing and determining once more when only one of the two sensors is included within the normal signal range.

[0187] Another embodiment of the present invention includes a step in which a liquid crystal display for displaying sensor module information is fixedly installed on the upper part of the sensing unit case, and one of the following can be displayed on the liquid crystal display for displaying information of the sensing unit by operating a button for operating the sensor module: display of the last shot count, display of the closed state, display of the remaining battery level, display of the communication sensitivity between the terminal and the control unit, display of the installation status, and display of whether there is stored data.

[0188] Based on the technical configuration described above, the scope of patent protection may be described as a system and service method for remotely monitoring a press forming process using a sensor module manufactured according to the present invention, or it may be protected by specifying various scopes of rights protection through a combination of various technical configurations. Industrial applicability

[0189] The present invention provides a press forming process monitoring system and service method using a sensor module that measures vibration signals and mold opening signals generated during press molding using a magnetic sensor, acceleration sensor, or vibration sensor embedded in the sensor module, stores the measured signals in a server database via a terminal through wireless communication means, analyzes whether the press forming process is proceeding normally by applying an algorithm according to the present invention to the stored signals, and displays the analyzed results on a monitor via a management server or computer or notifies an administrator, thereby enabling remote monitoring of whether the press forming process is proceeding normally, thus having very high industrial applicability. Explanation of the symbols

[0190] 100; Sensing unit 101; Upper part of sensing unit case 102; Button for operating the sensing unit 103; Cover for the LCD display for sensing unit information display 104; Silicone cover for the button for operating the sensing unit 105; PCB for controlling the sensing unit 106; Silicone member for fixing the sensing unit battery 107; Sensing unit battery 108; Battery fixing part 109; PCB for measuring the sensing unit 110; Insulation plate 111; Button for checking the installation of the sensing unit 112; Cover for the button for checking the installation of the sensing unit 113; Lower part of the sensing unit case 114; Button for operating the sensing unit 115; LCD display for checking the information of the sensing unit 116; Arithmetic processor (MCU) of the control PCB 117; Hall sensor 118; Accelerometer 119; Temperature sensor 120; Button for checking the installation of the sensing unit 150; Sensor module 200; Magnet unit 201; Main body of the magnet unit 202; Magnet part cover 203; Magnet 204; Magnet receiving groove 601; Punch plate (movable side) 602; Stripper plate 603; Die (fixed side) 604; Forming plate 701; Press holder contact time 702; Punch contact and press start time 703; Press end time 703; Mold opening start time 705; Material and product ejection time 801; Amplitude difference 901; Data transmission / reception terminal 902; Server / Cloud server

Claims

Claim 1 A method for providing a press forming process monitoring service using a sensor module comprises: a step of providing a press forming process monitoring service by installing a memory or database containing information including information on multiple sensor modules installed in multiple molds, a mold linked to the multiple sensor modules, a product being press-formed in the mold, and a company name, in order to provide the service from a management server to a personal or company computer requiring the press forming process monitoring service; a step of transmitting a signal measured from an acceleration sensor or vibration sensor embedded in a multiple sensor module installed in the mold to a memory of a control PCB embedded within the sensing part of the sensor module; a step in which the memory installed in the control PCB embedded in the sensing part of the sensor module is loaded with a firmware program to operate the sensor module in conjunction with an MCU, and a step of acquiring a signal exceeding a peak value or a set value among the signals measured by the sensor module as data using a control program and algorithm embedded in the memory of the control PCB; and a step in which the acquired data is transmitted to a transmitting / receiving terminal via Bluetooth communication installed in the control PCB embedded in the sensing part, and the transmitted data is transmitted through a communication means including Internet WiFi and stored in the memory or database of the management server, wherein the control of the sensing part A step of measuring a vibration signal generated in a press mold using an acceleration sensor or a vibration sensor embedded in a PCB; a step of comparing at least one of the press holder contact time, punch contact and press start time, press end time, mold opening start time, and material and product ejection time in the vibration signal of the press mold measured by the acceleration sensor or the vibration sensor with a set time range, and a step of displaying a product produced outside the set time range as a defective product on the computer monitor of an individual or company that requested service provision, or transmitting a message about a defective product;A method for a press forming process monitoring service using a sensor module, characterized by including the step of a management server equipped with mathematical statistical algorithms and AI / ML algorithms to provide a service requested by an individual or company based on data stored in memory or a database, and using a vibration signal of a press mold stored in memory or a database to display whether a produced product is a normal product on a computer monitor of the individual or company requesting the service provision for at least one of a press mold ID, a part ID, and a sensor module ID. Claim 2 A method for monitoring a press forming process using a sensor module according to claim 1, wherein the sensor module comprises a magnetic part and a Hall sensor, the magnetic part is fixedly installed on a lower mold or die, and the Hall sensor is embedded in a sensing part and fixedly installed on one of a punch plate and a stripper plate to count the number of times the press mold opens and closes. Claim 3 delete Claim 4 delete Claim 5 A method for monitoring a press forming process using a sensor module according to claim 1, wherein the sensing part of the sensor module is fixedly installed on one of a punch plate and a stripper plate where vibration occurs more severely than on a lower mold or die, and a magnetic part is fixedly installed on a lower mold or die where vibration occurs less; the sensing part has a control PCB and a measurement PCB embedded therein; the control PCB has a wireless communication part including a Hall sensor, a liquid crystal display, a memory equipped with an MCU and a control algorithm, and Bluetooth embedded therein; and the measurement PCB is equipped with a vibration measuring sensor and is installed in close contact with the bottom of the sensing part case to accurately measure the vibration signal. Claim 6 delete Claim 7 delete Claim 8 A method for monitoring a press forming process using a sensor module, characterized in that, in paragraph 2, at least one of the mold opening time and mold closing time of a lower mold and an upper mold measured by a magnetic sensor is measured in real time, and if at least one of the mold opening time interval and mold closing time interval deviates from the range of a set time interval, it is determined that there is an abnormality in the quality of the press formed product and this is displayed on a computer monitor of an individual or company that requested the service provision as a list of defective products. Claim 9 A method for monitoring a press forming process using a sensor module, characterized in that, in claim 1, a control unit is fixedly installed inside the sensing unit of the sensor module, and the control unit includes the step of setting a time interval for detecting signals from an acceleration sensor, a vibration sensor, and a magnetic sensor. Claim 10 delete Claim 11 A method for monitoring a press forming process using a sensor module, characterized in that, in claim 1, it includes the step of displaying the production volume of normal parts on a computer monitor of a company or individual who requested the service provision, using a press mold ID that produces multiple parts among the company or individual who requested the service provision, so that the production volume of parts produced normally by a normal forming process in a press mold can be verified. Claim 12 A press forming process monitoring service method using a sensor module, characterized in that, in claim 11, it includes the step of displaying the amount of products produced normally on a computer monitor of a company or individual who requested the service, based on data stored in memory or a database, so that the amount of products produced by a normal press forming process can be verified on a monthly, weekly, daily, and hourly basis. Claim 13 delete Claim 14 delete Claim 15 delete Claim 16 delete Claim 17 delete Claim 18 delete Claim 19 delete Claim 20 A method for monitoring a press forming process using a sensor module, characterized in that, in claim 1, a battery that supplies electrical energy to an electronic component embedded in a sensing part is fixedly installed in a battery fixing part located between a measuring PCB and a control PCB, a silicone member for fixing the battery is fixedly installed on the upper part of the battery so as not to separate the battery from the battery fixing part, and an insulating plate is fixedly installed on the battery fixing part of the sensing part so as to minimize heat transfer to the battery and not to exceed the operating temperature limit of the battery. Claim 21 A method for a press forming process monitoring service using a sensor module according to claim 1, wherein an information display liquid crystal display is fixedly installed on the upper part of the sensing unit case, and the information display liquid crystal display of the sensing unit includes a step of selecting and displaying one of the following by pressing a button for operating the sensor module: display of the last shot count, display of the mold closing status, display of the remaining battery level, display of the communication sensitivity between the terminal and the control unit, display of the installation status, and display of whether or not there is stored data. Claim 22 delete

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