Inline Measuring Device for Press Line Sheet Metal Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of shaped sheet metal parts in press lines is subject to significant production fluctuations affecting geometry, making it difficult to check each part for dimensional accuracy, especially in cramped press shop environments where space for additional measuring systems is limited.
Innovation Solution
A press line with integrated measuring devices at unoccupied tool stages or intermediate stations for automated geometric inspection, using a tool-like measuring device with tactile and contactless sensors for real-time geometry checks, allowing for 100% inline inspection without requiring additional space, and enabling quick cycle times and real-time classification of parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a separate measuring system is added to the press line, then inspection capability is improved, but space requirements increase and integration difficulty worsens
Solution Approach 1:
The measuring device is merged with an existing press by integrating it into the press structure. The measuring device utilizes the press's structural elements (such as the press bed or tool mounting locations) to house its components, thereby eliminating the need for separate space allocation while maintaining full inspection functionality.
Solution Approach 2:
The press structure serves dual functions: it performs both forming operations and houses the measuring device for inspection. This multi-functionality allows the same physical space to serve multiple purposes, resolving the contradiction between inspection capability and space requirements.
2Measurement precision
If inspection frequency is increased to check every part, then measurement coverage is improved, but production time increases
Solution Approach 1:
The measuring device is positioned to receive workpieces continuously from the press without interrupting the production flow. The inspection process is integrated into the existing cycle, allowing continuous measurement coverage of every part while maintaining uninterrupted production timing.
Solution Approach 2:
The measuring device performs rapid automated measurements that complete inspection tasks quickly, rushing through the inspection process efficiently. This allows every part to be measured without significantly increasing production time, as the measurement operation is optimized for speed and automation.
3Area of stationary object
If a measuring device is integrated into the press, then space utilization is improved, but device complexity increases
Solution Approach 1:
The measuring device is designed as a modular, segmented system that can be independently installed and configured within the press structure. This segmentation allows for simplified integration by breaking down the complex measuring system into manageable modules that can be added without overhauling the entire press.
Solution Approach 2:
The control system acts as an intermediary between the press operations and the measuring device, coordinating their interactions. This intermediary layer simplifies integration complexity by providing a standardized interface that manages the coordination between forming and measurement operations without requiring direct complex coupling.
4Productivity
If automated measurement is implemented, then inspection efficiency is improved, but initial investment increases
Solution Approach 1:
The measuring device is designed to be fully automated and self-operating, requiring minimal human intervention for setup, operation, or data collection. This self-service capability maximizes inspection efficiency while reducing the need for additional operational resources, thereby improving the return on initial investment through automation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient, real-time geometric inspection of all produced parts with minimal space impact, allowing for immediate process adjustments and detailed documentation, improving part classification and reducing production downtime.
Implementation Method 1
The measuring device has at least one tactile sensor, in particular a displacement sensor, with which reference points on the shaped sheet metal part can or are being measured
Implementation Method 2
The measuring device has at least one contactless sensor, in particular an optical sensor, with which reference points on the shaped sheet metal part can or are being measured
Data Source
Figure 1~2
AI summary
The invention relates to a production line (100) for producing molded sheet metal parts (300), in particular vehicle body components, comprising a plurality of press-bonded tools, in which in the cycle of the production line (100), successive forming and/or cutting operations for the continuous production of the molded sheet metal parts (300) can be carried out; a transfer system (110) for transporting parts between the tools; and at least one measuring device (200), on which in the cycle of the production line (100), the geometry of the produced molded sheet metal parts (300) can be inspected. According to the invention the measuring device (200) is arranged within the production line (100) at a free press tool space or at an intermediate station such that in the cycle of the production line (100), each produced molded sheet metal part (300) can be placed into the measuring device (200) by means of the transfer system (110) associated with the production line (100), and can be removed therefrom after the cyclical inspection. The invention further relates to such a measuring device (200) for use in such a production line (100).