Piezoelectric Composite Sheet Metal for Molding Pressure Mapping

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Solution Overview

Problem

Existing methods for determining pressure distribution in molding tools for reshaping sheet metal components are subjective and lack objective assessment of compressive loads, leading to imprecise production and increased waste due to production-related tolerances.

Innovation Solution

Incorporating piezoelectric material into the sheet metal component to create a composite that generates electrical voltage under mechanical load, allowing for spatially and temporally resolved detection of pressure distribution using sensors, eliminating the need for manual marking and providing objective data for tool optimization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If blue marking ink is used to assess pressure distribution, then the pressure pattern can be visualized, but the assessment remains subjective and imprecise

Engineering Contradiction:

Improvepressure distribution measurement precisionVSAvoidassessment subjectivity

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The patent replaces the mechanical/visual marking system with an electrical sensing system. Piezoelectric sensors embedded in the sheet metal component convert mechanical pressure into electrical signals, which are then processed objectively by evaluation devices, eliminating subjective visual assessment while maintaining pressure distribution visualization capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces piezoelectric sensors as an intermediary between the pressure application and the assessment process. These sensors mediate the conversion of mechanical pressure into electrical signals, providing an objective intermediate representation that can be precisely measured and evaluated, thereby resolving the subjectivity inherent in direct visual assessment

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If manual assessment of pressure patterns is performed, then the process is simple, but production tolerances increase and waste increases

Engineering Contradiction:

Improvesheet metal component precisionVSAvoidmeasurement system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent changes the measurement parameter from visual color intensity to electrical voltage signals. This parameter change enables precise quantification of pressure distribution, allowing for objective tolerance control and reduced waste, while the embedded sensor system manages the complexity through integration into the workpiece

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If piezoelectric material is introduced into the sheet metal component, then objective pressure measurement is achieved, but the device complexity increases

Engineering Contradiction:

Improvepressure measurement objectivityVSAvoidcomposite material complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent merges the measurement function with the workpiece itself by embedding piezoelectric sensors directly into the sheet metal component. This integration combines the structural function of the component with the measurement function, achieving objective pressure measurement while managing complexity through functional integration rather than separate measurement apparatus

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sheet metal component becomes self-measuring through the embedded piezoelectric sensors. The component itself generates the measurement signals during forming, eliminating the need for separate external measurement devices and reducing overall system complexity despite the material modification

Inventive Principle:

Principle #25Self-service

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 precise and objective determination of compressive loads, reducing production tolerances and waste, and facilitating simpler monitoring in serial production by replacing subjective human evaluation with objective measurement.

Implementation Method 1

introducing a piezoelectric material into a raw material of the sheet metal component to create a composite sheet metal component that can provide an electrical voltage under mechanical loads, such as a compressive load applied in the course of reshaping

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Data Source

PatentUS12551978B2Method for determining a pressure distribution of a molding tool device as well as reshaping apparatus and composite sheet metal component

Publication Date: 2026.02.17 DR ING H C F PORSCHE AG

AI summary

A method is provided for determining a pressure distribution of a molding tool device (1) for reshaping a sheet metal component (2). The pressure distribution represents a load on the sheet metal component (2) caused by reshaping in the molding tool device (1). The method includes introducing a piezoelectric material (3) into a raw material (12) of the sheet metal component (2) to form a composite sheet metal component (4) that provides an electrical voltage under mechanical loads. The method proceeds by arranging the composite sheet metal component (4) in the molding tool device (1) and reshaping the composite sheet metal component (4) with the molding tool device (1). The method then uses at least one sensor device (5) for detecting spatially resolved electric voltage signals that emanate from the composite sheet metal component (4) during the reshaping and determining the pressure distribution using the detected spatially resolved voltage signals.