Sheet-Metal Blank Sensing for Adaptive Press Forming
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Solution Overview
Problem
Existing sheet-metal component manufacturing processes lack detailed knowledge of material properties and process parameters for pre-manufactured blanks, leading to potential changes in material properties during storage, which can affect the forming process, and there is no real-time adaptation of process parameters to ensure quality.
Innovation Solution
A method and press apparatus that utilize a sensing device to measure characterizing parameters of sheet-metal blanks before forming, transmitting these parameters to an electronic computing device to adapt the forming process, ensuring accurate inline sensing and adaptation of material properties, reoiling, and labeling for traceability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If pre-manufactured sheet-metal blanks are stored for intervals up to six months, then availability for production is improved, but material properties may change and reliability deteriorates
Solution Approach 1:
The patent applies preliminary action by sensing the characterizing parameters of the sheet-metal blank before the forming process takes place. This allows the current state of the material to be captured at the time of use, rather than relying on historical data from manufacturing or storage. The sensing device measures parameters such as oiling state, thickness, or material properties immediately before forming, ensuring that any changes during storage are accounted for and the forming process can be adapted accordingly.
2Ease of manufacture
If global material test certificates are used for metal rolls, then documentation is simplified, but detailed knowledge of current material properties is lost
Solution Approach 1:
The patent implements feedback by using a sensing device to measure the actual characterizing parameters of the sheet-metal blank before forming. This measured information is then fed back to the control device, which uses it to adapt the forming process parameters. This closed-loop feedback ensures that the forming process is based on real, current material properties rather than relying solely on historical test certificates, thereby preventing information loss about the actual material state.
3Measurement precision
If sensing device is integrated in press apparatus, then inline sensing is achieved, but device complexity increases
Solution Approach 1:
The patent applies merging by integrating the sensing device and control device directly into the press apparatus. This combination allows the sensing, data processing, and process adaptation to occur within a single integrated system rather than as separate standalone components. The sensing device is positioned to measure the sheet-metal blank in-line with the forming process, and the control device is merged with the press control system, enabling seamless data exchange and real-time process adaptation without requiring complex external systems.
Data Source
AI summary
A method for forming a sheet-metal component in a press apparatus includes providing a sheet-metal blank as a base material for the sheet-metal component and sensing at least one characterizing parameter of the sheet-metal blank by a sensing device of the press apparatus before a forming process for the sheet-metal component takes place. The at least one characterizing parameter is transmitted to an electronic computing device of the press apparatus. The sheet-metal component is formed from the sheet-metal blank taking into account the at least one characterizing parameter.