The investigation of a novel sensor system, integrated in the main load region of forming machines, is the challenge. Therefore, it is important that the thin film system has an excellent tribological quality in combination with a piezoresistive behaviour. The layer system is deposited on the polished surface of a steel substrate. It has such geometries that it can be easily integrated in the drawing cushion of a deep drawing machine. The thin film sensor system exists out of a piezoresistive hydrogenated carbon layer. Onto this layer arrays of chromium structures are deposited. The structures are protected against wear by an insulating silicon doped hydrogenated carbon layer. The whole thin film system has a thickness of about 9 ?m. During the forming process the steel plate is in direct touch with the sensor system and moves over it. The position of the steel is measured in dependence on the forming stadium. The sensor system works as a control system to ensure that the shape of the product is perfect and without any cracks or creases

This paper presents the latest investigations of thin film sensor developments based on amorphous hydrogenated carbon films. The piezo resistive layer is deposited in a plasma enhanced chemical vapour deposition process in a thickness of 4-6 m. The advantage of this film is a excellent tribological behaviour with a hardness of 20-40 GPa and a coefficient of friction of 0,2 as it is well known from the diamond like carbon layers combined with a piezo resistive characteristic. This layer can detect loads without the need of elongation. A special sensor system in the shape of a washer can be easily integrated in screw joints to detect the normal load distribution

The investigation of a novel sensor system, integrated in the main load region of forming machines, is the challenge. Therefore it is important that the thin film system is multifunctional. It has an excellent tribological quality in combination with a piezoresistive behaviour. The layer system is deposited on the polished surface of a steel substrate. It has such geometries that it can be easily integrated in the drawing cushion of a deep drawing machine. The thin film sensor system exists out of a piezoresistive hydrogenated carbon layer, deposited in a PACVD process. Onto this layer arrays of chromium structures are deposited in a PVD process. The structures are protected against wear by an insulating silicon doped hydrogenated carbon layer. The whole thin film system has a thickness of about 9 ?m. During the forming process the steel plate is in direct touch with the sensor system and moves over it. The position of the steel and the load distribution is measured in dependence on the forming stadium. The sensor system works as a control system to ensure that the shape of the product is perfect and without any cracks or creases