Automatic Process Control in Press Shops

Hoffmann, Hartmut; Zäh, Michael F.; Faass, Ingo; Mork, Roland; Golle, Matthias; Griesbach, Bernd; Kerschner, Matthias

doi:10.4028/www.scientific.net/kem.344.881

Cited by 7 publications

(2 citation statements)

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“…For example, Wiebenga, Atzema, An, Vegter and van den Boogard [17] examine the variation in the mechanical properties of 41 coils. While many studies, such as from Hoffmann et al [18], assume that mechanical properties have the greatest impact on the quality of the parts, Annen, Gödel, Hora, Merklein and Oberpriller [19] show that the influence of material properties depends on the process state. This already shows that the process depends on interactions between different parameters.…”

Section: Sheet Metal 2015mentioning

confidence: 99%

Stamping Plant 4.0 – Basics for the Application of Data Mining Methods in Manufacturing Car Body Parts

Purr¹,

Meinhardt

Lipp

et al. 2015

KEM

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Data-driven quality evaluation in the stamping process of car body parts is quite promising because dependencies in the process have not yet been sufficiently researched. However, the application of data mining methods for the process in stamping plants would require a large number of sample data sets. Today, acquiring these data represents a major challenge, because the necessary data are inadequately measured, recorded or stored. Thus, the preconditions for the sample data acquisition must first be created before being able to investigate any correlations. In addition, the process conditions change over time due to wear mechanisms. Therefore, the results do not remain valid and a constant data acquisition is required. In this publication, the current situation in stamping plants regarding the process robustness will be first discussed and the need for data-driven methods will be shown. Subsequently, the state of technology regarding the possibility of collecting the sample data sets for quality analysis in producing car body parts will be researched. At the end of this work, an overview will be provided concerning how this data collection was implemented at BMW as well as what kind of potential can be expected.

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Section: Sheet Metal 2015mentioning

confidence: 99%

Stamping Plant 4.0 – Basics for the Application of Data Mining Methods in Manufacturing Car Body Parts

Purr¹,

Meinhardt

Lipp

et al. 2015

KEM

View full text Add to dashboard Cite

show abstract

“…While these systems are only able to detect the final state of the drawn part and neglect the draw-in curve, laser displacement sensors can overcome this shortcoming and may be an alternative [13]. Although several reliable data acquisition methods are available and control systems have been extensively investigated at laboratory [10,13,19] and production scale [9,20,21], a thorough preceding process analysis evaluating the expedience of a control system in series production is often simplified. Furthermore, the application of alternative concepts in metal forming such as decision-making assistance systems is widely disregarded and neglected.…”

Section: Introduction and State Of The Artmentioning

confidence: 99%

Methodological approach for the development of an operator assistance system for the press shop

Kott¹,

Echler

Groche

2021

Int J Adv Manuf Technol

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The productivity of a deep drawing process strongly relies on its robustness as well as the experience of the machine operator. Steadily increasing requirements regarding weight, design and efficiency lead to a production operating increasingly closer to the process limits, making it more challenging to ensure a high robustness of the process. Minimal process fluctuations caused by disturbances such as varying material properties or changing tribological conditions may negatively affect the process due to deteriorated product properties as well as an increased risk of scrap. Thus, a target-oriented adjustment of available parameters by the machine operator becomes more difficult, and an increased knowledge about the causes of defects is more important. In the past, several approaches with different combinations of sensors and actuators have been investigated to enable a stable process window based on a control system. This paper presents a method to address the need for a more robust process by developing an operator assistance system that enables the identification of the component state and provides decision support to the machine operator. The methodological approach includes a thorough process analysis to evaluate the expediency of such a system and to make a reasonable preselection of sensors in order to avoid unnecessary costs.

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A computer aided chaining approach for predicting the shape accuracy in manufacture of automotive structures

Papadakis

2010

Prod. Eng. Res. Devel.

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The increasing competition and the urge to reduce costs and shorten product-life-cycles in the automotive industries imply the application of virtual manufacturing mock-ups. Computer aided engineering methods including simulations of the structural behavior during manufacturing and assembly contribute to eliminate trialand-error along the production chains of vehicle structures. Such digital mock-ups also provide an input for additional tolerance analyses and allow the identification of the pending quality of structure components in advance. In this way large numbers of experiments and adjustments on the existent production lines can be avoided. In this paper an approach is introduced, which allows the replication of the physical effects along manufacturing chains based on thermo-mechanical models. The rendered results after considering successive operational steps provide the basis for initial estimations regarding the shape accuracy of structure assemblies. For a specific example of the automotive body-in-white a first run of a manufacturing process chain is investigated in order to predict the shape quality of a probable production cycle by applying a tolerance chain analysis. The results enable the scrap identification due to non-satisfied quality of assemblies. Finally, based on the achieved results a re-engineering of the manufacturing chain is suggested in order to fulfill quality requirements.Keywords Computer aided engineering Á Body-in-white Á Tolerance chain analysis 1 Background and motivation A major aim of production plants is to continuously preserve high efficiency and product quality in order to retain competitiveness and achieve maximum profitability. A central sector in automotive industries and particularly where high reproducibility is feasible and concurrently high product quality is required, is the body-in-white [1].In order to identify errors and predict inaccuracy of the final product, different methods have been developed to observe product quality along the manufacturing process chain. For this purposes an online acquisition of key quality attributes in the body-in-white with the aid of sensor systems concerning i.e. apparatus setups, material properties or semi-product accuracy is recommended [2]. Moreover such quality characteristics can be estimated in advance by applying computer aided methods, initially for single manufacturing operations and afterwards for complete manufacturing chains of major assemblies of modern automotive light-weight structures [3].Virtual manufacturing mock-ups are nowadays widely used to support production lines. They may span optimization algorithms to define successive steps within a manufacturing operation [4] or virtual reality programming in order to enable tele-presence [5]. Furthermore, simulations with the aid of the finite element analysis allow the replication of the mechanical and heat effects of manufacturing and assembly tasks [6,7] up to the crash properties of frame structures [8]. Such digital mock-ups can additionally contribute to the qua...

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Automatic Process Control in Press Shops

Cited by 7 publications

References 1 publication

Stamping Plant 4.0 – Basics for the Application of Data Mining Methods in Manufacturing Car Body Parts

Stamping Plant 4.0 – Basics for the Application of Data Mining Methods in Manufacturing Car Body Parts

Methodological approach for the development of an operator assistance system for the press shop

A computer aided chaining approach for predicting the shape accuracy in manufacture of automotive structures

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