Damping oscillations in a wire bending process

Baraldo, Anna; Bascetta, Luca; Caprotti, Fabrizio; Ferretti, Gianni; Ponti, Angelo; Sakcak, Basak

doi:10.1016/j.mechatronics.2022.102846

Cited by 2 publications

(1 citation statement)

References 19 publications

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“…The proposed algorithm, instead, automatically determines an optimized solution, starting from a description of the workpiece geometry and a mathematical representation of the concept of "best bending sequence", in terms of a suitable cost function. It thus allows to avoid the case-by-case trial-and-error procedure, significantly reducing the time required to setup the machine for the production of a new workpiece (Baraldo et al 2021) (consider that, according to industrial practice, the time required by an expert operator to determine a good bending sequence for a complex workpiece can vary from hours to half a day).…”

Section: Introductionmentioning

confidence: 99%

Automatic computation of bending sequences for wire bending machines

Baraldo¹,

Bascetta

Caprotti³

et al. 2022

International Journal of Computer Integrated Manufacturing

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Determining a feasible bending sequence, i.e., ensuring absence of wire self-collisions and wire-machine collisions, or even an optimal bending sequence, i.e., minimising time or energy required to perform it, can be a difficult and time consuming task for complex workpieces, even for an expert operator. The introduction of algorithms for the computation of wire bending sequences is thus crucial to increase productivity and production flexibility, and to decrease production costs. To this aim, this work proposes an algorithm to automatically determine an appropriate bending sequence for a given workpiece, bending tool, and machine 3D CAD model, that leverages on a representation of the wire as a robotic manipulator and of a bending sequence as a tree, and on the adoption of A as graph search algorithm. A cost and a heuristic function, suitable for the wire bending problem, and an approach to parallelise the execution of A are introduced, as well. In this way, a computationally simple and efficient wire bending sequence computation algorithm can be devised, able to determine a solution in an amount of time less or equal to the time used by an expert operator, without the need of high computational power. Finally, the effectiveness of this algorithm is assessed on two different test cases, relevant to industrial workpieces.

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Section: Introductionmentioning

confidence: 99%

Automatic computation of bending sequences for wire bending machines

Baraldo¹,

Bascetta

Caprotti³

et al. 2022

International Journal of Computer Integrated Manufacturing

View full text Add to dashboard Cite

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2D and 3D Wires Formability for Car Seats: A Novel Full-Automatic Equipment Concept towards High Productivity and Flexibility

et al. 2023

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The automotive industry demands high quality at very low prices. To this end, it is necessary to constantly innovate, making processes increasingly competitive, while continuing to ensure high levels of quality. Model diversification has forced the automotive industry to make its manufacturing processes more flexible, without losing competitiveness. This has been the case for car seats, where the quantities to be produced per batch are significantly lowering due to the diversity of existing models. The objective of this work was to increase the production rate of bent wires used in car seat cushions and increase the flexibility of changing wire types in production. After benchmarking the existing solutions so far, it was verified that none are capable of complying with the required production rate, while also offering the desired flexibility. Thus, it is necessary to start with a new concept of conformation of the wires used in these seat cushions. The new concept developed and integrated some of the previously known solutions, developing other systems capable of providing the desired response in terms of productivity and flexibility. To this end, new mechanical solutions and automated systems were developed, which, together with other existing ones, made it possible to design equipment that complies with all the necessary requirements. The developed concept is innovative and can be employed to other types of products in which it can be applied. The new concept developed yields a production rate of 950 parts/hour (initial goal: 800 parts/hour), features a setup time of around 30 min, ensuring the desired flexibility, and the tool costs about 90% less than traditional tools. The payback period is around 5 months, given that the equipment cost was EUR 122.000 in terms of construction and assembly, and generated a gain of EUR 280.000 in the first year of service.

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Damping oscillations in a wire bending process

Cited by 2 publications

References 19 publications

Automatic computation of bending sequences for wire bending machines

Automatic computation of bending sequences for wire bending machines

2D and 3D Wires Formability for Car Seats: A Novel Full-Automatic Equipment Concept towards High Productivity and Flexibility

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