Data-driven inline optimization of the manufacturing process of car body parts

Purr, S.; Wendt, Achim; Meinhardt, Josef; Moelzl, K; Werner, A.; Hagenah, Hinnerk; Merklein, Marion

doi:10.1088/1757-899x/159/1/012002

Cited by 11 publications

(10 citation statements)

References 5 publications

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“…The sheet metal forming (SMF) process involves non-stationary conditions and complicated phenomena such as non-linearities, temperature variation, batch-to-batch fluctuations in material properties, and complex product geometries, which makes it challenging to achieve desired product specifications and ensure process performance [1][2][3][4][5]. Due to the high tooling costs associated with SMF, justified by large-volume and efficient production runs, product quality control is of high importance [6].…”

Section: Introductionmentioning

confidence: 99%

“…In the past, most industrial process monitoring (IPM) approaches were focused on fault detection, i.e., on the ability to detect a fault and reduce the time between a faults' occurrence and detection [7]. More recently, with concepts like zero-defect manufacturing gaining importance, the focus has shifted toward fault diagnosis and troubleshooting activities that consume a considerably larger portion of the process downtime [1,7] compared to fault detection activities. In this context, several data-driven [7][8][9][10][11], model-based [12][13][14], and statistical [15] approaches have been proposed to support Processes 2020, 8, 89 2 of 11 the identification of the underlying root cause of a fault.…”

Section: Introductionmentioning

confidence: 99%

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A Hybrid Data-Based and Model-Based Approach to Process Monitoring and Control in Sheet Metal Forming

et al. 2020

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The ability to predict and control the outcome of the sheet metal forming process demands holistic knowledge of the product/process parameter influences and their contribution in shaping the output product quality. Recent improvements in the ability to harvest in-line production data and the increased capability to understand complex process behaviour through computer simulations open up the possibility for new approaches to monitor and control production process performance and output product quality. This research presents an overview of the common process monitoring and control approaches while highlighting their limitations in handling the dynamics of the sheet metal forming process. The current paper envisions the need for a collaborative monitoring and control system for enhancing production process performance. Such a system must incorporate comprehensive knowledge regarding process behaviour and parameter influences in addition to the current-system-state derived using in-line production data to function effectively. Accordingly, a framework for monitoring and control within automotive sheet metal forming is proposed. The framework addresses the current limitations through the use of real-time production data and reduced process models. Lastly, the significance of the presented framework in transitioning to the digital manufacturing paradigm is reflected upon.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A Hybrid Data-Based and Model-Based Approach to Process Monitoring and Control in Sheet Metal Forming

et al. 2020

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“…According to these publications, the amount of lubricant affects the friction and thus plays an important role in the deep drawing process of sheet metals. 8,9 Using scanning mirrors in combination with laser induced fluorescence allows for the first time to monitor the spatial distribution of lubricant on 100% of the metal sheets surface with strip speeds of several meters per second. 7 For typical lab applications of fluorescence spectroscopy, well-defined smooth surfaces, such as microscope slides or glass cuvettes, are used as substrate material under the fluorescent layer.…”

Section: Introductionmentioning

confidence: 99%

Quantitative Measurement of Fluorescent Layers with Respect to Spatial Thickness Variations and Substrate Properties

2020

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Imaging fluorescence spectroscopy proves to be a fast and sensitive method for measuring the thickness of thin coatings in the manufacturing industry. This encouraged us to systematically study, theoretically and experimentally, parameters that influence the fluorescence of thin layers. We analyzed the fluorescence signal as a function of the scattering and reflectance properties of the sample substrate. In addition, we investigated effects of the layer properties on fluorescence emission. A ray-tracing software is used to describe the influence of these parameters on the fluorescence emission of thin layers. Experiments using a custom-made system for imaging fluorescence analysis verify the simulations. This work shows a factor five variation of fluorescence intensity as a function of the reflectance of the sample substrate. Simulations show variations by a factor of up to eight for samples with different surface roughness. Results on tilted samples indicate a significant increase of the detected fluorescence signal, for fluorescent droplets on reflective substrates, if illuminated and coaxially observed at angles greater than 25°. These findings are of utmost relevance for all applications which utilize the fluorescence emission to quantify thin layers. These applications range from in-line lubricant monitoring in press plants to monitoring of functional coatings in medical technology and the detection of filmic contaminations.

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“…The identified faults were then commonly mitigated in an ad-hoc manner through trial and error based on the expertise of the machine operators on-site. More recently, with concepts like zeroဨdefect manufacturing gaining importance, the focus has shifted towards fault diagnosis and troubleshooting activities that consume a considerably larger portion of the process downtime [1,2] compared to fault detection activities. In this context, several dataဨdriven [1,[3][4][5][6], modelဨbased [7][8][9] and statistical [10] approaches have been proposed to support the identification of the underlying root cause of a fault.…”

Section: Introductionmentioning

confidence: 99%

Towards Improving Process Control in Sheet Metal Forming: A Hybrid Data- and Model-Based Approach

Tatipala

Wall

Larsson

et al. 2020

Advances in Transdisciplinary Engineering

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Ability to predict and control involved parameters and hence the outcome of sheet metal forming processes demand holistic knowledge of the product/-process parameter influences and their contribution in shaping the output product quality. Recent improvements in the ability to harvest inline production data and the capability to understand complex process behaviour through computer simulations opens up the possibility for new monitoring and control approaches for improving production process performance and output product quality. Current work presents a framework for monitoring and control of sheet metal forming processes which incorporates a hybrid dataï£¡and modelï£¡based approach. An initial attempt to evaluate the proposed frameworks’ ability to support output product quality and process performance enhancements is made by implementing the proposed approach via an in-house built wire-bending machine prototype. Initial experiments conducted using the built prototype indicate that the proposed framework has the potential to support such enhancements and further work is needed to validate the overall framework.

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Data-driven inline optimization of the manufacturing process of car body parts

Cited by 11 publications

References 5 publications

A Hybrid Data-Based and Model-Based Approach to Process Monitoring and Control in Sheet Metal Forming

A Hybrid Data-Based and Model-Based Approach to Process Monitoring and Control in Sheet Metal Forming

Quantitative Measurement of Fluorescent Layers with Respect to Spatial Thickness Variations and Substrate Properties

Towards Improving Process Control in Sheet Metal Forming: A Hybrid Data- and Model-Based Approach

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