Process Monitoring using Digital Twin-Based Sensors integrated in Tool Clamping Surfaces

Abstract

Process monitoring in forming technology can serve as a basis for transparent manufacturing and closed-loop control systems. Particularly, sensor systems associated with tool clamping interfaces offer great potential for robust inline process monitoring but are hardly investigated. In this paper, a concept to monitor a sheet metal forming process combined with a digital twin-based approach for virtual sensors is introduced. Here, sensors integrated into the T-slots of tool clamping surfaces in forming machines are enhanced by a mathematical representation of the elasto-mechanical behavior of the tool clamping interfaces. Moreover, the potential of the certain sensor system for inline process monitoring is highlighted. The resulting approach is substantiated by simulative analysis and by experimental investigation.

New Method for Precise Measurement of Clamping Plate Deformations on Forming Presses

“…Other approaches for the in-process measurement of bolster plate deformations are based on strain gauge-and piezo-based sensors for the measurement of width changes of T-slots under load [12,34,35] (Figure 2k), as well as novel clamping systems for forming tools [36,37] where the deformation of the clamping devices themselves is used to infer the bolster plate deformation. However, the calculation of absolute deformation values from the measurement data of both systems can currently only be achieved through prior calibration measurements using established measurement methods.…”