Process monitoring and closed loop controlled process

There are a number of variables which can seriously affect the sheet metal forming process. By determining the process fluctuations, it will ultimately be possible to improve the production process. To do this, monitored or closed loop controlled processes potentially constitute an important tool for the reduction of defects, reduction of rework and a better quality of final products. The Fraunhofer Institute for Machine Tools and Forming Technology (IWU) in Chemnitz investigated typical process variables such as flange movement as the basis for control systems. Different kinds of non-contact sensors were successfully tested. A multi-point cushion or tool integrated piezo-elements in conjunction with torsion-elastic tools were used as reacting systems. One application used process monitoring with one or more sensors to support quality control, or the same system with an add-on for early error recognition and automatic recommendation of corrective measures. Finally, fully controlled loop systems based on intelligent algorithms were developed.