Forming tool

A servo press is monitored with displacement sensors, existing force sensors and control data, which software evaluates stroke by stroke. Automotive Center Südwestfalen equipped its servo press with additional sensors and ifm SmartStamp in 2023. Because it mostly runs prototype trials with few strokes, the part and the pressing process are assessed after every stroke. Via moneo, every workstation has access to the press's process and condition data.

An excessive tilting moment puts undue load on the press guides and damages them over time. According to ifm, bearing damage, gearbox damage or cracks in the press crown can also result. Causes include the design or misalignment during a tool change, which leads to off-centre loading. SmartStamp detects tilt and eccentricity within milliseconds and alerts the operator as soon as the press moves outside its target ranges.

With stroke monitoring, the operator can detect an incorrectly mounted tool as early as the first stroke cycle. ifm SmartStamp processes the displacement sensors on the four press columns, the force sensors and the tool number and stroke count from the control. The software shows whether the tool is mounted correctly or needs adjusting. Otherwise, misalignment during a die change would increase off-centre loading and thus the tilting moment.

Real press data feeds into forming simulation when every stroke is recorded with forces and kinematics and then reused in the virtual simulation. Automotive Center Südwestfalen uses ifm SmartStamp on its servo press for this. This brings the real process and IT-based simulation closer together. In future, the acs wants to record all process-relevant variables in real time and accompany every product with a digital twin from the start of development.