The trend toward lightweight construction and increasing part complexity can result in higher deformation levels in stamping and metal forming operations. Process-integrated monitoring provides an effective way to detect a broad range of quality defects, such as cracks in components, strip marks, broken tool elements or turned or mis-introduced parts, to provide 100 percent workpiece quality control. In Booth D-45755, Marposs Corporation (Auburn Hills, MI) will demonstrate their Brankamp X3S intelligent process monitoring system for metal forming and stamping operations. These real-time monitoring units help to immediately identify manufacturing faults as well as part or tool variations, enabling shops to optimize machine efficiency, improve part quality, and limit unplanned downtime and tooling costs. The X3S is an economical solution for this type of monitoring, with 12 channels for receiving sensor signals that are measuring force, acoustic emission, distance, temperature and other variables.
These systems work in the following manner: Sensors are placed on the machine or tool in relevant locations, converting energy into electrical signals that monitor tool and machine performances related to the forces applied. From these sensors, the systems learn the normal limits of the process. The control unit then observes the signals of each cycle and compares it with the stored curve. When the signal moves outside of the envelope curve, the formed part is sorted out or the machine is stopped. The X3s feature a 9 in touch screen with an intuitive operator interface. In addition to the multi-channel display, the systems have various analysis functions, e.g. automatic recording of run and set-uptimes or downtimes, as well as different counters and storage media to ensure repeatability of the various processes.
The X3S has data collection masks for connecting to the FactoryNet®4.0 MES software suite that is designed to provide a powerful interface between machine, operator, production and resource planning and higher-level ERP systems. FactoryNet 4.0 enables end-to-end documentation of the processes due to its connection directly with process monitoring. This connection delivers knowledge that can be used to reduce set-up and downtime, optimize lead times, and enhance machine utilization.
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