Smart In-Process Monitoring of Stamping and Forming Operations

Brankamp X7 “smart” in-process monitoring systems for cold and hot forming, thread rolling and stamping operations from Marposs Corporation (Auburn Hills, MI) use artificial intelligence capability that enables quick machine monitoring setup and provides an effective way to control machine performance by detecting manufacturing faults, as well as part or tool variations. This enables press rooms to optimize machine efficiency, improve part quality, and limit unplanned downtime and tooling costs. With the X7 process-integrated monitoring systems, shops can streamline setup and reduce rework to increase capacity for additional orders without having to invest in additional presses. The X7 is operated via a 15 in touchscreen with 30 channels capable of monitoring maximum forces, envelope curves and trend progressions, as well as run times, setup times and downtime, or sensitive process areas such as distorted parts or a missed feed.

Here’s how the X7 works: Depending upon the application, sensors are placed either on the machine, in the tooling or in the dies, connecting the press to a Brankamp X7 unit and enabling users to see at a glance if their machines are running, if their Operational Equipment Efficiency (OEE) is where it needs to be and what, exactly, is happening at the machine. The sensors convert energy into electrical signals that monitor tool and machine performances related to the forces applied. Using an adaptive pattern recognition process, the system learns the correct sensor signal profile for a given cycle. If the signals match the learned curve, the process is continuously observed, recording data for supervision of production, batch size, runtime behavior, and process trend aiming higher line efficiency. If the signal moves outside of the recognized envelope curve, the system informs the operator of the specific type, cause and location of the fault. If necessary, the system also triggers emergency-stop switching.

Enabled by the Brankamp FactoryNet 4.0 capability, machine information gleaned from the X7 unit can be passed on directly by the operator to other stakeholders by means of intelligent online communication. Plus, the operator can filter the information, presetting it individually as desired so that each employee receives only the relevant data they need out of the multitude of production process data available. Displayed directly on-screen using a push procedure, the operator gets a real-time overview of the current production status and is able send information by text message or e-mail to any number of people via a mobile number or email address.

Marposs Corporation, 3300 Cross Creek Parkway, Auburn Hills, MI 48326, 248-370-0404, www.marposs.com.