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Chytrý přidržovací kolík pro lisy plošného tváření plechů 4.0
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Technologická agentura
Obecná forma
The close exchange of data between the product to be produced and the production process within the framework of the future concept "Industry 4.0" promises a significant improvement in industrial processes. In particular, the further development of the production-accompanying quality measurement technology and its extensive data-exchange is of essential importance for the monitoring and optimization of production processes and product quality. This approach includes an exact characterization of the production means and processes. The proposed project deals with the measurement of the clamping forces in the pressing process. During the so-called “die try-out”, the technology parameters as well as the tool parameters must be optimized or readjusted. Of particular importance in this case is the clamping force between the drawing cushion pins and the sheet metal to be formed. If the clamping force of the cushion pin is too low, unintentional wrinkles and edge shrinking of the workpiece occur during shaping. If the clamping force is too high, the flow of the sinking material into the forming zone is too strongly inhibited, resulting in cracks and neckings. The clamping forces are essential technology parameters, the exact knowledge of which would be of the highest value for failure diagnosis and process monitoring. The precise knowledge of the real force conditions in the surface contact between dies and sheet metal as the potential to significantly shorten and improve the try-out process for new or revised forming tools by replacing the trial and error principle based on incomplete process knowledge. This is exactly where the idea of the "SmartCushionPin 4.0" project starts. By means of intelligent cushion pins with integrated force measuring electronic, the cushion forces are detected directly in the forming die. The measurement data are transferred wirelessly to the central unit where a digital "fingerprint" of the actual force distribution in the die is calculated and visually displayed. This fingerprint serves on the one hand as an aid for the reworking of new or revised dies. On the basis of the exact knowledge of the clamping forces between die and sheet metal, the workload could be reduced by a targeted rework of the dies by approx. 30% to 50%. On the other hand, the fingerprint can also be used during the ongoing production for condition monitoring, whereby a permanent compliance of the detected actual forces with the permissible process / tool limits takes place. Thus, die wear can be detected at an early stage and capital tool damage can be prevented. For the end-user, the application of the smart cushion pins is very similar to the application of the standard cushion pin. The plant staffs simply inserts the smart cushion pins - instead of the standard cushion pins - into the holes provided in the press table or ram plate.
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