Sensors monitor cold forming
A
Kistler Instruments product story
Edited by the Engineeringtalk editorial team
Mar 20, 2007
To eliminate faulty joins, Kistler has introduced systems using piezoelectric sensors to monitor cold forming processes off-line and on-line.
The use of cold forming processes, such as clinching and riveting, is replacing welding in the manufacture of an increasing number of sheet metal assemblies.
Although used for many years, it is only recently that a real understanding of the forces needed for reliable plastic deformation of metals has made cold forming acceptable in the manufacture of quality components including car doors, bonnets and tailgates in both aluminium and steel.
To eliminate faulty joins, Kistler has introduced systems using piezoelectric sensors to monitor the processes off-line and on-line.
On-line monitoring of the force needed for plastic deformation during the clinching process can detect wear in the clinching tool, punch or swage breakage, deviations in the dimensions or number of parts and incorrect machine setting.
Continuous monitoring makes the clinching cycle transparent for QA recording and identifies any long-term changes in machine performance.
Off-line checking of the clinching tongs using a Kistler hand-held calibration transmitter can be used to monitor and, if necessary, adjust the on-line system sensors.
A similar method can be applied to monitor pop and blind riveting machines to eliminate faults in the process.
Data from the monitoring sensors can be fed to a central production control system or processed locally using Kistler CoMo Net or CoMo View process monitoring systems.
Both systems can provide a signal to activate a faulty unit rejection mechanism.
Force monitoring of clinching and riveting processes eliminates faulty components from the production output to ensure a consistently high product quality.
As the need for manual QA inspection is minimised, overall productivity is enhanced and costs minimised.
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