SBIR Phase I: Advanced Tonnage Analysis System for Forging Processes

该小型企业创新研究（SBIR）第一阶段项目旨在将先进的信号处理方法（如主成分分析（PCA））应用于锻造过程。 该项目将满足锻造行业对基于PCA的在线应用控制图的需求。我们的目标是证明有能力检测故障的签名，是弱到总信号幅度的1%。第一阶段研究将包括评价现有的数据分析方法，如主成分分析法。针对模具温度偏低的故障，采用真实的锻压机数据对所选方法进行了检验。如果成功，开发的控制图将在测试现场实施，以验证30天的检测性能。先进的过程监控的需要是由行业很好地记录。锻造工业协会将使用先进传感器系统的锻造工艺/设备监测和控制确定为美国锻造行业所需的5项技术计划之一。该项目的成功将对锻造行业产生直接影响，特别是在原材料处于创纪录的高价值以及对提高生产力的需求前所未有的情况下。ATA系统一旦商业化，可以帮助目标行业提高设备效率和减少废料。ATA系统如果开发成功，预计将大幅减少废料量，从而提高节能和环境保护。这项技术发展的潜在商业价值很高。据估计，美国市场规模为1500万美元，全球为1亿美元。

This Small Business Innovation Research (SBIR) Phase I project aims to apply advanced signal processing methodologies such as Principal Component Analysis (PCA) to forging processes. This project will address the need of the forging industry with PCA-based control charts for in-line applications. The goal is to demonstrate the ability to detect signatures of faults that are as weak as 1% of the total signal magnitude. The Phase I research will include the evaluation of available data analysis methodologies, such as the PCA. The selected methods will be tested with real forging press data for the fault of colder than-normal die temperature. If successful, the developed control charts will be implemented on a test site to verify the detection performance for 30 days. The need of advanced process monitoring is well documented by the industry. The Forging Industry Association identified forging process/equipment monitoring and control with advanced sensor systems as one of the 5 needed technical programs by the US forging industry. A success of this proposed project will have an immediate impact to the forging industry, particularly in the time the raw material is at a record high value and the demand for improved productivity is unprecedented. The ATA system, once commercialized, can help the target industry with better equipment efficiency and less scrap. The ATA system, if successfully developed, is expected to reduce the amount of scrap drastically and in turn, improve energy preservation and environmental protection. The potential commercial value associated with this technological development is high. The estimated market size is $15 million the US and $100 million globally.