Development and implementation of a control loop for connections in the progressive die process

拟议的研究将致力于采用工业4.0方法在连续冲压模具中引入智能工艺设计和在线工艺控制。如今，级进模的设计和开发在很大程度上掌握在工匠和工匠手中，在工艺速度、效率和质量方面的进一步进步遇到了重大的技术障碍。不幸的是，由于传统的工匠设计方法，几乎没有现成的工程方法来克服这些障碍。 这种当前的模式为应用工业4.0方法来实现新的效率和高度优化的连续冲压工艺提供了理想的机会，这种方法迄今尚未应用于该工艺。因此，拟议的研究提供了高度的新奇。 三个主要的技术发展将追求：（一）优化拉伸网配置（拉伸腹板是将工件连接到正在形成的金属板带的几何特征，并且对工艺速度和可成形性施加控制影响）;（ii）开发和模拟具有实时数据采集和工具特征驱动的演示工具;以及（iii）使用工业4.0方法实施集成过程控制。 该项目代表了德国和加拿大紧密的“2+2合作”，包括两个中小企业，成型技术公司。与滑铁卢大学和慕尼黑技术大学合作的“工作中的男人”组织。 这项研究的最终成果将是：（i）FTI的FormingSuite软件包中用于自动化，智能选择拉伸珠功能的软件设计工具;以及（ii）基于工业4.0的控制策略，以提高产品质量和产量，供加拿大工具和模具行业使用。通过提高模具和制造业的创新竞争力，加拿大将从中受益。

The proposed research will address the introduction of intelligent process design and inline process controls within progressive stamping dies using Industry 4.0 methodologies. Today, the design and development of progressive dies lies largely in the hands of artisans and craftsmen and further advances in process speed, efficiency and quality have come up against significant technological barriers. Unfortunately, very little established engineering methodologies exist to overcome these barriers due to the traditional artisan design approach. This current paradigm presents an ideal opportunity to apply Industry 4.0 methodologies to achieve new efficiencies and highly optimized progressive die stamping processes, an approach not yet applied to this process to-date. Thus the proposed research offers a high degree of novelty. Three primary technological developments will be pursued: (i) optimization of stretch web configurations (stretch webs are the geometric features connecting the work piece to the sheet metal strip being formed and exert a controlling influence on process speed and formability); (ii) development and simulation of a demonstrator tool with real-time data acquisition and tooling feature actuation; and, (iii) implementation of integrated process control using Industry 4.0 methodologies. The project represents a tight German-Canadian "2+2 collaboration" comprising two SMEs, Forming Technology Inc. and Men at Work GbmH, working with the University of Waterloo and the Technical University of Munich. The final outcomes of this research will be: (i) software design tools for automated, intelligent selection of stretch bead features within FTI's FormingSuite software package; and, (ii) Industry 4.0-based control strategies to improve product quality and throughput, for use by the Canadian tool and die industry. Benefit to Canada will be accrued through improved innovation-based competitiveness of the tooling and manufacturing sectors.