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

这项拟议的研究将解决在使用Industry 4.0方法的级进冲压模具中引入智能工艺设计和在线工艺控制。今天，级进模的设计和开发主要掌握在工匠和工匠手中，工艺速度、效率和质量的进一步进步遇到了重大的技术障碍。不幸的是，由于传统的手工设计方法，几乎没有成熟的工程方法来克服这些障碍。这一目前的范例为应用Industry 4.0方法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，这一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颖性。将追求三个主要的技术发展：(I)优化拉伸网结构(拉伸网是连接工件和正在成形的板材带材的几何特征，并对加工速度和成形性产生控制影响)；(Ii)开发和模拟具有实时数据采集和模具特征驱动的演示工具；以及(Iii)使用Industry 4.0方法实施集成过程控制。该项目代表着德国和加拿大紧密的“2+2合作”，由两家中小企业组成，Foring Technology Inc.和Men at Work GbmH，与滑铁卢大学和慕尼黑工业大学合作。这项研究的最终结果将是：(I)软件设计工具，用于在FTI的FormingSuite软件包中自动、智能地选择拉延筋特征；以及(Ii)基于行业4.0的控制策略，以提高产品质量和生产能力，供加拿大工具和模具行业使用。加拿大将通过提高工具和制造部门基于创新的竞争力而获益。

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.