In-Process Tool Deflection Measurement in Incremental Sheet Metal Forming

2022 IEEE Sensors Applications Symposium (SAS) Pub Date : 2022-08-01 DOI:10.1109/SAS54819.2022.9881345

M. Terlau, A. Freyberg, D. Stöbener, A. Fischer

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Abstract

Incremental sheet forming is an economical alternative to deep drawing for forming large sheets in small quantities. However, the shape deviations resulting from a process-force-caused tool deflection limits the measuring accuracy. Therefore, an optical multi-sensor system is proposed to enable the contactless in-process measurement of the tool deflection independent of the machine kinematics for the first time. The presented design study of the sensor system aims to meet the requirement of a maximal measurement uncertainty of 15 µm at a measuring distance of up to 2 m. The multi-sensor system consists of a large number of inexpensive angulation sensors, each of which measures an angle to a light source on the tool. Based on the measured angles of all sensors calibrated to each other, the position of the tool in the three-dimensional manufacturing volume can be calculated by multi-angulation. Via experimental characterization of a realized angulation sensor as well as an uncertainty propagation, the measurement uncertainty achievable with the overall system is estimated. As a result, the multi-sensor concept fulfills all requirements for the measurement of the tool deflection in incremental sheet metal forming.

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渐进式钣金成形过程中刀具挠度测量

增量板成形是一种经济的替代深拉深成形大板在小批量。然而，由加工力引起的刀具偏转导致的形状偏差限制了测量精度。因此，提出了一种光学多传感器系统，首次实现了与机床运动学无关的刀具挠度的非接触式过程测量。提出的传感器系统设计研究旨在满足测量距离为2 m时最大测量不确定度为15 μ m的要求。多传感器系统由大量廉价的角度传感器组成，每个传感器测量工具上光源的角度。根据测量到的各传感器相互校准的角度，可以通过多角度计算出刀具在三维制造体中的位置。通过对所实现的角度传感器的实验表征和不确定度传播，估计了整个系统可实现的测量不确定度。因此，多传感器概念满足了增量钣金成形中刀具挠度测量的所有要求。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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2022 IEEE Sensors Applications Symposium (SAS)

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