ورق فلزی تشکیل دهنده سیستم کنترل جهانی بر اساس سیستم بینایی مصنوعی و سنسورهای نیروی آکوستیک

Forming processes are manufacturing processes based on deformation of raw material applying pressure in one or several stages until getting the final product. This process depends on many factors, e.g. process parameters, material properties or lubrication, leading to possible defective parts. Correct forming of parts is very important as any defective part may result in big economical losses, e.g. the return of a complete set of parts or the loss of some clients. Thus, in our European Craft Pro2Control project, leading German, French, Italian and Spanish companies, universities and forming industries are defining and implementing a zero-defect forming control system, minimizing costs and maximizing the throughput of parts.

The automotive industry is demanding to their suppliers, higher complexity parts, manufactured with less formability materials, at higher production rates and with stricter quality requisites. The strains suffered by the materials during the forming stage have increased considerably and, as a consequence, even small variations in the properties of the raw material or in the variables of the process (e.g. lubrication or slight material strength variation) may lead to defective parts. However, good forming of parts is a very critical factor, as any defective part may result in big economical losses, e.g. the return of a complete set of parts or the loss of some clients.

This paper deals with the construction of a global control system for metal forming, based on artificial intelligence techniques. Two types of sensors feed the control system: force/acoustic and artificial vision system. Details about the artificial vision system are explained, in particular, its division into an “intelligent camera” were most demanding computations are performed, and a PC (i.e. a co-design). Implemented algorithms as well as obtained results are presented confirming the presented approach. This approach provides a fully mastered development, and guarantees durability and maintainability of the system, as well as it maximizes the throughput, minimizing the overall cost. Future works relates to the detection of the thickness of the parts by means of lateral cameras with telecentric lenses, and total implementation of all algorithms in the intelligent camera, as well as integration in the overall global control system.