Efficiency and quality for very small parts: process monitoring sensors for metal stamping, forming and automation technology

Every part manufactured with processes such as metal stamping, fine blanking and forming must meet the key criteria of absolute accuracy and efficiency. For over 50 years, our sensors have been supporting customers who operate metal stamping and forming technology in automobile and connector production, the medtech sector, and many other industries. Our process monitoring solutions make use of light barriers as well as piezoelectric measurement technology.

Tried-and-tested technology from Kistler monitors production processes for parts of any size – even including the very smallest components. Our portfolio for progressive tools and automation technology comprises various types of light barriers with aluminum housings. We also have the expertise needed to manufacture special items in line with customers' specific requirements. The light barriers operate contact-free; they can be used with all materials, and are simple to install. For applications in environments with high oil mist content, we can equip the sensors with an optional cleaning nozzle.

Kistler piezoelectric sensors for force monitoring in dynamic processes give users the guarantee of absolute accuracy. They deliver important measurement data as the basis for conclusions about tool status and process reliability.

Loop control: uniform, jolt-free winding and unwinding of continuous strips

A perfectly tuned winding machine is essential to ensure that metal stamping processes operate continuously. This contact-free loop control ensures that strips with thicknesses of 0.2 mm or more are wound and unwound uniformly and without jolting, thus eliminating tension and strain. The loop control regulates the winding drive to guarantee continuous, vibration-free operation in accordance with decreasing or increasing spool diameters.

Double sheet control: for early detection of stamping waste

If stamping waste is present in the tool, the only way to avoid tool damage is if the machine switches off as quickly as possible. Double sheet control checks whether any stamping waste or slugs have been left behind in the tool. Depending on the size of the tool module, up to four sensors are deployed to monitor the parallelism and final position of the presser plate. If the plates are skewed, the sensors reliably detect this error and the tool protection system will stop the press.

Process force monitoring: the key to early detection of tool breakages and other anomalies

With piezoelectric sensors from Kistler, you can monitor the force applied by the tool in the process, either directly or indirectly. Deviations due to changes in material properties, tool wear or other process anomalies can thus be identified with maximum accuracy. State-of-the-art process monitoring systems visualize the force-time curves to allow objective assessments. For evaluation in the machine control, the measurement signals can be made available via a charge amplifier. These sensors are equipped with overload protection, they cover a wide measurement range, and they are easy to retrofit.

Ejection control: reliable counting of produced parts

After each stamping operation (stroke), it is essential to ensure that there are no stamped parts or stamping waste left in the tool, so as to prevent tool damage in the next stroke. Ejection control makes use of a sensor with multiple light beams (light grid) to reliably monitor whether a stamped part measuring 0.8 mm or more was ejected from the tool. The ejection control system counts the parts at the same time.

Immersion depth measurement: precise distance measurement in the stamping process

Immersion depth measurement is used to detect double sheets or stamping waste, and for quality assurance in metal stamping and forming processes. For these purposes, it monitors and measures the sequence of movements performed by the presser plate. The analog output signal is proportional to the measurement distance, so highly accurate distance measurements are ensured. The benefits: you will avoid errors as well as unnecessary tool downtime.

Feed control: the right position for the stamping strip

Feed control makes use of a light barrier in the stamping tool to monitor whether the stamping strip is located in the correct position. This requires at least one signal change per advance – if the signal does not change, the strip is in the wrong position and the tool monitoring system will stop the machine.