A new counting method based on the acceleration sensor for stamping tools
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ORIGINAL ARTICLE
A new counting method based on the acceleration sensor for stamping tools Yiqi Cao 1 & Hua Xiang 1,2 & Xincun Zhuang 1,2 & Zhen Zhao 1,2 Received: 28 May 2019 / Accepted: 17 August 2020 / Published online: 3 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Stamping tools play an important role in the stamping process, which directly influences product quality and production efficiency. To evaluate and manage these tools, tool lifetime expressed in terms of the number of times of tool reciprocating motion is an indispensable parameter. Traditional methods for counting tool movements employ mechanical counting devices with presses. In this paper, a new counting method based on the acceleration signals of tool movement is presented that involves installing an acceleration sensor on the tool itself. In order to reduce the effect of noise signals, a Butterworth low-pass filter was first applied to the collecting signals. Then, based on the analysis of the filtering signals of four typical tool motion modes, DPV and T in the return segment of every cycle, also termed uniqueness, are introduced as the threshold parameters. Finally, a count algorithm based on the dynamic threshold values is studied to count tool movement. To verify the accuracy of the counting method, eight typical motion modes of stamping tools were tested. The results show that the proposed method is effective for counting tool movements in various tool motion modes. Keywords Stamping tools . Acceleration sensor . Count . Dynamic threshold
1 Introduction Stamping is an important precision plastic forming technology characterized by high forming quality, high production efficiency, and low energy consumption. It is widely used to manufacture automobile parts, instruments, and household appliances, in addition to being used in other industry fields [1, 2]. In the stamping process, the stamping tool plays a decisive role in determining product quality and production efficiency [3]. However, wear and fracture of stamping tools during continuous stamping are unavoidable [4]. Figure 1 shows the wear volume of one type of stamping tool at different stages in its lifetime [5]; tool wear increases dramatically when the tool lifetime reaches a certain number. Because serious tool damage affects product quality, the stamping tool is subjected
* Zhen Zhao [email protected] 1
Institute of Forming Technology & Equipment, Shanghai Jiao Tong University, Shanghai 200030, China
2
National Engineering Research Center of Die & Mold CAD, Shanghai Jiao Tong University, Shanghai 200030, China
to remedial operations, such as grinding of the punch edge or replacement of the punch. Therefore, tool lifetime is an important parameter for predicting tool damage, in addition to being a key index for estimating tool quality and managing the tool. Traditional methods for recording tool lifetime involve counting tool reciprocating motions by using mechanical counting devices or infrared sensors, which are usually installed on pre
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