Compact systems offer in-process monitoring of forming operations

Marposs has announced the availability of its Brankamp X1 and X3 in-process monitoring systems for cold and hot forming, thread rolling, and stamping operations. These all-in-one units provide real-time monitoring of machine parameters, helping to identify manufacturing faults, part variations, and tool variations immediately. This capability enables manufacturers to optimize machine efficiency, improve part quality, and limit unplanned downtime and tooling costs, the company states.

Sensors are placed in the right positions to convert energy into electrical signals that monitor tool and machine performances related to the forces applied. From these sensors, the systems learn the normal limits of the process. The control unit then observes the signal of each cycle and compares it with the stored curve. When the signal moves outside of the envelope curve, the formed part is sorted out or the machine is stopped.

The systems provide eight channels for sensor signals and four others as zoom channels for detailed monitoring of specific, sensitive process areas. For example, the sensor signals are displayed as maximum forces, envelope curves, and trend progressions. These additional inputs can monitor things such as distorted parts or a wire feed stop.

The X1 is operated by a 7-in. touchscreen, and the X3 has a 9-in. touchscreen with an intuitive operator interface. Each system allows for the type of machine to be monitored. In addition to the multichannel display, the systems have various analysis functions, such as automatic recording of run and setup time or downtime, as well as different counters and storage media to help ensure repeatability of the various processes.