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Controlling the sensor properties of smart structures produced by metal forming
Journal of Materials Processing Technology ( IF 6.3 ) Pub Date : 2018-07-17 , DOI: 10.1016/j.jmatprotec.2018.07.014
Martin Krech , Andreas Trunk , Peter Groche

A rotary swaging process is presented which allows the manufacturing of smart structures by forming hollow shafts and joining sensor elements simultaneously. A reasonable form- and force-fit of the sensor element is required to ensure the desired sensory properties of the structure, such as linearity, long-term stability and repeatability. However, the conjoint forming process is subjected to uncertainty which leads to fluctuations of the remaining pre-tension forces. In order to increase the adjustability and accuracy of the process, the utilization of the sensor signals for a control approach is investigated. A prediction model is established on the base of a correlation analysis. It was found that the sensor forces occurring during the integration process can be used as a measure to predict the resulting pre-tension with sufficient accuracy. In order to manipulate the process in a beneficial way a control variable has to be identified. Therefore, several test series are conducted to investigate the suitability of infeed speed and mandrel force as possible control variables. A prerequisite is that the joining process can be manipulated, while the resulting geometry of the part remains unchanged. A possible time slot for an intervention is determined and a first control approach is implemented. Two different target values of the pre-tension force are tested. Compared to open loop controlled processes the accuracy of the targeted pre-tension condition could be improved significantly.



中文翻译:

控制通过金属成型生产的智能结构的传感器属性

提出了一种旋转型锻工艺,该工艺允许通过形成空心轴并同时连接传感器元件来制造智能结构。需要传感器元件的合理形状和力配合,以确保结构所需的感官特性,例如线性,长期稳定性和可重复性。然而,联合成形过程受到不确定性的影响,这导致剩余的预拉伸力的波动。为了提高过程的可调节性和准确性,研究了将传感器信号用于控制方法。在相关分析的基础上建立了预测模型。已经发现,在积分过程中出现的传感器力可以用作一种措施,以足够的精度预测所产生的预紧力。为了以一种有益的方式操纵该过程,必须确定一个控制变量。因此,进行了几个测试系列,以研究进给速度和心轴力是否适合作为控制变量。前提条件是可以操纵连接过程,而零件的最终几何形状保持不变。确定用于干预的可能的时隙并且实施第一控制方法。测试了两个不同的预紧力目标值。与开环控制过程相比,目标预紧条件的精度可以得到显着提高。进行了几个测试系列,以研究进给速度和心轴力是否适合作为控制变量。前提条件是可以操纵连接过程,而零件的最终几何形状保持不变。确定用于干预的可能的时隙并且实施第一控制方法。测试了两个不同的预紧力目标值。与开环控制过程相比,目标预紧条件的精度可以得到显着提高。进行了几个测试系列,以研究进给速度和心轴力是否适合作为控制变量。前提条件是可以操纵连接过程,而零件的最终几何形状保持不变。确定用于干预的可能的时隙并且实施第一控制方法。测试了两个不同的预紧力目标值。与开环控制过程相比,目标预紧条件的精度可以得到显着提高。

更新日期:2018-07-17
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