Skip to main content
SpringerLink
Log in

A new counting method based on the acceleration sensor for stamping tools

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

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.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16

Similar content being viewed by others

References

  1. Kleiner M, Geiger M, Klaus A (2003) Manufacturing of lightweight components by metal forming. CIRP Ann-Manuf Technol 52(2):521–542

    Article  Google Scholar 

  2. Li G, Long X, Yang P, Liang Z (2018) Advance on friction of stamping forming. Int J Adv Manuf Technol 96(1-4):21–38

    Article  Google Scholar 

  3. Chen FK, Liao YC (2002) An analysis of Draw-Wall wrinkling in a stamping die design. Int J Adv Manuf Technol 19(4):253–259

    Article  Google Scholar 

  4. Lange K, Cser L, Geiger M, Kals JAG (1992) Tool life and tool quality in bulk metal forming. CIRP Ann-Manuf Technol 41(2):667–675

    Article  Google Scholar 

  5. Ersoy-Nürnberg K, Nuernberg G, Golle M, Hoffmann H (2008) Simulation of wear on sheet metal forming tools-an energy approach. Wear 265(11-12):1801–1807

    Article  Google Scholar 

  6. Qiu H, Lee J, Lin J, Yu G (2006) Wavelet filter-based weak signature detection method and its application on rolling element bearing prognostics. J Sound Vib 289(4):1066–1090

    Article  Google Scholar 

  7. Su W, Wang F, Zhu H, Guo Z (2010) Rolling element bearing faults diagnosis based on optimal Morlet wavelet filter and autocorrelation enhancement. Mech Syst Signal Process 24(5):1458–1472

    Article  Google Scholar 

  8. Mello RGT, Oliveira LF, Nadal J (2007) Digital Butterworth filter for subtracting noise from low magnitude surface electromyogram. Comput Methods Prog Biomed 87(1):28–35

    Article  Google Scholar 

  9. Challis RE, Kitney RI (1982) The design of digital filters for biomedical signal processing Part 1. Basic concepts in three parts. J Biomed Eng 4(4):267–278

    Article  Google Scholar 

  10. Osakada K, Mori K, Altan T, Groche P (2011) Mechanical servo press technology for metal forming. CIRP Ann-Manuf Technol 60(2):651–672

    Article  Google Scholar 

  11. Miyoshi K (2004) Current trends in free motion presses. Proceedings of the 3rd Japan Society for Technology of Plasticity (JSTP), International Seminar on Precision Forming

  12. Otsu M, Yamagata C, Osakada K (2003) Reduction of blanking noise by controlling press motion. CIRP Ann-Manuf Technol 52(1):245–248

    Article  Google Scholar 

Download references

Funding

This research is supported by National Science & Technology Major Project of China (Grant No.2018ZX04024001-004) and National Natural Science Foundation of China (Grants 51875351 and 51575345).

Author information

Authors and Affiliations

  1. Institute of Forming Technology & Equipment, Shanghai Jiao Tong University, Shanghai, 200030, China

    Yiqi Cao, Hua Xiang, Xincun Zhuang & Zhen Zhao

  2. National Engineering Research Center of Die & Mold CAD, Shanghai Jiao Tong University, Shanghai, 200030, China

    Hua Xiang, Xincun Zhuang & Zhen Zhao

Authors
  1. Yiqi Cao
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hua Xiang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Xincun Zhuang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Zhen Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Zhen Zhao.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Cao, Y., Xiang, H., Zhuang, X. et al. A new counting method based on the acceleration sensor for stamping tools. Int J Adv Manuf Technol 110, 2143–2154 (2020). https://doi.org/10.1007/s00170-020-05967-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-05967-7

Keywords

Search

Navigation