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Monitoring Solutions for Forging Machines

Brankamp monitoring systems protect automatic forging machines and tools from overloads, detect process disturbances, improve the quality of the produced parts and support the operator in the fast machine setup. In case of production problems (e.g. double loaders or ejection errors), they stop the warmformer early in order to prevent or minimize costly consequential damage to the machine, tool or transfer. Typical quality defects on forged parts (e.g. insertion-, pierce- or transfer failures etc.) that often occur individually and randomly on work pieces trigger the sorting device without interrupting the production. The failure detection is carried out by a 100% in-process monitoring of all produced parts that are produced on automatic forging machines.

Monitoring systems are an effective way to gain insight into the process and its stability, to detect production faults and quality deviations and, if necessary, to intervene in the machine in a controlling manner (sorting). Deformation failures on forged parts can occur during insertion, forming or ejection. By mounting sensors to the machine frame, to single forming stations, to the transfer or bar stop, process signals can be measured and evaluated using suitable monitoring methods. This prevents machine and tool overloads, detects quality defects, increases the efficiency of the machine and saves a lot of time during setup.

Our goal is to support our customers in achieving maximum productivity and manufacturing quality of forged parts. Brankamp monitoring systems are the key to efficient machine, tool and quality monitoring when millions of parts are produced every month.

Monitoring Solutions for Forging Machines
  • Precise machine and tool protection to avoid consequential damage and downtimes, reduction of repair costs
  • Detailed monitoring of the manufacturing quality to improve the quality level (0 ppm)
  • Increased productivity through extended runtimes, reduced downtimes and optimized production speed
  • Reduction of tool and scrap costs through early failure detection
  • Insight into the process to reduce set-up times and optimize production
  • Operator support through various counters for piece counting (good and bad parts), recording of shift performance and tool life, counters for quality inspection and maintenance intervals, parts/box and dosing counter
  • Recording of article-related productivity distributions (production, set-up, stop, rejects) enable precise calculation of part costs
  • Network interface for communication with external programs (MDE/BDE/MES, Teleservice, IoT)
  • Comprehensive documentation of production allows precise runtime analysis and failure tracking

How it works

To avoid machine overloads, calibrated strain sensors measure the total load of the machine on both  sides of the frame as well as the total forging force. Uncalibrated force sensors are installed in individual forming stations (pressure plate or bolster piece) in order to be able to evaluate low forming forces. In addition to the forging force measurement, ejection forces or gripper monitoring can also be included into the monitoring. This allows possible overloads in individual stations to be detected in advance of a double loader.  In addition, the bar-stop force can be evaluated in a special monitoring channel. During the bar change, slivers can be detected by deviation of the idle stroke signals.

Special features

  • Calibrated measurement of frame load and total forging force
  • Detailed monitoring and control at bar change
  • WIRE STOP monitoring for detection of short cut offs and optimum setting of the bar feed
  • Transfer monitoring of the gripper detects ejection errors and sticky parts
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