HIGH SPEED STAMPING PROCESS IMPROVEMENT

THRU FORCE AND DISPLACEMENT MONITORING

Rich Grogan
Helm Instrument Co., Inc.
361 W. Dussel Drive
Maumee, OH 43537

Abstract
Practical methods can be used and associated numerous benefits derived from the implementation of
force sensors and displacement sensors on high speed stamping dies. Such dies are typically of the
multi-station progressive die type, and are operated in the 200-1000 SPM range. The parts made in
high speed stamping dies are normally small and very complex, with a large number of intricate forming
operations involved. Examples of the wide variety of parts that can be made include electronic connector
pins and sockets, integrated circuit lead frames, and terminals for electrical cable assemblies. Force and
displacement monitoring can be used to improve the overall high speed stamping process, as aids to
achieve faster and better machine set up, and also as an online production monitor. The production
monitoring benefits include tooling protection and enhanced part quality. Guidelines have been
established for locating the force sensors and displacement sensors on high speed dies. Various types of
instrumentation display and control features are available, with strong emphasis on the defined relationship between the forming force or tool displacement and resultant part quality.

Force Monitoring
Force monitoring technology for manufacturing machines has been in existence for approximately 30
years. In its infancy, the technology incorporated simple bolt-on force sensors mounted on the machine
frame and basic "peak force" monitors, used primarily for press overload protection on metal stamping
presses. As the technology advanced over the years, the types of machines being successfully
monitored have expanded greatly. They now include not only stamping presses, but also forging
machines, die cast machines, injection molders, assembly machines, compaction presses, and slide
forming machines. With the advent of very expensive and sophisticated tooling, and also the great
emphasis placed on part quality, the focus of force monitoring has shifted from press overload protection
to tooling protection and achieving enhanced part quality. This is particularly true for high speed
stamping operations with multi-station progressive dies. In such operations, numerous complex and
precise forming steps are involved, cycle rates typically exceed 200 parts per minute, and extremely
high quality is expected. Force monitoring technology is commercially available for high speed
stamping operations, so that those manufacturers can achieve the process improvements of better set
up, tooling protection, and improved product quality.
There are many down-to-earth practical reasons and associated benefits for monitoring the forces
developed on high speed stamping presses. These include the following crucial items:
-Improved Process Reliability / Part Quality
-Reduce Machine Set-Up Time
-Reduce Waste
-Improved Production Control
-Allow For Unattended Operation
-Enable Analysis of Machine Condition
An additional reason for high speed machine monitoring is to reduce off-tolerance parts. This goes
hand in hand with the "reduce waste" item listed above. What we can measure, we can control. The
quality of a finished, formed part has been shown to be closely linked and dependent upon the force
required to form the part. In essence, by using force measurement as an indicator of part quality for
each formed part, and by controlling that force within a certain narrow window, better and more
consistent quality parts can be produced and off-tolerance parts minimized.
Yet another good reason for monitoring force is to achieve predictive tool maintenance and predictive
machine maintenance. Many variables can affect the force required to make a part on a high speed
progressive die. These include such items as machine condition, tooling condition, material characteristics, and lubrication. By establishing initial "good part" force values and force signatures for a given
machine running a given part, and monitoring subsequent force values and signatures, changes over
time can be used to predict when a tool may need to be changed or a machine re-worked. The idea is
to monitor the press forming operations on a continuous basis and to look for small changes in the force
values, indicating non-critical tooling or machine conditions that can be scheduled for correction before
major problems develop.
Repeatability of the forming process is a very important element for proper machine / tool operation
and the production of consistent quality parts. Force monitoring of the high speed stamping process
provides a very useful tool that relates forming force to the consistency of the operation. Force values
that show great repeatability and little variation indicate a highly repeatable and stable production
process. By monitoring the force developed to form each part on a continuous production basis, and
establishing the initial set-up condition for the machine to allow for "good part" production, proper
"cycle-to-cycle" repeatability and associated good part quality can be maintained.

From a machine set-up standpoint, the concept of "duplicating a previous run" is very important.
This also hinges on the principle of the forming force value being closely related to the quality of the
finished part and to a proper machine and tooling set-up condition. When the machine and tooling are
initially adjusted using conventional techniques to allow for "good part" production, the force values and
signatures for that condition can be stored. When that same part is to be run again, those stored "good
part" force values and signatures can be recalled and used as a set-up reference for the present force
values and signatures. The initial "good part" condition thus becomes a set-up tool for the machine
operator, allowing him to make machine/tooling adjustments to duplicate the previous good run, and get
back to the desired operating condition. This yields a more accurate set-up, with the additional benefit
of time savings. In the absence of force monitoring, tooling set-up on a typical high speed progressive
die may take 8 hours or more, sometimes with a by guess or by golly approach. Relating force values
to a good set-up condition can reduce this time considerably, saving expensive labor and allowing for
more machine up time. Some force monitors allow for the storage and recall of such force-based
set-up criteria by job number or part number.

The quality of a finished formed part on a high speed

stamping machine is directly related to the force required to
make it. Measurement of the forming force provides an
objective, scientific criteria to define a "good part" and "in
spec" condition. From a control standpoint, if the measured
force for each part stays within a narrow band called the
"quality window", the production of good parts that meet
specification can be maintained. The allowable size of this
quality force window must be determined, often by trial and
error, for the particular part and its associated specifications.

Since many variables in the process can affect the forming force, in the event that the force has
changed (increased or decreased), the monitoring system can not necessarily identify the particular
culprit responsible for the change (machine condition, tool condition, material property variations, etc.).
However, the system can definitely detect that the force has changed due to some process change,
resulting in a quality change of the product. The detection of such a change in force can be used to
better control the process. If the change in force is small, resulting in a force value still within the "quality
window" and parts still within spec, such a small change can be used to indicate a tooling wear or
material variation condition. A larger change in force, resulting in a force value outside the "quality
window" and parts out of spec, can be used in the control process to divert off-tolerance parts. Beyond
that, in the event of several consecutive off-tolerance
OVER (HIGH)
parts, an adjustable "fault counter" can be used to
OK
stop the machine so that corrective action can be
UNDER (LOW)
taken by the operator. At this point, the condition is
considered to be serious enough that the machine
should be stopped before a lot of off-tolerance parts
are made, and before an unchecked condition deteriorates further with possible resulting tool and/or machine damage.
FORMING FORCE "QUALITY WINDOW"

First . . . you must make a good force measurement. There are many useful things that can be done
downstream from the force measurement in terms of manipulating the data and controlling the process.
However, the success of these downstream functions all hinges on initially making a valid force
measurement. The crux of proper force measurement on a high speed stamping machine is where to
measure those forces. For successful monitoring of the process, the force must be measured in a
location where it relates directly to the forming operation and the part being made. Force sensor
location is crucial in order to properly link the force measured to the quality of the product. Depending
upon the machine configuration and the tooling, there are various desired and proven sensor locations.

There are several types of force sensing elements that are commercially available. A couple of these
lend themselves very nicely to making force measurements on high speed stamping machines, and
have demonstrated very good performance in many field installations. The two types of sensors that
are most commonly used in the industry are strain gage and piezoelectric force sensors. Each type of
sensor has its own unique characteristics, with corresponding benefits and also limitations for machine
force measurements.

The first type to be discussed is the strain gage force

sensor. Strain gage technology has been in existence for
some fifty years, and is now extremely well perfected. A
TENSION /
COMPRESSION
strain gage force sensor typically incorporates a precision
DEFLECTION
machined metal structure, to which is bonded small foil
AXIS
resistive strain gage sensing elements. The metal structure, typically machined from heat treated stainless steel,
is designed to deflect under load in the elastic region in
either tension or compression. The location at which the
"DUAL ELEMENT"
strain gages are bonded usually has a reduced cross FOIL STRAIN GAGE
section, in order to maximize deflection at the gages and
increase the output of the sensor. In practice, most commercially available strain gage sensors
incorporate "dual element" strain gages, with multiple such gages bonded to the same structure and all
wired together to form a "Wheatstone Bridge" circuit. Thus, each gage bonded to the structure includes
two foil resistive sensing element grids. One grid is aligned with the primary deflection axis (tension or
compression), and the other grid (called the Poison gage) is aligned 90 degrees to the primary deflection
axis. Each grid is made of a copper alloy material such as constantan, and is arranged in a serpentine
fashion. The copper alloy material is specially formulated to allow for a very precise and linear change
in resistance when physical deflection (elongation or contraction) occurs. The manufacturing process
for strain gage sensors includes the bonding of strain gages to the structure with a special adhesive,
wiring, cable attachment, and the application of special protective potting over the gages.

The principle of operation of the strain gage sensor is very simple. The sensor structure is physically
attached to the machine and/or the tooling in a location that will physically deflect as the machine
operates to make a part. The deflections are typically very small, on the order of perhaps 10-100
millionths of an inch per inch (micro-strain), but measurable physical deflections nonetheless. As the
machine deflects when a part is formed, the sensor structure with the attached strain gage sensing
elements also deflects, typically in tension or compression. The sensing elements ultimately deflect,
producing a resistance change for each grid proportional to the deflection and to the actual force applied
to the structure. This minute but measurable change in resistance for the various grids wired into the
"Wheatstone Bridge" result in a proportional millivolt output signal from the overall sensor.

Most strain gage force sensors have the internal strain gage
elements wired in a full "Wheatstone Bridge" circuit configuration. This requires a minimum of four individual foil resistive
sensing elements which undergo deflection under a loaded
condition. For proper operation of the bridge, opposing gage
elements undergo the same type of deflection (both in either
tension or compression), and adjacent gage elements undergo
dissimilar deflection (one in tension and the other in compression). The full "Wheatstone Bridge" arrangement provides the
positive features of high output, temperature compensation, and
bending compensation. There are four external wiring connections to the bridge. Two of these are from the regulated DC
power supply in the monitoring instrument, and provide the necessary "excitation" voltage to the bridge.
The other two are the output connections or "signal" lines. Under a no load and un-deflected condition,
the bridge is electrically balanced, and there is no output signal on the signal lines. Under a loaded
condition, the bridge is unbalanced, and a millivolt signal proportional to the applied force appears
across the signal lines. At the monitoring instrument, this signal is conditioned and amplified, and
ultimately used to drive the display meter.
To summarize, strain gage force sensors have the following characteristics and features:
-Consistent repeatable output under dynamic and static loads
-Full bridge configuration allows for temperature and bending compensation
-Recommended for moderate to heavy loads
-Suitable for slow speed to high speed operations (up to 1200 SPM)
-Peak Force monitoring or Signature Analysis monitoring capability
-True load signature for analytical work
-Require external excitation voltage

Strain gage force sensors can be mounted to the high speed stamping machine frame or within the
progressive die assembly. The most basic version of the strain gage sensor is the simple bolt-on type
for machine frame installation. In general, due to its low cost and ease of installation, it should be the
first considered choice for force monitoring on any type of press or manufacturing machine.

The basic bolt-on strain gage force sensor is

"GAP-FRAME" STAMPING PRESS
typically mounted directly to the machine frame.
This is the most common method of force sensor installation on conventional metal stamping
2 CHANNEL
presses, such as the Gap-Frame press shown
FORCE MONITOR
in the illustration. On such presses, two bolt-on
LOADGARD
sensors with a two channel instrument are typically used to monitor left side and right side
loads.
For straightside presses with four
columns, four bolt-on sensors with a four channel instrument are used to monitor individual
corner loads. This approach has been successFRAME-MOUNTED
FORCE SENSOR
fully used on many types of presses for over 30
years. Depending upon the particular press and
the parts being run, this may be a workable arrangement. It relies upon consistent and reasonably linear
press frame deflection under a forming load condition to provide the force measurement output signal.
A minimum amount of press deflection is required for this arrangement to work properly. The bolt-on
frame mounted device is referred to as "parallel" type force sensor, and experiences only a small

fraction of the total force developed in the machine frame. For this reason, a field calibration procedure
utilizing calibration load cells and portable instrumentation are typically used on such installations to
calibrate the sensors to a known load condition. In general, the bolt-on force sensor approach performs
very well on conventional stamping presses, where the ram movement during the forming operation is
only in a single direction, and predictable deflections are generated in the frame due to the forming
force.
Machine frame sensors may be considered and have
been used with some success over the years on high speed
stamping machines. However, due to the machine/tooling
configurations and the high speed dynamics typically involved in such operations, machine frame sensors are
useful practically for press overload protection only. Machine frame sensors for high speed operations are extremely limited in their capabilities for tooling protection and
part quality control. This is due partly to the fact that many
high speed progressive dies require small tonnage compared to the capacity of the press in which they are run. It is
not uncommon for five ton progressive dies to be run in
presses ranging from 30-50 tons in capacity. This results in
low press frame deflections, and corresponding low machine frame sensor output signals that may be
unusable from a monitoring standpoint. Another factor results from the condition that most high speed
progressive dies have many, many complex forming stations. A machine frame sensor relies on press
frame deflection to generate a force signal, which is a composite signal relating to several tool stations
in a multi-station tool. Because such sensors are so far removed from the precision forming that occurs
in any particular tool station, it is unlikely that a frame-mount sensor will yield a significant signal change
due to a fault (chipped punch, scrap in die, etc.) in an individual station. Thus, such faults would go
undetected. An additional reason why machine frame sensors are quite limited for high speed stamping
relates to the sensor signal components from the acceleration/deceleration dynamic effects in the press
frame itself at high speed. As shown in the typical Frame-Mount sensor signal from a multi-station tool
at 560 SPM, a background acceleration/deceleration frame signal and between cycle press ringing
signal are superimposed upon the forming force signal to be monitored. Thus, spurious signal factors,
along with the possible detrimental signal effects of hitting on stop blocks, can often mask the critical
in-die forming signals that are actually desired to be monitored.
In view of the many limitations associated with frame-mount
sensors, In-Die force sensing offers the maximum tooling
protection and part quality control benefits for high speed
stamping. In-Die force sensing consists of locating a sensor
within or beneath an individual tool station, in order to generate
the strongest possible signal and one that relates most directly
to the particular forming operation. By placing the sensor as
close as possible to the actual point of operation, subtle faults
occurring in the individual station produce a significant signal
change that is detectable at the monitor. The In-Die sensor
signal shown is from the same 560 SPM press and tool as the
Frame-Mount sensor signal above. The signal was generated
from a strain gage force sensor located beneath an individual
staking station. In comparing the In-Die sensor signal to the Frame-Mount sensor signal, it is readily
apparent that the In-Die signal is much cleaner. It offers an individual signal relating directly to the
staking operation, and exhibits a stable zero line between cycles with no ringing. As such, it is a
tremendously useful forming force signal that can be used for the detection of a wide variety of forming
faults. These include material variations, misfeeds, damaged tooling, worn tooling, and scrap in die.

In the general metalworking industry, In-Die force monitoring has been successfully done for many
years on a wide variety of multi-station tools. The force sensing technology developed for those general
stamping applications can also be applied to many different types of high speed operations, including
coining, embossing, bending, staking, and hole piercing. The In-Die sensing approach consists of
locating force sensors within or beneath critical tool stations, to separate multi-station forming loads, and
to achieve the highest degree of tooling protection and enhanced part quality.
The two most common types of In-Die force sensors include conventional strain gage load cells,
and an implant type of glued-in sensor called a Die Plug. The load cell option involves the use of
strain gage load cells placed into machined pockets beneath individual secondary operation dies or
punches. The other approach, involving the Die Plug sensor, has been in existence for about ten
years, and is rapidly becoming the sensor of choice. This is due to its low cost and ease of installation.

The conventional strain gage load cell approach

consists of mounting such a cell within or beneath an
individual tool station. This load cell approach allows
for a very direct and high force signal output even on
light load applications, and also allows for the separation of force signals on multi-station tools. Such cells
allow for a calibrated force readout directly in pounds
or tons. Strain gage load cell design is a well perfected
science. Strain gage load cells incorporate strain gage
sensing elements bonded typically to cylindrical or ring shaped steel structures. The completed strain
gage force sensors or load cells can be made in many different physical shapes, sizes, and capacity
ratings. The load cell structure is precision machined from a material such as 17-4 PH stainless steel.
The physical size of the structure controls the deflection that it experiences under load, and therefore the
capacity rating of the cell. Load cells designed for higher force values are typically physically larger than
smaller capacity cells. All of the strain gage sensor principles as outlined above apply to strain gage
load cells. These devices generally incorporate a reduced cross-sectional area groove concentrically
machined at the middle of the cell structure. This provides a physical protected location for the strain
gages, and also determines the actual force rating of the cell.

Strain gage load cells typically operate under a compression loading condition, with the compressive deflection of the reduced area gage
section resulting in a proportional output signal from the multiple bonded
strain gages wired in a full "Wheatstone Bridge". These cells are
referred to as "series" type force sensors. As such, all of the force to be
measured is transferred through the cell. This type of cell is usually
factory calibrated under test loading conditions before being shipped for
field installation. There are several quality manufacturers of strain gage
load cells in the industry. Many of these offer standard "catalog" load cells that are pre-engineered, and
may be produced on a stock basis by the manufacturer. A wide variety of sizes and capacities of such
load cells is available. For those applications where a strain gage load cell is required, it is strongly
recommended to initially verify if a standard device will physically fit into the machine and have the
desired capacity rating. This allows for the quickest and most economical installation. In the event that
a standard design is not available to fit the application, custom load cells can often be provided.

As opposed to a conventional strain gage load cell, the Die Plug force sensor is an implant type
device that is roughly half the cost of a load cell. It incorporates a highly sensitive strain gage or
piezoelectric sensing element that is located at the front of a tube. The sensor cable runs along the tube,
and "self-centering" legs are attached to the outside of the element. The application of the sensor is very
simple, in that it is simply glued with industrial epoxy into a small hole machined beneath a tool station.
"DIE PLUG" FORCE SENSOR
As the tool (die or punch) is involved in performing the operation, very
small deflections that occur in the tool holder or support steel where the
"Die Plug" is located also cause minute physical deflections of the sensor.
This yields a dynamic output voltage signal that is proportional to the
applied tool force.

Since the Die Plug sensor is available in strain gage and

piezoelectric versions, each has its own characteristics. The
strain gage version functions like a miniature strain gage load
cell, with all of the associated properties. The piezoelectric
version incorporates a very highly sensitive piezoelectric sensing element. This element is typically made of a crystalline or
ceramic material. It is the same basic type of sensing element
that is used in extremely sensitive microphones. A piezoelectric
sensing element self-generates a proportional voltage output
signal when it undergoes physical deflection. Its extremely high
output, great sensitivity, and wide operating range make it a good choice for certain machine force
measurements. However, the piezoelectric sensor is rate-sensitive, responds only to dynamic forces,
and is not well suited to calibrated actual force measurements. In general, for high speed operation
monitoring, it is recommended that the piezoelectric Die Plug sensor be reserved for very light load
and/or very high speed operations (exceeding 1200 SPM). Regardless of whether a strain gage or
piezoelectric Die Plug is used, the measurements are almost always of the uncalibrated reference
force value type.

There are three very basic steps involved to properly install a "Die Plug" force sensor. The first
involves installing the sensor in the machined tooling hole to the proper depth. The front sensing
element should be centered as closely as possible beneath the tool to be monitored, and within the
compressive "footprint" of the tool. The second step involves injecting a special high strength epoxy
potting into the injection tube. This allows the epoxy to backflow around the sensing element and to
completely fill the hole, permanently encapsulating the sensing element into place. The final step
includes cutting off the excess tubing that projects beyond the sensor hole, and connecting the cable to
the monitoring instrument. Modular wiring interconnect systems, including miniature tool-mounted

connectors, plug-in cables, and junction boxes, are available to easily route the sensor wiring to the
monitoring instrument. Due to its small size and high sensitivity, the "Die Plug" type of sensor can be
used very effectively for high speed progressive die force monitoring, especially where installation
space is limited and the forces involved may be small. For many high speed prog die applications, the
Die Plug sensors are typically located in the stationary tooling hard plate beneath individual critical
tool stations.

The quantity of Die Plug force sensors and their locations in progressive dies depends largely on
the particular operations taking place. Not all stations necessarily need a sensor. However, it is
recommended that one sensor always be located very near the first die station. This location provides
a means for detecting variations in material such as thickness, hardness, temper, etc. Other sensor
locations can include forming stations where early characteristics of punch and die wear can be
identified, as well as faults such as damaged tools, scrap in die, etc. Monitoring such stations later in the
progression allows for real time in process inspection of the finished part quality. Typical Die Plug
sensor locations for a high speed progressive die are shown in the illustration. The part being made is a
small bracket, with multiple forming operations. In general, it is most desirable to locate the sensors
beneath the stationary tools, avoiding flexing cables at high speed. Depending upon the tool geometry,
it is sometimes necessary to locate one or more Die Plug sensors beneath moving punch tools. This
can occur when the stationary die tool area does not provide a clean force path to the sensor. In those
cases, the moving side punch tool can be utilized for the sensor location.

PROGRESSION

MONITOR PIERCING

MONITOR BENDING

MONITOR
MATERIAL THICKNESS
AND HARDNESS

MONITOR BENDING

(4) IN-DIE FORCE SENSORS

A two channel approach is popular for small, high-speed progressive dies which have a number of
stations in a very small area. The
first sensor is typically located at
or near the first station to monitor
for gross faults such as misfeeds
and material variations. The second sensor is typically located in
a station towards the end of the
progression that relates to the finished part quality. Chipped or broken punches, scrap, misfeeds, or
other process variations taking
place along the progression will
be detected as the strip or product
exits the die.

Having located the right type of force sensors in the proper locations to generate meaningful output
signals, a monitoring device of some sort is needed to complete the system. The force monitoring
instrument performs certain basic functions that can be depicted in a block diagram. These functions
include:
- Force measurement
- Signal conditioning
- Load display
- Alarm capability and adjustment
- Alarm firing (control)
- Alerting the operator (control)
- Stopping the process (control)
Several levels of force monitoring instruments are available. One common feature to all is that the
display meter almost always displays the force value for each machine cycle in a digital format. For a
strain gage force sensor, this usually represents a calibrated or actual force value. For a piezoelectric
type force sensor, this represents an uncalibrated reference force value. Another common feature is
that the instruments typically monitor and display the peak force value developed in the machine or the
tool. An exception to this is the most advanced type of monitor, which incorporates "tracking alarms",
and monitors the whole force signature throughout the entire forming cycle. It should be noted that all
of the various types of monitors, from the simplest to the most advanced, are generally available in both
single and multi-channel configurations. The number of channels is dictated by the maximum number
of tool stations with corresponding sensors to be monitored. This becomes a matter of economics, and
selecting the most critical stations to monitor in order to get the most bang for the buck.

The simplest type of force monitor is a basic peak force monitor with discreetly
adjustable high and low alarms. In the event of either a high or low alarm
condition, indicating a change and a possible fault in the process, an alarm relay
would fire to stop the process. This allows for corrective action to be taken.

A refinement in the way of force monitors is a microprocessor circuitry "self- programming" unit. Based upon an
initial "good part" operating condition, the operator initiates a sampling routine at the unit whereby it "learns" a
"good part" force value based upon the sample taken.
Subsequent machine cycles are then automatically monitored with respect to the "good part" condition.
Microprocessor-based units offer the user some very powerful force monitoring capabilities, such as "good part"
self-programming and automatic alarm setting, with a
minimum of operator involvement.

A recent advancement in force monitoring instrumentation is the

PLC-based force monitor. As opposed to the other instrument
options, which are dedicated specialized units, the PLC-based unit
incorporates force monitoring into a standard PLC rack. This is done
Processor
by plugging force signal conditioning modules into the PLC rack,
and configuring the PLC program for the desired force display,
Display
monitoring, and alarm functions. Such an approach can yield signifiStrain Gage
cant savings, since the force monitoring hardware is simply the
Input (2)
required number of modules installed into an existing machine
PLC-BASED
FORCE MONITOR
control PLC rack, or a new PLC rack if required. Also, if an existing
PLC machine control is involved, the display for that control can often
be used to display the force information as well. This modular building block type of approach can
save considerable monies and space, compared to the more traditional type of dedicated force monitor.
This is especially true on systems with many channels.
2 Channel
Strain Gage Module

HI GH

1 2

LOW

Setu p Run

As stated previously, the quality of the finished parts is directly related to the forming force required
to make them. The primary and perhaps most important function of the "force sensor/monitoring
instrument" combination is to monitor forming forces for all parts on a continuous production basis, and
to verify if those forces go beyond the force "quality window". In that event, corrective action in the way
of off-tolerance part diversion or machine stoppage is initiated. Another important function is to use the
monitor as a set-up tool to achieve better and quicker machine/tool set-up. This is done by recording
force values during initial set-up of a given part to a known good part condition. With such good
part force values thus established during set-up, that same tool can be adjusted during subsequent
set-ups by duplicating those force values. This allows for a more scientific and predictable set-up
procedure, resulting in time savings and a dimensionally good part.

In terms of effective force monitoring, the level at which the alarm limits are set is crucial. A machine
cannot be monitored for a 5% load change, when the process itself normally involves a 20% load
variation from machine sloppiness or other factors. To do so would create continual nuisance alarms,
unwanted machine shutdowns, and ultimately defeat the purpose of force monitoring. It should be
recognized that every forming operation, even the most precisely controlled, will have some variation in
the cycle-to-cycle forming forces. The idea is to control those "normal variation" process variables as
closely as possible, and then to set the monitor alarm limits beyond the normal variation levels.

One of the newer and most exciting features available in advanced load monitors is a "tracking alarm"
function that monitors each forming cycle throughout
the entire stroke. Peak force monitors capture and
display the peak force value for each machine cycle,
and monitor with respect to that peak force. As useful
as that function is, the newer "tracking alarm" type
monitors extend the force monitoring function much
further. Based upon a learned "good part" force signature, the "tracking alarm" monitor establishes a high
and low alarm band that tracks this signature throughout the entire forming cycle. The signature for each
subsequent part is then compared to the learned "good
part" signature, and a change in load at any point along the signature that goes beyond the tracking
alarm band is recognized as an alarm condition. This allows for the detection of very subtle faults in the
process that may not be manifested as a change in the peak force. Thus, greater sensitivity to load
changes throughout the entire forming cycle and better process control can be achieved.

Displacement Monitoring
Displacement sensor die monitoring systems have been commercially available for metal stamping
presses for approximately 20 years. Although the sensors and monitoring electronics have been
continually upgraded, with corresponding performance improvements, the basic system components
and operation have remained relatively unchanged. Displacement monitoring systems can be used to
good benefit on a large variety of metal stamping operations. However, the performance features and
benefits are most fully realized when applied to high speed progressive dies. Displacement monitoring
technology should not be regarded as competing directly with force monitoring technology. Since each
has its own unique benefits, limitations, and cost factors, they should be considered as complimentary
technologies that can be used together for enhanced stamping process improvement and part quality
control.

A displacement sensor die monitoring system is very simple, making it easily installed and very cost effective for monitoring high
speed progressive dies. A typical system consists of one or more
noncontact precision Eddy current displacement sensors, with a
corresponding number of instrumentation channels for the sensors.
The monitoring instrument is typically configured in a modular
stackable arrangement, with a main base unit at the bottom with
the power supply and one channel, and additional channel units that
can stack on top. Each channel has a digital meter to show
displacement deviation values, and also the alarm setpoints.

In practice, the sensors are mounted in a protected location on the stationary die or die shoe. For
each sensor, a mating steel target is mounted to the spring-loaded stripper plate or the upper die.
During initial system set-up with the material strip in the die, the steel targets are adjusted for a nominal
sensor-to-target displacement gap (typically .040-.060) at bottom dead center. During normal machine
operation with parts being made, the system monitors the sensor-to-target separation gap between the
upper and lower dies, and looks for subtle deviations in stripper position or die height at each sensor
location. Using sensors with high frequency response, and microprocessor-based electronics, this
monitoring process can be done with resolution to 1/1000mm (.00004) and at speeds up to 2500 SPM.
Each channel of the monitor has its own adjustable plus/minus alarm setpoint. In the event that a fault
occurs in the process, causing the sensor-to-target displacement gap change to exceed the alarm
setpoint, an alarm relay would activate to stop the machine. In this way, the displacement monitor can
be used to detect a variety of different forming faults, including:
Misfeeds
Pulled slugs
Scrap in die
Material changes
Stroke deviation
Misalignment between punch and die
Coining depth abnormalities
Broken punch or die assemblies
Double hits

There are two basic options for the location where the sensor targets can be mounted. The first
option involves mounting the targets on the spring-loaded stripper. This is the most typical and widely
used location, and is the best for pulled slug and scrap-in-die detection. The second option involves
mounting the targets on the upper die assembly itself. This provides the best performance for the
detection of tooling/forming faults such as broken dies and coining depth abnormalities.

The
illustration
shows a typical installation of the sensor
target on a springloaded stripper. The
tool station represents
a hole pierce or blanking operation, with a
slug ejected during
each stroke. Under a
normal condition as
shown at bottom dead
center, the stripper
maintains
uniform
parallel contact on the
material strip. The
sensor-to-target displacement gap is very
repeatable and consistent
for
this
normal condition.

This illustration also shows

the stripper mounting location for the sensor target,
but with an abnormal
pulled slug condition. If
the pulled slug falls anywhere on top of the material
strip, which is a quite likely
location, the additional interference from the slug
presence causes the stripper to become cocked at an
angle. For the displacement sensor closest to the
slug, the sensor-to-target
displacement gap increases
appreciably. Provided that
the alarm limits at the monitor have been set properly
and that the displacement
change
exceeds
the
normal condition limit, an
alarm would then activate to stop the press. After the machine operator has cleared the slug from the
die, the alarm can be reset and normal press operation resumed. This stripper mounting arrangement
for the sensor targets has proven extremely successful in the field in detecting pulled slugs and scrap in
the die for many types of dies, different materials, and material thicknesses.

The other option for sensor

target mounting is to locate
them on the upper die assembly itself. This mounting location is the best one
for detecting faults involved
in bottom form operations,
such as coining, embossing,
and bending. The tool station in the illustration represents a coin station with the
sensor mounted on the upper die. For this type of
application, a broken die or
punch would create a
change in the coin depth
and in the sensor-to-target
displacement gap, resulting
in an alarm shutdown. It
should be noted that this
sensor option on the upper
die is the only one available
for dies with non springloaded box strippers.

In terms of the recommended number of sensors for particular dies, those guidelines have been well
established by the displacement monitor equipment manufactures. In general, the very small dies can
utilize only one sensor with good results. The large and more complex dies typically incorporate two
sensors, which would be mounted along diagonal corners of the die set. Using the fewest sensors, this
approach provides the best overall coverage for abnormal forming conditions that can occur from side to
side or front to back. The very largest dies typically incorporate four sensors, with one mounted at each
corner of the die set.

In terms of the displacement sensor monitor performance, there are typically two different modes of
operation. These modes relate to the normal condition benchmark displacement values to which the
current displacement values are compared. One mode is called a Mean Value Comparison Mode,
which incorporates a stroke-to-stroke rolling average for the normal condition benchmark. The other
mode is called an Absolute Value Comparison Mode, which incorporates a learned sample for the
normal condition benchmark. The operating features and benefits of each particular mode are outlined
below.

Conclusion
As stated previously, both force monitoring and displacement monitoring technologies are commercially available for high speed stamping operations. Their functions compliment each other, and they
can both be used to achieve substantial process improvements. A key element in using these
technologies is to relate in-die forming force and upper to lower die displacement to finished part quality.
By comparing normal condition force and displacement values to current ongoing ones, and monitoring
for changes outside normal limits, many crucial types of forming faults can be detected. These include
such things as damaged tools, tooling wear, pulled slugs, scrap in die, and material changes.

Helm Instrument Company, Inc. 361 W. Dussel Drive, Maumee, OH 43537

Phone 419-893-4356 FAX 419-893-1371