InImpact: The Journal of Innovation Impact

Publisher Future Technology Press
Vol. 7 No. 2 KES Transactions on SDM I - Sustainable Design and Manufacturing 2014
Volume Editors KES International
Journal ISSN 2051-6002
Article TitleAdaptive process control strategy for a two-step bending process
Primary AuthorFranz Dallinger, ETH Zurich
Other Author(s) Jos Havinga; Emile Roux; Roberto d'Ippolito; Pavel Hora; Ton van den Boogaard
Pages 618 - 627
Article ID sdm14-072
Publication Date 01-May-16
AbstractA robust production is an important goal in sheet metal forming in order to make the process outcome insensitive to variations in input and process conditions. This would guarantee a minimum number of defects and reduced press downtime. However, for complex parts it is difficult to achieve robust settings. Parts without defects can only be realized if the process parameters are adapted to the changed conditions.

In this paper, an approach for adaptive process control is presented, taking the uncertainties and tolerances of the process and material into consideration. The proposed control approach combines feedback and feed-forward control strategies. The most significant improvement is to incorporate feed-forward control with knowledge about the system (also known as predictive models). To create these models high fidelity numerical models have been created. Furthermore, a procedure is presented to update the coefficients of the predictive model to adapt it to the actual process state.

To evaluate the control strategy prior to its implementation, a testing environment has been developed. Different test scenarios for common states of the process have been generated to evaluate the improvement of the proposed control strategy.
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