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Tecnología de medida de impulso de alta frecuencia (HFIM) para medir fisuras en tiempo real durante procesos de transformación de metal

Resumen

Tipo:
Oferta Tecnológica
Referencia:
TODE20160209001
Publicado:
23/02/2016
Caducidad:
23/02/2017
Resumen:
Una pyme alemana ha desarrollado un nuevo sistema de medida de impulso de alta frecuencia que detecta fisuras y cambios estructurales durante el mecanizado, soldadura, conformado y otros procesos de producción. El proceso se adapta a la pieza de trabajo. El sistema de medida permite interrumpir automáticamente el proceso de producción en caso de avería, reduciendo considerablemente los costes de mantenimiento. La empresa busca socios para implementar la tecnología mediante acuerdos comerciales con asistencia técnica y buscar nuevas aplicaciones.

Details

Tittle:
High frequency impulse measurement (HFIM) technology to measure cracks in real-time during metal processing
Summary:
A German SME developed a new high frequency impulse measuring system that detects cracks during machining, welding, forming or other production processes. The process is adjusted to the workpiece. The measurement system is able to interrupt the production process automatically in case of failure. Thus maintenance costs and scrap are significantly reduced. They seek partners to implement the technology via commercial agreements with technical assistance and for research for new applications.
Description:
In straightening press processes, a stamp pushes against a clamped workpiece and bends it. This produces high pulling and thrust forces which can lead to a crack. In that case a shockwave runs through the workpiece and the machine tools causes vibrations in connected machine parts.

A German SME developed a new high frequency impulse measuring system that detects cracks and structural changes during machining, welding, bending and straightening, wire-drawing, forming or numerous other production processes.

The measuring process is adjusted to the workpiece. The measurement system is able to interrupt the production process automatically in case of failure. Thus maintenance costs and scrap are significantly reduced. Measurement computers render it possible to evaluate many production processes, to detect cracks in the very moment they occur and to check if production parameters stay inside tolerance thresholds:
· crack detection
· raise life time of tools
· Tool monitoring
· Process optimization

Broadband vibration sensors pick up the acoustic emission signals on the surface of the machine parts. Thanks to sensor and pre-filtration technology, ratio between signal and noise is very good.

If a crack occurs in a workpiece, this emits a certain kind of signal. This signal is characterized roughly by three properties: steep start, broadband and smooth finish.

With every workpiece exchange, the device performs a self-test. It checks the pre-amplification chain and the connection as well as the coupling of the sensor itself. It is possible to save threshold values and pre-amplification settings on every measuring position and workpieces. The sensors are capable of detecting signals up to 25 MHz. The machine does 25.000 spectral analyses per second.

The company is looking for industrial partners interested to implement the technology within the framework of commercial agreements with technical assistance. The German company would accompany the adjusting process.
There is also an interest in common research projects with industrial or research partners for the development of new applications.
Advantages and Innovations:
Innovation:

Optical measurement systems that are often applied in order to analyse product quality cannot detect cracks that are closed at the surface of the product.

Unlike conventional methods, this new crack detection system works during the process, in real-time. That means the production process can be interrupted immediately in case of failure.

Damaged workpieces can be more easily and accurately be separated from non-damaged workpieces. The data provided allows the optimization of the production process and to reduce scrap. Additionally, it´s possible to detect tool wear and to optimize the whole process - for example, to lengthen maintenance cycles or to eliminate sources of trouble.

Advantages of the measurement system are:

· Optimal signal detection and pre-filtering of noise like mechanical or electrical noise
· Measuring is adjusted to the workpiece, tool and process
· Availability of the device is constantly monitored by complex self-testing functions
· Measuring data is stored and can be used later for statistical evaluation
· High reliability
Stage of Development:
Already on the market
IPs:
Patents granted
CommeR Statunts Regarding IPR Status:
Europe, USA, Asia

Partner sought

Type and Role of Partner Sought:
The German company is looking for partners interested in implementing the technology and in common research projects for the development of new applications:

Industrial partners to implement the technology are sought from metal processing industry, i.e., automotive, machine engineering, shipbuilding and metal working. The German company would accompany the adjusting process with know-how transfer and advice.

As there are still new application opportunities for this technology the company is also interested in cooperation with research organizations for the development of new solutions e.g. in smart manufacturing (Industry 4.0), Internet of Things (IoT) and others.

Client

Type and Size of Client:
Industry SME 11-49
Already Engaged in Trans-National Cooperation:
Si
Languages Spoken:
English
German

Keywords

Technology Keywords:
02002005 Forming (rolling, forging, pressing, drawing)
02003005 Information processing & Systems, Workflow
02007010 Metals and Alloys
09001001 Tecnología acústica relacionada con la realización de medidas
09001009 Tecnología de sensores relacionada con la realización de medidas