Inline Monitoring of the Geometry of Free-form Bent Components

Lorenzo Scandola, Daniel Maier, Johannes Meier, Wolfram Volk
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Abstract

The free-form bending process shows a high potential for the manufacturing of bent structural components. Especially in the automotive sector, the process can be employed for the production of arbitrary geometries evolving in the 3D-space, reducing tooling costs and production times. In addition, it is characterised by an outstanding flexibility, and allows the manufacturing of variants of a single component just with the adaption of the tool kinematics. Nevertheless, the reproducibility of the process is a challenging task, and a process monitoring approach is required. In this contribution, an inline-measurement strategy for evaluating the resulting geometry of free-form bent parts is developed. First, a review of the actual measurement system is given. Successively, the inline measurement of the bending radius using a laser displacement sensor, as well as of the bending angle by means of an IR-camera are presented. The obtained inline signals are then processed to retrieve the geometry of the obtained part, and the strategy is validated by comparison with the offline measurement results. The developed inline-system represents the first step towards the development and the monitoring of the free-form bending process.
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自由曲面弯曲组件几何形状的在线监测
自由曲面折弯工艺在折弯结构件的制造方面显示出巨大的潜力。特别是在汽车领域,该工艺可用于生产在三维空间中不断变化的任意几何形状,从而降低模具成本并缩短生产时间。此外,该工艺还具有出色的灵活性,只需调整工具的运动学特性,就能制造出单个部件的各种变体。然而,工艺的可重复性是一项具有挑战性的任务,因此需要一种工艺监控方法。在本文中,我们开发了一种在线测量策略,用于评估自由形态弯曲部件的几何形状。首先,对实际测量系统进行了回顾。随后,介绍了使用激光位移传感器在线测量弯曲半径以及使用红外摄像机在线测量弯曲角度的方法。然后对所获得的在线信号进行处理,以检索所获得部件的几何形状,并通过与离线测量结果的比较对该策略进行验证。所开发的在线系统是开发和监控自由形态弯曲过程的第一步。
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