Virtual Sensor of Gravity Centres for Real-Time Condition Monitoring of an Industrial Stamping Press in the Automotive Industry
This article proposes the development of a novel tool that allows real-time monitoring of the balance of a press during the stamping process. This is performed by means of a virtual sensor that, by using the tonnage information in real time, allows us to calculate the gravity centre of a virtual loa...
| Main Authors: | , , |
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| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2023-07-01
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| Series: | Sensors |
| Subjects: | |
| Online Access: | https://www.mdpi.com/1424-8220/23/14/6569 |
| _version_ | 1797587556268769280 |
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| author | Ivan Peinado-Asensi Nicolás Montés Eduardo García |
| author_facet | Ivan Peinado-Asensi Nicolás Montés Eduardo García |
| author_sort | Ivan Peinado-Asensi |
| collection | DOAJ |
| description | This article proposes the development of a novel tool that allows real-time monitoring of the balance of a press during the stamping process. This is performed by means of a virtual sensor that, by using the tonnage information in real time, allows us to calculate the gravity centre of a virtual load that moves the slide up and down. The present development follows the philosophy shown in our previous work for the development of industrialised predictive systems, that is, the use of the information available in the system to develop IIoT tools. This philosophy is defined as I3oT (industrializable industrial Internet of Things). The tonnage data are part of a set of new criteria, called Criterion-360, used to obtain this information. This criterion stores data from a sensor each time the encoder indicates that the position of the main axis has rotated by one degree. Since the main axis turns in a complete cycle of the press, this criterion allows us to obtain information on the phases of the process and easily shows where the measured data are in the cycle. The new system allows us to detect anomalies due to imbalance or discontinuity in the stamping process by using the DBSCAN algorithm, which allows us to avoid unexpected stops and serious breakdowns. Tests were conducted to verify that our system actually detects minimal imbalances in the stamping process. Subsequently, the system was connected to normal production for one year. At the end of this work, we explain the anomalies detected as well as the conclusions of the article and future works. |
| first_indexed | 2024-03-11T00:40:35Z |
| format | Article |
| id | doaj.art-f0ff131678b34b239bcb93e505fff4f4 |
| institution | Directory Open Access Journal |
| issn | 1424-8220 |
| language | English |
| last_indexed | 2024-03-11T00:40:35Z |
| publishDate | 2023-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Sensors |
| spelling | doaj.art-f0ff131678b34b239bcb93e505fff4f42023-11-18T21:19:33ZengMDPI AGSensors1424-82202023-07-012314656910.3390/s23146569Virtual Sensor of Gravity Centres for Real-Time Condition Monitoring of an Industrial Stamping Press in the Automotive IndustryIvan Peinado-Asensi0Nicolás Montés1Eduardo García2Department of Mathematics, Physics and Technological Sciences, CEU Cardenal Herrera University, C/San Bartolomé 55, 46115 Alfara del Patriarca, SpainDepartment of Mathematics, Physics and Technological Sciences, CEU Cardenal Herrera University, C/San Bartolomé 55, 46115 Alfara del Patriarca, SpainFord Motor Company, Polígono Industrial Ford S/N, 46440 Almussafes, SpainThis article proposes the development of a novel tool that allows real-time monitoring of the balance of a press during the stamping process. This is performed by means of a virtual sensor that, by using the tonnage information in real time, allows us to calculate the gravity centre of a virtual load that moves the slide up and down. The present development follows the philosophy shown in our previous work for the development of industrialised predictive systems, that is, the use of the information available in the system to develop IIoT tools. This philosophy is defined as I3oT (industrializable industrial Internet of Things). The tonnage data are part of a set of new criteria, called Criterion-360, used to obtain this information. This criterion stores data from a sensor each time the encoder indicates that the position of the main axis has rotated by one degree. Since the main axis turns in a complete cycle of the press, this criterion allows us to obtain information on the phases of the process and easily shows where the measured data are in the cycle. The new system allows us to detect anomalies due to imbalance or discontinuity in the stamping process by using the DBSCAN algorithm, which allows us to avoid unexpected stops and serious breakdowns. Tests were conducted to verify that our system actually detects minimal imbalances in the stamping process. Subsequently, the system was connected to normal production for one year. At the end of this work, we explain the anomalies detected as well as the conclusions of the article and future works.https://www.mdpi.com/1424-8220/23/14/6569virtual sensorDBSCANpredictive maintenancetonnage monitoringI3oT |
| spellingShingle | Ivan Peinado-Asensi Nicolás Montés Eduardo García Virtual Sensor of Gravity Centres for Real-Time Condition Monitoring of an Industrial Stamping Press in the Automotive Industry Sensors virtual sensor DBSCAN predictive maintenance tonnage monitoring I3oT |
| title | Virtual Sensor of Gravity Centres for Real-Time Condition Monitoring of an Industrial Stamping Press in the Automotive Industry |
| title_full | Virtual Sensor of Gravity Centres for Real-Time Condition Monitoring of an Industrial Stamping Press in the Automotive Industry |
| title_fullStr | Virtual Sensor of Gravity Centres for Real-Time Condition Monitoring of an Industrial Stamping Press in the Automotive Industry |
| title_full_unstemmed | Virtual Sensor of Gravity Centres for Real-Time Condition Monitoring of an Industrial Stamping Press in the Automotive Industry |
| title_short | Virtual Sensor of Gravity Centres for Real-Time Condition Monitoring of an Industrial Stamping Press in the Automotive Industry |
| title_sort | virtual sensor of gravity centres for real time condition monitoring of an industrial stamping press in the automotive industry |
| topic | virtual sensor DBSCAN predictive maintenance tonnage monitoring I3oT |
| url | https://www.mdpi.com/1424-8220/23/14/6569 |
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