Real-time monitoring in metal forming with piezoelectric sensors
Integrate piezoelectric sensors with high-speed data acquisition for real-time force monitoring in metal forming, enhancing process optimization and product quality.
Overview
This innovative solution involves the integration of piezoelectric sensors with a high-speed data acquisition system into the lower tooling of a metal forming press. This approach allows for real-time monitoring of force variations during the forming process, providing a significant improvement over traditional force measurement methods. By capturing intricate details of the forming process, it enables early identification of potential issues such as excessive force or uneven pressure distribution, leading to enhanced product quality and consistency.
Technical specifications
- Piezoelectric Sensors: These sensors are known for their ability to capture dynamic force changes, making them ideal for real-time applications.
- High-Speed Data Acquisition: The system operates at a minimum of 10 kHz, ensuring detailed monitoring and analysis of the forming process.
- Sensor Placement: Optimal locations within the lower die set are identified to avoid impact zones while maintaining proximity to the forming area.
- Embeddable Design: Sensors are embedded within the die set using specialized mounting techniques to minimize stress concentrations.
Technology readiness level
Currently, this technology is at a TRL 2, indicating that the concept has been formulated and experimental proof of concept activities have been initiated. Future steps include consulting with sensor specialists, analyzing tooling assembly for optimal sensor placement, and designing embedding methods for sensor integration.
About Scientific and Industrial Research and Development Centre
The Scientific and Industrial Research and Development Centre (SIRDC) is the national research and development agency of Zimbabwe, established by the government in 1993. The centre operates through a structured cluster system comprising 12 specialized research institutes that focus on fields ranging from biotechnology and food technology to information technology, energy, and mining. SIRDC develops technological solutions, provides consultancy services, and undertakes research projects aimed at supporting the manufacturing, agricultural, service, and mining sectors. Its operations integrate advanced manufacturing, artificial intelligence, and data analytics to transition toward modern industrial standards and national development goals.
SIRDC serves as a partner to diverse stakeholders by commercializing its research outputs, which include foundation seeds, agricultural products, energy-efficient electronics, and industrial equipment. Through its commercial arm, Zimbabwe Technological Solutions (ZTS), the centre ensures that its innovations are translated into industrial reality. By providing technical training, equipment calibration, and sustainable infrastructure design, SIRDC helps businesses and institutions improve operational efficiency, comply with quality standards, and implement sustainable practices. The centre's multi-disciplinary approach addresses critical challenges in water management, environmental protection, and small-scale enterprise development across the region.
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