LET’S ABOLISH FULL INSPECTION WITH OUR SMART FORGING SYSTEM THAT CAN AUTOMATICALLY INSPECT DEFECTIVE PRODUCTS

Do you find any similarities with these thoughts?

“Full inspection costs a lot. How can we reduce time and save money?”

“No more defective products should leave from the factory anymore.”

Our “Smart Forging System” can judge whether the products are good or bad “when they are forged” and sort them out.

In this article, we will introduce overviews of full inspection, die-set, and our “Smart Forging System” and a case study.

If you are thinking about abolishing full inspections and preventing defective products without replacing your press machines, please check this article.

1 MINUTE   INTRODUCTION – SMART FORGING SYSTEM

WHAT IS FULL INSPECTION/100% INSPECTION?

Full inspection means “A process of inspecting all products individually”.

This is an effective way to fully guarantee the product quality because it can sort out defective products, and pick only good products. There are some ways to inspect products, popular ways are: “Visual inspection by people” and “Mechanical inspection using AI and IoT (Internet of Things) technology”

“Visual inspection by people”, can be an easier and more convenient way of inspection when you have enough people. However, employing people for inspection costs much, and inspecting products takes time, too. In particular, full inspection for small components is not realistic; they are cheap and can be mass-produced. Considering the possibility of human error, full inspection by people cannot be said as the best way to 100% guarantee the product quality.

That is why full inspection by “Machinery with AI and IoT technology” has been in the spotlight. Mechanical inspection is less likely to have chances of oversights and can decide good or bad products precisely. It can finish inspection quickly, and improve efficiency too. Moreover, because machines can inspect automatically, they do not need people to check, which means it also leads to a reduction in labor costs.

WHAT IS DIE SET

A Die Set is a set of accessories to fix metal dies on a press machine for a press working process.

A die set comprises several components such as the upper and the lower dies, spacers, holders, guide posts, die plates, and so on. To produce precision products with high accuracy, it is very important to perfectly keep the concentricity of the upper and the lower dies. Whether metal dies and other components are easy to replace, and their maintainability are also necessary to improve precision and accuracy.

If you need further information, please click the link below.

DIE SETS OFFERED BY YAMANAKA ENG

WHAT IS SMART FORGING SYSTEM?

Smart Forging System is ”A system to prevent defective products leaving from a factory” that has been developed by us.

With sensors mounted on the die set, you can visualize the state of the die and the process, and compare the changes in the state of defective products with the good products, to sort the defective products out. Because machinery (the system) can judge the good products and bad ones automatically, there is no need for a total inspection. This system can be introduced to any kind of component productions using press working methods, and is suitable for mass productions, and the productions of components that require precision and accuracy including car components.

Also, this system enables you to visualize and quantify the load state of the dies, achieving management of die life. Additionally, the system enables you to detect abnormality of dies, but also the abnormality of die sets and press machines. This can be used to maintain equipment.

Not only enabling to detect abnormality of dies, but also abnormality of die sets and press machines

COMPONENTS OF SMART FORGING SYSTEM

The Smart Forging System we have developed is composed of a die set and the following:

・The Piezoelectric Load Sensor “PiezoBolt”: Measures the load on the dies and the die sets
・The dedicated monitoring system “EdgeSenses”: Analyzes data to receive signals from PiezoBolt
・Monitoring screen: Displays analyzed data in real-time
・Rotary Beacon Light: Alerts detection of defective products
・Chute: Sorts out defective products

CASE STUDY

Now we will introduce the case study of monitoring the load state of the forging dies and the die set during the forging process, to detect defective forging products and prevent them leaving from the factory.

We mounted “Piezo Bolt” on the ring-shaped jig attached to the outside of the die. In this case, we inspected unfilled products by visualizing the elastic-plastic behavior that synchronizes the filling conditions of the products.

We set the rules as a monitoring system to inspect the state of unfilled products compared with the state of good products through the process.

When the system inspects the unfilled products, the rotary beacon light alerts and the chute sorts out the defective products.

CONCLUSION

Thank you for reading! We hope you liked it.

With our Smart Forging System, you can pick only good products automatically. That means you do not need to conduct a full inspection, so you can reduce labor costs, and also you can improve the quality of products without any human error.

Other than the Smart Forging System, we have other products and services such as “Self Aligning Die Set”, “Forging System with High Precision and Accuracy” and so on, to help you solve problems in your production sites.