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Research Papers

A Control Strategy for Intelligent Stamp Forming Tooling

[+] Author and Article Information
William J. Emblom

Department of Mechanical Engineering,  University of Louisiana at Lafayette, Lafayette, LA 70504wjemblom@louisiana.edu

Klaus J. Weinmann

Department of Mechanical Engineering,  University of California—Berkeley, Berkeley, CA 94720

J. Manuf. Sci. Eng 133(6), 061026 (Dec 27, 2011) (10 pages) doi:10.1115/1.4005310 History: Received April 24, 2011; Accepted October 05, 2011; Published December 27, 2011; Online December 27, 2011

This paper describes the development and implementation of closed-loop control for oval stamp forming tooling using MATLAB ® ’s SIMULINK ® and the d SPACE® CONTROLDESK ® . A traditional PID controller was used for the blank holder pressure and an advanced controller utilizing fuzzy logic combining a linear quadratic gauss controller and a bang–bang controller was used to control draw bead position. The draw beads were used to control local forces near the draw beads. The blank holder pressures were used to control both wrinkling and local forces during forming. It was shown that a complex, advanced controller could be modeled using MATLAB ’s SIMULINK and implemented in DSPACE CONTROLDESK . The resulting control systems for blank holder pressures and draw beads were used to control simultaneously local punch forces and wrinkling during the forming operation thereby resulting in a complex control strategy that could be used to improve the robustness of the stamp forming processes.

Copyright © 2011 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Process/press optimization system [7]

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Figure 2

Aluminum 6111-T4 test panel

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Figure 3

Location of the oval stamp forming research die instrumentation [22]

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Figure 4

Lower die with sensors and draw beads and schematic of forming [22]

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Figure 5

Open-loop pressure control

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Figure 6

Open-loop response to BHP step command

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Figure 7

Pressure model in SIMULINK

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Figure 8

Comparison between simulation and test for BHP 6 step command

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Figure 9

Closed–loop control of BHP using PID controller in a typical feedback loop

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Figure 10

Closed–loop control of BHP using PID controller for the d SPACE control system

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Figure 11

BHP response comparing an open-loop and a closed-loop PID controller simulation

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Figure 12

Closed-loop control of LPF based upon BHP

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Figure 13

Closed-loop control of LPF 13 in the punch nose. DB = 2 mm.

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Figure 14

Control of LPF 15 using BHP. LPF 19, also shown, is not controlled.

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Figure 15

The SIMULINK model of wrinkle control

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Figure 16

Wrinkle as a function of draw depth for a partial draw test. DB = 2 mm.

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Figure 17

Wrinkle shown as a function of time successful test. DB = 2 mm.

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Figure 18

Step response of DB during an open–loop test compared to simulations from a SIMULINK model

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Figure 19

Advanced PID controller including a Kalman filter

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Figure 20

Simulation results comparing a bang–bang controller and open–loop responses for a 10 mm step command

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Figure 21

Experimental results for DB control using fuzzy logic to control db

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Figure 22

Closed-loop control of die shoulder sensors LPF 1 and 7 using independently controlled DB 1 and 2

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Figure 23

Closed-loop control of wrinkle while at the same time controlling LPF 1 [22]

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Figure 24

Closed-loop control of LPF 1 while at the same time controlling wrinkle [22]

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