Inline Wear Detection in High-Speed Progressive Dies Using Photometric Stereo
The progressive forming of complex components, including blanking, deep-drawing, and bending, represents an economically efficient sheet metal processing method. Wear control is crucial for ensuring product quality by preventing defects and minimizing material waste. The integration of optical senso...
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| Format: | Article |
| Language: | English |
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EDP Sciences
2025-01-01
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| Series: | MATEC Web of Conferences |
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| Online Access: | https://www.matec-conferences.org/articles/matecconf/pdf/2025/02/matecconf_iddrg2025_01031.pdf |
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| _version_ | 1850267800265818112 |
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| author | Moske Jonas Kutlu Hasan Steinmeier Adrian Groenewold Phil Santos Pedro Kuijper Arjan Weinmann Andreas Groche Peter |
| author_facet | Moske Jonas Kutlu Hasan Steinmeier Adrian Groenewold Phil Santos Pedro Kuijper Arjan Weinmann Andreas Groche Peter |
| author_sort | Moske Jonas |
| collection | DOAJ |
| description | The progressive forming of complex components, including blanking, deep-drawing, and bending, represents an economically efficient sheet metal processing method. Wear control is crucial for ensuring product quality by preventing defects and minimizing material waste. The integration of optical sensors for qualitative wear detection, driven by advancing digitisation and miniaturisation, supplements conventional monitoring techniques. This study introduces a modular, agile camera-based measurement system that records component geometry and allows cause-specific feedback on wear progression. By assigning anomalies to distinct process stages, the system enhances defect diagnosis. The employed photometric stereo analysis relies on multiple images captured under varying illumination angles. Photometric reconstruction enables the calculation of normal maps, facilitating the assessment of surface characteristics through pixel-wise brightness variations. Deviations from predefined standards allow for the precise identification of irregularities. By delivering real-time, non-intrusive insights into the forming process, this approach establishes a foundation for efficient, reliable, and adaptive manufacturing. Its contributions to intelligent forming technologies enable enhanced process control and quality assurance, advancing the state of modern industrial production. Through the fusion of optical monitoring and computational analysis, the proposed methodology represents a significant step towards data-driven, self-optimising manufacturing systems. |
| format | Article |
| id | doaj-art-d68f9cc53a3f48c4a0b5f8bc9ac87f9e |
| institution | OA Journals |
| issn | 2261-236X |
| language | English |
| publishDate | 2025-01-01 |
| publisher | EDP Sciences |
| record_format | Article |
| series | MATEC Web of Conferences |
| spelling | doaj-art-d68f9cc53a3f48c4a0b5f8bc9ac87f9e2025-08-20T01:53:37ZengEDP SciencesMATEC Web of Conferences2261-236X2025-01-014080103110.1051/matecconf/202540801031matecconf_iddrg2025_01031Inline Wear Detection in High-Speed Progressive Dies Using Photometric StereoMoske Jonas0Kutlu Hasan1Steinmeier Adrian2Groenewold Phil3Santos Pedro4Kuijper Arjan5Weinmann Andreas6Groche Peter7Institute for Production Engineering and Forming Machines - PTU, Technical University DarmstadtFraunhofer Institute for Computer Graphics Research IGDInstitute for Production Engineering and Forming Machines - PTU, Technical University DarmstadtFraunhofer Institute for Computer Graphics Research IGDFraunhofer Institute for Computer Graphics Research IGDFraunhofer Institute for Computer Graphics Research IGDComputer Vision, Imaging and Data Analysis Group, Hochschule DarmstadtInstitute for Production Engineering and Forming Machines - PTU, Technical University DarmstadtThe progressive forming of complex components, including blanking, deep-drawing, and bending, represents an economically efficient sheet metal processing method. Wear control is crucial for ensuring product quality by preventing defects and minimizing material waste. The integration of optical sensors for qualitative wear detection, driven by advancing digitisation and miniaturisation, supplements conventional monitoring techniques. This study introduces a modular, agile camera-based measurement system that records component geometry and allows cause-specific feedback on wear progression. By assigning anomalies to distinct process stages, the system enhances defect diagnosis. The employed photometric stereo analysis relies on multiple images captured under varying illumination angles. Photometric reconstruction enables the calculation of normal maps, facilitating the assessment of surface characteristics through pixel-wise brightness variations. Deviations from predefined standards allow for the precise identification of irregularities. By delivering real-time, non-intrusive insights into the forming process, this approach establishes a foundation for efficient, reliable, and adaptive manufacturing. Its contributions to intelligent forming technologies enable enhanced process control and quality assurance, advancing the state of modern industrial production. Through the fusion of optical monitoring and computational analysis, the proposed methodology represents a significant step towards data-driven, self-optimising manufacturing systems.https://www.matec-conferences.org/articles/matecconf/pdf/2025/02/matecconf_iddrg2025_01031.pdfphotometric stereoinline wear detectionprogressive diesprocess interaction |
| spellingShingle | Moske Jonas Kutlu Hasan Steinmeier Adrian Groenewold Phil Santos Pedro Kuijper Arjan Weinmann Andreas Groche Peter Inline Wear Detection in High-Speed Progressive Dies Using Photometric Stereo MATEC Web of Conferences photometric stereo inline wear detection progressive dies process interaction |
| title | Inline Wear Detection in High-Speed Progressive Dies Using Photometric Stereo |
| title_full | Inline Wear Detection in High-Speed Progressive Dies Using Photometric Stereo |
| title_fullStr | Inline Wear Detection in High-Speed Progressive Dies Using Photometric Stereo |
| title_full_unstemmed | Inline Wear Detection in High-Speed Progressive Dies Using Photometric Stereo |
| title_short | Inline Wear Detection in High-Speed Progressive Dies Using Photometric Stereo |
| title_sort | inline wear detection in high speed progressive dies using photometric stereo |
| topic | photometric stereo inline wear detection progressive dies process interaction |
| url | https://www.matec-conferences.org/articles/matecconf/pdf/2025/02/matecconf_iddrg2025_01031.pdf |
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