Optimal sensor selection and press blow detection for hammer systems

One of the biggest challenges in the control of hammer systems is the reduction of the press blow and the avoidance of rebound impacts as it results in energy waste, tool wear and increased maintenance. In this paper, we take a step in this direction by proposing and evaluating various sensor systems and subsequent press blow detection systems which serve as a measure of the required forming energy. Specifically, we discuss and evaluate the potential sensor types, namely displacement/speed sensors, acceleration sensors as well as structure-borne sound sensors, as well as their optimal placement on the hammer system. Furthermore, based on the different sensor signals, we derive conditions for the press blow detection and intensity estimation within hammer systems. We evaluate the approach on a hammer system in a laboratory environment as well as in industrial serial production with very encouraging results indicating the strength and limitation of the different sensor systems.