Acoustic Emission

 

Typical Failures

The Mission:

  • Rapid detection of tool failures
  • Reduction of tool costs
  • Quality improvement and increased machine utilization
  • Visualization of dynamix processes
  • Optimization of machine and tool settings
     
    


bad part (broken punch)


 

die crack

 

unejected scrap

The Solution: Acoustic Emission

Acoustic Emission detects the die crack that would not be detected with force measuring.

Acoustic Emission Monitoring:

  • Early and reliable detection of errors
  • Tool protection
  • Damage and cost reduction
  

AEvolution for stamping quality

THE solution for broken punches, cracks in the die and slugs.

AE on presses

Many presses are already equipped with machine protection. However, you need to protect not only your machine, but also your tools against cracks or other damage. The ideal protection for all of this is AE (Acoustic Emission).

AE is an efficient, innovative monitoring program that offers an optimal supplement to existing machine protection.

AE recognises process fluctuations where conventional monitoring methods do not react. This allows AE to protect both the machine and tools against follow-on damage.

  

AE sensor on upper tool recognises:

  • broken punches
  • machine vibration related to poorly optimized running speed
  • dynamic process variations
  • broken spring and tooling elements

AE sensor on lower tool recognises:

  • cracks in the die
  • slugs returns and build-up
  • broken springs and tooling elements

AE Sensors

To monitor your production machine, one AE sensor can be sufficient. Two AE sensors are optimal: one sensor on the upper and lower tool respectively. The installation of the AE sensors is extremely simple. The AE sensor is fixed to the tool with only one screw. Retrofitting is very easy.

For tools larger than 2,500 x 1,500mm, or for some modular tool constructions and transfer presses, several AE sensors can be necessary.

 

 

 

AE applications

  • Stamping presses
  • Mechanical presses
  • Hydraulic presses
  • Transfer presses
  • Toggle presses
  • Bending machines
  • Clinching
  • and other applications

AE Visualisation

With the Brankamp PK 4U the user can quickly intervene directly to adjust the process. For example an incorrect stroke rate can cause vibration between the machine and tooling. The consequense: The punch wears faster.

AE recognises this resonance and simplifies machine and tool adjustments for the operator.

BRANKAMP AE Units

Benefits to the user through rapid detection of typical tool failures:

  • Reduction of the tool costs
  • Quality improvement and increased machines utilisation
  • Visualisation of dynamic processes
  • Optimization of machine and tool setting