Portable gauge equipment and software for measuring metal forming loads in DWI can-making bodymakers
Three high quality piezo-electric load sensors are housed in a gauge ring. The gauge
ring fits behind the final ironing ring of bodymakers with cradle type tool-packs.
The gauge ring is 10mm thick and so can fit in most tool-packs with only small modifications
to the widths of modules or coolant spacers.
The equipment fits into a small briefcase size carry case and connects to a standard
notebook computer. It is quick to setup and easy to use.
The gauge technology was originally developed by Rasselstein, the German steel maker,
and has proven to be effective and reliable in extensive testing.
It has now been packaged with new software written by Delta-H Technology, the makers
of dynamic ram alignment measuring equipment known as the Free Stroke Analyser, which
is used in many can plants worldwide.
In on-line mode, the gauge will capture the data and display it in real-time. The
data is automatically saved and displayed graphically as shown.
The forming loads during the redraw and 1st, 2nd and 3rd ironing stages can clearly
Another graphic shows the forming loads during the latest stroke, in relation to
pre-defined reference values.
Snapshot of loads during latest stroke
Trend graphs show how the loads and the signal lengths have changed over time.
Trending over time
Process variations such as those caused by tooling wear, die changes, coil changes
and temperature variations are clearly identified on the trend graphs.
The signal length is related to the untrimmed can length and can therefore be used
to detect short cans. The short can percentage during a run is displayed on the screen.
After capture, the results can be analysed in more detail. Strokes can be selected
using on-screen tools. Any number of strokes from one up to the entire database can
be selected and analysed.
Example showing a sequence of 10 strokes with 1 short can
Mean and peak loads within specified sections of the load signals can be analysed
in detail. These are displayed in the trend graphs and average values for the selected
strokes are given numerically.
The equipment is intended for can-makers, aluminium and steel producers, as well
as bodymaker and tooling suppliers. Its uses are many. For example, it could be used
by R&D departments investigating the effects of tooling design or coil grade/supplier.
Can plants could also use it as a SPC tool for can production or to provide data
if they have problems with particular coil or tooling suppliers. Coil or tooling
suppliers could use it to provide evidence of the advantages of their products over
those from alternative suppliers.