Digitalisation of bulk forming processes by retrofitting

The aim of the research project "DiReProFit" is a software demonstrator with a growing database that enables companies to obtain an assessment of the cost-benefit ratio of possible retrofit projects in their own machinery and also provides information on the steps required for implementation.

In the forging industry, equipment without interfaces to Industry 4.0 is still frequently in operation. These allow no or only limited communication with the digital environment, which means that no automated data processing is possible. Procurement of "Industry 4.0-capable" machines is associated with high investments and is hardly economically viable for SMEs.

A tool that enables the user to carry out an investment estimate independently of retrofit service providers does not yet exist. There is a demand for action to support companies in overcoming this hurdle by means of a digital guide and thus enable them to carry out a data-based investment assessment as well as a potential analysis of a possible retrofit.

The aim is to develop a digital and generally applicable guide that evaluates forming processes with regard to the potential of a future retrofit and provides an algorithm-supported retrofit recommendation. For this purpose, the process parameters relevant for a retrofit are identified and it is examined how these can be measured or influenced by retrofitted sensors or the press control. Possible parameters can be: Forming forces, tool and workpiece temperatures, transport and holding times, lubricant quantity and concentration, machine load.

The evaluation of possible retrofit measures is carried out by means of an evaluation algorithm. This AI-based algorithm accesses the data generated in the project, processes it and calculates a recommendation for a retrofit on the basis of the parameters specified by the user.