Evolution in the press shop

Intelligent, camera-based tool protection in stamping and forming technology

Boosting efficiency through digitalisation – almost no branch of industry can evade it, states IDS Imaging Development Systems and Schuler Pressen. Also, operators of press shops are increasingly networking their production.

But, regardless of whether it's a single press or press lines, it's not always necessary to replace the entire plant, in order to stay up to date. “Retrofitting existing lines, true to the principle of ‘sensible evolution, instead of cost-intensive revolution’, is often the order of the day,” they insist.

With Visual Die Protection, Schuler Pressen says it offers a solution for avoiding expensive die damage and its consequential costs in stamping and forming technology – retrofittable for existing lines. Equipped with industrial cameras from IDS Imaging and intelligent software, the production process can be monitored as required.

Possible causes of die damage

The principle of the system is simple: Visual Die Protection (VDP) detects possible causes of die damage in the press shop at an early stage and stops the line in fractions of a second before damage and downtime occur. Different monitoring functions can be set up for the various areas in the press installation space. This way, a wide range of error sources can be covered to prevent unforeseen incidents. The probability of failure is reduced and the safe operation of the systems is ensured.

The control functions range from checking the component position to foreign object detection and in-process inspections to the targeted monitoring of individual tool functions. For example, if a foreign object, such as a scrap of sheet metal from the previous press pass, is detected in the die, the press stops automatically, so that the foreign object cannot push into the die surfaces or cause damage.

Faults detected and the press stopped

For this purpose, 2 to 4 cameras per system monitor the tool room of the press or, if desired, other areas of the plant, such as the scrap chutes. At each stroke, the current process is compared with the target state. If the process deviates significantly from the norm – eg, due to the above-mentioned foreign object in the tool – the system is stopped, and damage and its consequential costs are prevented.

In addition, all image and analysis data are available to the customer for complete traceability. For continuous improvement processes, the system simultaneously links image and process data, and optimises its settings with the help of intelligent data analyses. It only intervenes in the production process when there is a critical deviation. Visual Die Protection thus ensures greater process reliability of production plants, prevents tool damage, increases plant availability and secures the user's ability to deliver. Especially in just-in-time supply chains, this is a decisive competitive advantage.

Avoidance of incidents by checking position of components

The system can be used for a wide range of monitoring tasks, even outside the actual pressing plant. “Thanks to the easy retrofitting of existing systems and the wide range of applications, the monitoring functions can be set up in just a few minutes,” it is stated. “Accordingly, customers benefit immediately from camera-based tool protection. That also applies to non-Schuler systems. With the help of product data handling, even monitoring of already set-up tools can be loaded and monitored from the first press stroke.”

One or more IDS industrial cameras monitor tool room

The image data on which the Schuler system is based is supplied by uEye CP industrial cameras from IDS. CP stands for ‘Compact Power’ and symbolises compact, visual power packs for industrial applications of all kinds. They are said by IDS Imaging to offer “maximum functionality with extensive pixel pre-processing and are perfect for multi-camera systems, thanks to the internal 120 MB image memory for buffering image sequences”.

The GigE cameras, with a size of only 29 x 29 x 29 millimetres, are reported to score particularly well, in terms of light sensitivity, dynamic range and colour reproduction. This makes them predestined for applications that need to deliver a perfect result even in low light conditions, such as in quality assurance or automation.

"The quality of the image data convinced us. Even under rather unfavourable lighting conditions in press shops, the camera provides perfect source material for our inspection systems," explains Christoph Pölzl - project manager in the Digital Solutions division at Schuler Pressen. For integration, the company used the IDS Camera Manager, a central and convenient tool for managing all uEye industrial cameras.

VDP – stamping its mark

Visual Die Protection has been on the market since 2019 and has since established itself in stamping and forming technology as a reliable visual protective tool. With artificial intelligence and industrial cameras, it provides a clear view in the press shop. "For the future, we expect a continuously growing market," predicts Pölzl.

In addition to process and tool monitoring, further applications in the area of in-process quality monitoring are added. Also, the diagnostic tools for linking image and process data are constantly being expanded. So, the evolution continues and perhaps. in time, may lead to a small revolution?

Digitisation in the press shop.
Digitisation in the press shop.
This image and one below: the system detects unexpected causes of faults and stops the press.
This image and one below: the system detects unexpected causes of faults and stops the press.
This image and one above: the system detects unexpected causes of faults and stops the press.
This image and one above: the system detects unexpected causes of faults and stops the press.
One or more IDS industrial cameras monitor the tool room.
One or more IDS industrial cameras monitor the tool room.

IDS Imaging Development Systems

Landmark House
Station Road
Hook
RG27 9HA
UNITED KINGDOM

+44 (0)1256 962910

uksales@ids-imaging.com

www.ids-imaging.com

More from IDS Imaging Development Systems

IDS camera has Eye on the main prize

Posted 1 week ago

Robots on their own

Posted 1 week ago

All-in-one embedded vision platform with new tools and functions

Posted 3 weeks ago

From smallest housed camera with C-mount over 10GigE to AI

Posted 2 months ago

High order intake and promising new products

Posted 2 months ago

Triple vision in quest for excellence

Posted 3 months ago

IDS expands Ensenso 3D camera portfolio

Posted 4 months ago

Drive-through control

Posted 4 months ago

Time to take your pick

Posted 4 months ago

Eyeing up the new uEye sensors

Posted 4 months ago

Engage with image processing experts to ‘Capture the Light’

Posted 5 months ago

Eyes on the uEye XLE models

Posted 5 months ago

It takes a lot of bottle to fight the pandemic

Posted 6 months ago

Precision vision aids productivity

Posted 6 months ago

Making space for additive manufacturing

Posted 9 months ago

Real know-how when picking the unknown

Posted 9 months ago

New industrial vision online channel sees the light of day

Posted 10 months ago

Affordable, compact and powerful new camera family

Posted 1 year ago

New C-Mount lenses bring focus for machine and system builders

Posted 1 year ago

IDS extends Ensenso N3D camera series

Posted 1 year ago

5 megapixels polarisation cameras reveal hidden details

Posted 1 year ago

Learn how to create an intelligent camera

Posted 1 year ago

IDS NXT ocean - unique all-in-one AI-based image processing

Posted 1 year ago

IDS launches industrial cameras with 20 MP Sony sensor

Posted 2 years ago

Modular uEye ACP for developing customised industrial cameras

Posted 2 years ago

Ensenso XR 3D camera family features integrated data processing

Posted 2 years ago

Board-level cameras with liquid lenses and autofocus

Posted 2 years ago

IDS launches more than 100 new models of USB3 Vision camera

Posted 2 years ago

On a voyage of discovery with IDS cameras

Posted 2 years ago

Vision app-based cameras now available from IDS

Posted 2 years ago

Registration opens for IDS UK Industrial Vision Days

Posted 2 years ago

uEye CP camera with high-resolution 12 MP rolling shutter sensor

Posted 2 years ago

Sony sensor: excellent image quality under difficult conditions

Posted 2 years ago

Board-level cameras feature liquid lenses and Active Focus

Posted 2 years ago

IDS achieves sales increase well above industry average

Posted 2 years ago

Self-programmed camera functions meet GenICam standard

Posted 2 years ago

3D vision system creates data twice as fast

Posted 2 years ago

IDS NXT rio and rome industrial cameras are AI-ready

Posted 3 years ago

IDS unveils Ensenso XR 3D camera with onboard processing

Posted 3 years ago

IDS unveils 10 GigE uEye FX high-speed camera with PoE

Posted 3 years ago

IDS strengthens presence in South Korea

Posted 3 years ago

IDS 3D vision system helps robots assemble flat-pack furniture

Posted 3 years ago

IDS at the world's leading trade fair for machine vision

Posted 3 years ago

New USB 3.1 board-level cameras with liquid lens control

Posted 3 years ago

IDS delivers its millionth camera

Posted 3 years ago

GigE Vision camera firmware 1.5 with new trigger modes

Posted 3 years ago

IDS NXT vegas model with colour sensor and further developments

Posted 3 years ago

3D camera system from IDS wins VSD Award

Posted 3 years ago

App-based industrial cameras now with colour sensors

Posted 3 years ago

EnsensoSDK 2.2 makes 3D image processing even more convenient

Posted 3 years ago

IDS introduces app-based vision sensors and cameras

Posted 3 years ago

See new app-based cameras and 3D cameras at UKIVA event

Posted 3 years ago

uEye Python interface for interactive programming of IDS cameras

Posted 4 years ago

How to simplify the prototyping of embedded vision systems

Posted 4 years ago

Robust 3D camera with IP65/67 for harsh ambient conditions

Posted 4 years ago

Versatile industrial camera with GigE or USB 3.1 Type-C port

Posted 4 years ago

New Gigabit Ethernet industrial cameras with CMOS sensors

Posted 4 years ago

IDS Vision Suite: easy evaluation, setup of GigE Vision cameras

Posted 4 years ago

IDS: successful in the vision market for two decades

Posted 4 years ago

Robust IP65/67 GigE uEye FA industrial cameras with PoE

Posted 4 years ago

IDS presents GigE uEye CP Gigabit Ethernet machine vision camera

Posted 4 years ago

New USB 3.1 Gen 1 cameras with the PYTHON 480 sensor

Posted 4 years ago

3D camera system is easier to implement and more versatile

Posted 4 years ago

IDS highlights embedded vision at UKIVA Conference

Posted 4 years ago

New USB 3.0 industrial camera models with Sony sensors from IDS

Posted 4 years ago

IDS enhances presence in Great Britain and Ireland

Posted 4 years ago

GigE industrial cameras from IDS for use in harsh environments

Posted 5 years ago

IDS adds GigE vision interface support to industrial cameras

Posted 5 years ago

IDS shows new products and developments at VISION show 2016

Posted 5 years ago

First USB 3.1 Gen 1 machine vision cameras with Type-C connector

Posted 5 years ago

IDS Imaging Development Systems among the top 100

Posted 5 years ago

USB 3.0 industrial cameras with next-generation CMOS sensors

Posted 5 years ago

USB 3 uEye XC machine vision camera wins Red Dot Award

Posted 5 years ago

New TechTip: use of sequencer to vary image acquisition settings

Posted 5 years ago

New version 4.80 of the IDS Software Suite available

Posted 5 years ago

New IDS USB3 cameras with fast Python CMOS sensors

Posted 5 years ago

USB 3.0 single-board camera with 18 MP Aptina colour sensor

Posted 5 years ago

Adaptive Vision machine vision software available from IDS in UK

Posted 5 years ago

GigE and USB 3.0 cameras with Sony IMX249 sensor from IDS

Posted 6 years ago

50m cable lengths for USB 3.0 cameras approach GigE capabilities

Posted 6 years ago

High-performance CMOSIS sensors for IDS USB3 industrial cameras

Posted 6 years ago

New lenses extend applications for IDS uEye XC 13 MP USB3 camera

Posted 6 years ago

New robust 3D stereo cameras are sealed to IP65/67

Posted 6 years ago

Daniel Seiler joins IDS management board

Posted 6 years ago

IDS and Stemmer Imaging to end collaboration

Posted 6 years ago

UVC version of USB 3 autofocus industrial camera released by IDS

Posted 6 years ago

IDS to host Future Vision Day in UK on 17 June 2015

Posted 6 years ago

Platform-independent, board-level USB industrial cameras

Posted 6 years ago

IDS pushes forward with CMOS industrial cameras

Posted 6 years ago

New technical note for multicast configuring of IDS GigE cameras

Posted 6 years ago

High-performance CMOS sensors for IDS USB 3.0 CP cameras

Posted 6 years ago

Technical note on new methodology for high-speed imaging

Posted 7 years ago

IDS to launch two new USB 3.0 cameras at VISION 2014

Posted 7 years ago

GigE 3D stereo camera for 3D and robot vision applications

Posted 7 years ago

IDS extends its USB 3.0 camera portfolio with three new families

Posted 7 years ago

GigE industrial cameras with 2.2 and 4.2 MP CMOS sensors

Posted 7 years ago

Ensenso 3D camera makes bin picking easy and cost efficient

Posted 7 years ago

More news

Login / Sign up