Metal inserts with embedded micro sensors for force monitoring in forming dies

Overview

The innovative solution involves the integration of micro thin film sensors into metal inserts used in forming dies, molds, and other tooling systems. These embedded sensors allow for advanced real-time monitoring and control by significantly enhancing the spatial and temporal resolution of in-process sensing systems. The small size of the sensors ensures they do not interfere with normal operations or compromise the structural integrity of the tooling. This advancement can lead to improved efficiency and intelligence in manufacturing processes, particularly in die casting, stamping, forging, and injection molding.

Technical specifications

• Micro thin film sensors: Small and responsive, these sensors can be embedded at critical locations inaccessible to conventional sensors.
• Sensor types: Includes thin film thermocouples and strain gauges, capable of responding to changes within approximately 50 ns.
• Integration: Sensors are embedded in metal inserts that can be incorporated into pre-machined holes/channels in forming dies.
• Protection: Sensors are insulated with dielectric multilayers to prevent shorting and protect from harsh environmental conditions.
• Data management: Methods for in-situ calibration, data acquisition, interpretation, and analysis are being developed, with both wired and wireless transmission options.
• Testing: Comprehensive tests under static and dynamic conditions, assessing resolution, bandwidth, shock sensitivity, and stability across temperature variations.

Technology readiness level

The technology is at a TRL 4, indicating that it has been validated in a laboratory environment. Future steps involve further design optimization, integration, and comprehensive testing to progress towards higher TRLs.