Soft sensor for predicting internal forces using external microstrain data
This innovative soft sensor technology integrates physics-based and data-driven modeling to predict internal forming forces in metal forming processes using external microstrain data. This approach enhances product quality, efficiency, and maintenance capabilities.
Overview
The proposed soft sensor technology leverages a hybrid modeling approach that integrates physics-based and data-driven techniques to predict internal forces within metal forming processes. By utilizing external microstrain sensors, this solution provides a non-invasive method of monitoring force dynamics, enhancing product quality, production efficiency, and enabling preventative maintenance. The technology addresses the challenges of sensor integration in high-speed manufacturing environments by offering real-time predictions and feedback.
Technical specifications
- Hybrid modeling approach: Combines physics-based models with data-driven algorithms for accurate force prediction.
- External microstrain sensors: Non-invasive, highly sensitive monitoring of force dynamics.
- Optimized sensor placement: Location determined through structural FE simulations for maximum data accuracy.
- Real-time prediction system: Integration with software interfaces for interaction between the model, sensor data, and process control systems.
- Validation procedures: Includes experimental trials, high-speed data acquisition, and process parameter recording.
Technology readiness level
This technology is at Technology Readiness Level 6, indicating that it has been tested and validated in a relevant environment. Future plans include further experimental validation and refinement of the hybrid model for enhanced accuracy and application in various metal forming scenarios.
About Clemson University
Clemson University is a comprehensive public land‑grant research university in Upstate South Carolina with a main campus and statewide outreach. Industry engages through co‑located facilities: an automotive innovation campus in Greenville, an energy testing complex in Charleston, and a research and technology park near the main campus with labs and offices. A strong co‑op program and corporate engagement team connect companies with faculty expertise and student talent, while the Extension network supports field trials and regional pilots. Research is backed by competitive federal funding from agencies such as NSF, NIH, DOE, USDA, and DOD. A dedicated technology transfer office provides IP, licensing, and startup support with clear pathways for industry‑sponsored agreements.
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