Architectural setup for online monitoring and control of process parameters in robot-based ISF

摘要

This article describes new developments in an incremental, robot-based sheet metal forming process (Roboforming) for the production of sheet metal components for small lot sizes and prototypes. The dieless kinematic-based generation of the shape is implemented by means of two industrial robots, which are interconnected to a cooperating robot system. Compared to other incremental sheet forming (ISF) machines, this system offers high geometrical design flexibility without the need of any part-dependent tools. However, the industrial application of ISF is still limited by certain constraints, e.g. the low geometrical accuracy. Responding to these constraints, the authors introduce a new architectural setup extending the current one by a superordinate process control. This sophisticated control consists of two modules, i.e. the compensation of the two industrial robots' low structural stiffness as well as a combined force/torque control. It is assumed that this contribution will lead to future research and development projects in which the authors will thoroughly investigate ISF process parameters influencing the geometric accuracy of the forming results.