Adaptive process control strategy for a two-step bending process

A robust production is an important goal in sheet metal forming in order to make the process outcome insensitive to variations in input and process conditions. This would guarantee a minimum number of defects and reduced press downtime. However, for com-plex parts it is difficult to achieve robust settings. Parts without defects can only be real-ized if the process parameters are adapted to the changed conditions. In this paper, an approach for adaptive process control is presented, taking the uncertain-ties and tolerances of the process and material into consideration. The proposed control approach combines feedback and feed-forward control strategies. The most significant improvement is to incorporate feed-forward control with knowledge about the system (also known as predictive models). To create these models high fidelity numerical models have been created. Furthermore, a procedure is presented to update the coefficients of the predictive model to adapt it to the actual process state. To evaluate the control strategy prior to its implementation, a testing environment has been developed. Different test scenarios for common states of the process have been generated to evaluate the improvement of the proposed control strategy.