PSI - Issue 77

Carolina Francisco et al. / Procedia Structural Integrity 77 (2026) 567–574 C. Francisco et al. / Structural Integrity Procedia 00 (2026) 000–000

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1. Introduction

Metal forming is essential in modern manufacturing since it allows the production of components close to their final shape, reducing the need for additional machining operations He et al. (2025). Stamping is one of the most widely used processes in sheet metalworking, being the primary process for manufacturing across multiple industries Huang et al. (2021). Stamping presses allow the process to be continuously performed at high speeds and with pre cision, ensuring repeatability in production. These processes involve numerous variables such as material, sharpness, lubrication, clearance and surface roughness of tools C. Zhang et al. (2012), making the monitoring of both process parameters and machine components crucial to maintain consistent product quality. Breakdowns on the production lines due to equipment failure or defects in the final product, such as splits, necking and wrinkling, occur recurrently, increasing production costs and material waste Peinado-Asensi et al. (2021). While periodic maintenance tasks en sure proper functionality and reduce the risk of unplanned stoppage, their time-based nature can lead to unnecessary stoppages and may fail to detect emerging faults that develop between inspections. Condition-based maintenance strategies are being developed to address these limitations Mei et al. (2022). By col lecting sensor data from machines, condition monitoring allows the prediction of equipment health and the scheduling of maintenance operations before failures occur, improving productivity, product quality, and cost-e ffi ciency. To address the need for e ff ective condition-based monitoring, this paper introduces a monitoring system developed for a new servo-motorized stamping press and integrated from the earliest design stages. The system was designed in parallel with the press to ensure full integration. This work focuses on the preliminary development phase, cover ing system architecture design, sensing plan definition, and initial data analysis to evaluate processing methods and determine whether the measurements reveal meaningful features for condition monitoring. The proposed monitoring system consists of five main components as illustrated in Figure 1: sensor data acquisi tion, data storage, data pre-processing , continuous monitoring and the visualization of data and resulting insights on the press condition. The sensor data is stored locally in a database. O ffl ine pre-processing is used to determine the reference curves and operating limits under well-defined conditions of the press. Online monitoring then applies these results to continuously analyze the acquired data and compare it against the parameters in order to assess the press condition. Finally, both the raw data and the monitoring results are displayed in a visualization dashboard, which also works as an interface between the user and the monitoring system, enabling process control. 2. System architecture

Fig. 1: Architecture of the proposed monitoring system.

2.1. Data acquisition

The monitoring system uses data acquired from sensors to evaluate the condition of the press, based on the as sumption that the measurements reflect both the behavior of the press components and the overall stamping process.