Machine Monitoring Solutions Providing Tool, Quality & Production Control

Detection of Transfer Faults

By: Process Technologies Group, Inc.
Topics: Cold Forming, Transfer Faults, Rotated Heads, Envelope Profile Monitoring, IMPAX-SK

Detecting hexagonal heads that are damaged due to rotation during transfer

Transfer faults, or so-called "rotated heads," are a common problem when producing hexagonal parts on multi-station cold forming machines.

The parts tend to rotate during the transfer from one die to the next and will no longer match up with the hexagonal die pre-form. The corners of the hexagon are sheared off and remain as excess material on the external diameter of the part.

Good and faulty parts
Hexagon parts with "rotated heads":
At left, a partial rotation fault, with partially trimmed corners.
At right, a full 60-degree rotation fault, with all corners sheared off.

This error typically occurs randomly and is very difficult to find with manual inspections. Forming forces will not change significantly enough to be detected reliably with standard monitoring limits.

IMPAX/SK has developed a special algorithm which is capable of reliably detecting rotated heads using a separate zoom channel.

Zoomed view of process
Detection of rotated parts using Zoom:
Excessive forces are detected easily by zooming in to the process.

This technology is available for our monitoring systems IMPAX/SK 2, IMPAX/SK 4, IMPAX/SK 7, and IMPAX/SK 100, and can also be retrofitted on select systems.

IMPAX/SK Process Monitor
IMPAX/SK Process Monitor

Company and Product Profile

IMPAX/SK Monitors use process enveloping to provide the highest quality process monitoring. They also have advanced production tracking capabilities, an easy-to-use visual interface, and many enhanced software features.
More information: IMPAX/SK Monitors

Process Technologies Group, Inc. (PTG) designs and manufactures process monitors, efficiency monitors, sensors, and data collection software for all production environments.
More information:

Request More Information, or a Quote

Back to Articles