Condition-Based Monitoring System for a Stamping Press

Stamping presses are essential in manufacturing due to their ability to produce components with high speed, precision and repeatability. However, unplanned downtime due to equipment failure can disrupt production and raise costs. While preventive maintenance schedules, commonly used by manufacturers, help reduce these risks, their time-based nature can lead to unnecessary stoppages and may miss emerging faults that develop between inspections. Condition-based systems capable of estimating the current condition of a press and detecting potential component faults offer significant advantages, as it can lead to energy and cost savings, as well as increased productivity and product quality. To address this need, a monitoring system was developed alongside the manufacturing of a new servo motorized stamping press. The system utilizes multi-sensor data collected from strategically placed sensors on the press. Sensor signals are filtered by dedicated modules and transmitted to a computer, where algorithms analyze the data to evaluate the press’s condition. The results of the estimated condition, along with the sensor data, are displayed on a dashboard also operating as an interface to manage data processing. The system’s modular architecture enables flexible integration or removal of sensors according to evolving requirements. This paper describes the early stage of developing the monitoring system, including the design of the system architecture and the definition of the sensing plan. To support the development and validation of the processing algorithms, data were collected from a stamping presses ensuring representative signal characteristics for press operation.