AP&T in Ulricehamn supplies production lines to automotive manufacturers worldwide. The systems include automation, presses, furnaces, and tooling for the production of press-hardened components for the automotive industry.
To produce strong and durable body components, the automotive industry uses lighter sheet metals such as aluminum and thin steel. Through the press hardening process, these lightweight materials become strong enough to form the vehicle’s structural frame. This makes it possible to meet all safety requirements without adding unnecessary weight to the vehicle, helping to reduce both fuel consumption and battery usage.
The manufacturer needs to be able to measure and monitor the metal sheets both before and after the pressing process. It is important that the heat is evenly distributed when the sheet exits the furnace and that it is correctly positioned in the press tool. It is also essential that no hot spots remain after the sheet has been cooled in the press tool. If any of these conditions are not met, the components will not achieve the required mechanical properties. In addition, there is a risk that the press tool itself could be damaged.
AP&T needed an automated solution to help automotive manufacturers save time and money by quickly detecting defective parts in the press hardening process. They therefore turned to Termisk Systemteknik, a company based in Linköping specializing in thermal imaging systems.
Termisk Systemteknik developed the Infrared Press Hardening Analysis (IPHA) system. The IPHA system is based on non-contact temperature monitoring using thermal imaging cameras from Teledyne FLIR.
IPHA – Thermal Imaging for Non-Contact Temperature Monitoring
The IPHA system can measure all three key factors that determine quality in the press hardening process: the sheet metal temperature before and after pressing, as well as its positioning in the press.
IPHA measures the temperature of the sheet metal using two Teledyne FLIR thermal imaging cameras mounted on either side of the press. The two cameras in the IPHA system are equipped with wide-angle lenses, ensuring accurate temperature measurement across the entire surface of a three-dimensionally shaped sheet.
Depending on the required image quality, the cameras can be either the Teledyne FLIR A70 or the Teledyne FLIR A615.
Two visual HD cameras are used for position monitoring. These cameras are also equipped with wide-angle lenses to effectively monitor the positioning of the entire sheet inside the press.
Accurate Measurement of Heat Distribution on Formed Sheet Metal
The process is fully automated. Once the sheet is inside the press, the press line control system sends a signal to IPHA to perform an image analysis. If both the positioning and temperature are approved, IPHA sends a signal back to the press line to continue the process.
After pressing and cooling, IPHA measures the temperature and heat distribution of the sheet. Here as well, if no deviations are detected, the process can continue without any manual operator intervention.
The thermal images are high-resolution, making it possible to quickly and accurately identify areas where the material has not reached the correct temperature.
The system also simplifies press tool changeovers. Users can define and save analysis parameters for a range of different press tools, enabling quick reconfiguration when switching production between different pressed components.
Accurate and Flexible Solutions for Thermal Image Analysis from Teledyne FLIR
The wide-angle capability of the Teledyne FLIR A70 means that just two cameras — one mounted on each side of the press — are sufficient to monitor even large sheet metal parts. IPHA alerts operators to any deviations, allowing them to investigate the cause and resolve the issue as quickly as possible to avoid both material waste and production delays.
In applications that require higher-resolution thermal imaging in IPHA, the Teledyne FLIR A615 can be used instead of the Teledyne FLIR A70. The A615 provides the same non-contact temperature measurement capabilities but offers greater accuracy and improved ability to detect temperature differences, even at longer distances.
IPHA can be installed in both new and existing production lines. So far, Termisk Systemteknik has delivered more than 40 IPHA systems to AP&T