다단계 냉간 단조 장비의 동적 기울어짐 편차 모니터링을 이용한 장비 이상 감지 및 제조 안정화 = Anomaly Detection and Manufacturing Stabilization via Dynamic Ram Tilt Deviation Monitoring for Multi-stage Cold Forging Equipment

다국어 초록 (Multilingual Abstract)

This paper proposes a real-time Ram Tilt variation monitoring system to detect equipment abnormalities and stabilize production in multi-stage cold forging processes. As equipment wear progresses, misalignment often occurs, leading to product defects and tool damage. The proposed system utilizes dual distance sensors to capture micro-variations in Ram Tilt during reciprocating motion and calculates the Ram Tilt deviation (mm) through real-time processing. Data collected over one year from eight forging machines were analyzed using SPC X̄-R charts, and abnormal control patterns were classified into three types: chronic instability, intermittent spike, and mean shift. The system was integrated with an MES to automatically stop equipment when deviations exceed thresholds, minimizing downtime and tool damage. Furthermore, the statistical independence between cycle time and Ram tilt (Pearson correlation coefficient ) was verified, proving its reliability as a condition indicator. The results demonstrate improved manufacturing reliability, including a 98% reduction in defect rates, and reduced operator dependence, suggesting potential applications in smart factory environments with low-volume, high-mix production.