SmartBending—Inline Measurement for Process Correction

Inline process optimization for error compensation in swivel bending

Christian Donhauser ORCID Icon, Reinhard Schmied, Marco Susic
JournalIndustry 4.0 Science
Issue Volume 42, 2026, Edition 3, Pages 134-141
Bibliography Share Cite Download

Abstract

Swivel bending is an established forming process that minimizes material loss and enables efficient use of resources. However, the process requires complex optimizations that have traditionally relied heavily on the expertise of machine operators. This results in significant time and material costs, as optimization steps are performed iteratively. Given the shortage of skilled workers, a technological upgrade of the machines in line with Industry 4.0 is necessary. As part of a research project, intelligent sensor technology was used to record critical influencing factors that reveal correlations between product defects and machine deformations. Based on this, a methodology was developed that forms the foundation for inline compensation, enabling the equipment to autonomously adjust process parameters to correct product defects and, in the long term, enable defect-free production from the very first component.

Keywords

, , , , ,

Article

Due to its flexible applicability, swivel bending is a widely used process in industrial sheet metal forming [1]. At first glance, it appears to be a comparatively simple process: sheets are clamped between upper and lower beam tools and bent along a defined line using a swiveling bending beam (Figure 1) [2]. To achieve the desired bending angles with sufficient dimensional accuracy over the entire sheet length, considerable adjustment effort and experienced machine operators are required despite modern Computerized Numerical Control (CNC) systems [3, 4]. A major cause of angle deviations …

Access limited

You are currently not logged in / not yet registered.

To read the content in full, you must have an appropriate subscription. Alternatively, you can also obtain access by paying a one-off fee.

Subscription included Purchase
without − 29,00 €
Digital − 27,55 €
Expert ✓ 0,00 €
Professional ✓ 0,00 €

Read for once 29,00 €

All prices include 7% VAT

After purchasing access rights, you will automatically be redirected back to this page.

You might also be interested in

Experiential Knowledge Powered by AI 

Experiential Knowledge Powered by AI 

Practical insights from industry
Martin Schmauder ORCID Icon, Gritt Ott ORCID Icon, Bianca Windisch
The use of experiential knowledge is a key success factor for companies. Based on four corporate case studies, this article analyzes the technical, organizational, and personnel challenges associated with the use of retrieval-augmented generation (RAG) systems. The results show that the success of such systems depends on the strategic development and maintenance of the knowledge base, as well as on employee engagement.
Industry 4.0 Science | Volume 42 | 2026 | Edition 5 | Pages 128-135 | DOI 10.30844/I4SE.26.5.15
Inclusive Work System Design

Inclusive Work System Design

Automation, standardization, and adaptability
Sebastian Schlund ORCID Icon
The design of inclusive work systems is gaining importance due to demographic change and the increasing digital penetration of value creation processes. While traditional ergonomic approaches are based primarily on percentile logic and thus address only a portion of the user population, the integration of digital technologies opens up new possibilities for the dynamic and individualized adaptation of work systems. This article presents a conceptual framework for inclusive work system design that integrates standardization, automation, and adaptability. Methodologically, the article is based on a conceptual analysis of existing approaches from ergonomics and human-centered design. The article makes a theoretical contribution to the systematization of inclusive work system design and identifies areas of focus for further research and industrial practice.
Industry 4.0 Science | Volume 42 | 2026 | Edition 5 | Pages 70-76 | DOI 10.30844/I4SE.26.5.8
MTM Analyses with AI and Rule-Based Algorithms

MTM Analyses with AI and Rule-Based Algorithms

An approach to interpreting textual process descriptions
Constantin Eckart ORCID Icon, Martin Benter, Peter Kuhlang
MTM methods are a proven standard for analyzing and designing human work processes. However, work planners continue to face challenges in applying these methods correctly and efficiently. Artificial intelligence — particularly in the case of large language models — holds significant potential for combatting these challenges. However, the use of AI raises legitimate questions regarding the reliability and traceability of the results. The approach presented here combines LLMs with a rule-based algorithm to extract the information required for MTM analyses from textual process descriptions such as work instructions. This information is then translated into MTM analyses in accordance with the MTM methodology. This approach ensures that the resulting analyses can be transparently traced back to the original input data by the user.
Industry 4.0 Science | Volume 42 | 2026 | Edition 5 | Pages 62-69 | DOI 10.30844/I4SE.26.5.7
AI-Powered Lubrication Strategies for Thread Forming

AI-Powered Lubrication Strategies for Thread Forming

Adaptive spray jet control to increase process reliability and tool life
Reinhard Schmied, Marco Susic, Christian Donhauser ORCID Icon
Thread forming requires precise lubricant application because high contact pressures and process temperatures strongly influence tool loading, friction, and process stability. Although minimum quantity lubrication (MQL) systems are widely used, current spray-based approaches can still suffer from spray losses, insufficient wetting of the thread grooves, and unstable droplet transport. This article presents a concept for adaptive precision lubrication in thread forming based on computational fluid dynamics (CFD)-supported flow analysis, experimental validation, and artificial intelligence (AI)-assisted optimization. The focus is on droplet size, spray jet geometry, nozzle position, ambient flow conditions, and their influence on wetting intensity. Preliminary simulation-based investigations indicate that data-driven optimization can help identify wetting deficiencies and support the development of future control strategies for resource-efficient lubricant application.
Industry 4.0 Science | Volume 42 | 2027 | Edition 3 | Pages 76-83
Optimized Manual Processes in Automotive Production

Optimized Manual Processes in Automotive Production

A module-based approach for the efficient creation of work system simulations
Barbara Brockmann, Tobias Jurk, Beate Stoffels, Jochen Deuse ORCID Icon
In the manufacturing industry, the integration of digital human models into the product development and manufacturing process is becoming increasingly important. Particularly in assembly, which is characterized by a high proportion of manual tasks, motion simulations enable a realistic representation of human work and thus make a significant contribution to the evaluation of motion economy, process validation, and efficiency improvement. However, widespread application in production planning faces various challenges, such as the high initial effort required to create human simulations as well as volatile planning conditions. This article presents a practice-oriented solution from the automotive assembly sector that enables the creation of simulations with reduced effort as well as their early and consistent use in the planning process.
Industry 4.0 Science | Volume 42 | 2026 | Edition 3 | Pages 48-55
Malou Baumann