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.
