Artificial intelligence helps in machine modernization

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A press responds to material types

The AI also detects deviations from the ideal tool position. For instance, if the two halves of the tool are not exactly aligned with each other, it harms the component quality. The same applies if the semifinished product is not exactly centered in the tool. Incorrect material can also lead to errors—and a mix-up is often not easily detectable with the naked eye. Different steel grades also require different temperatures and forming forces. The AI recognizes the difference and points out material mix-ups. This allows the system to be stopped and the error corrected before a large number of faulty components are produced.

But! An AI must first be trained!

Retrofitting sensors and installing AI software, done? No, say the researchers! It's not that simple. AI-supported process monitoring is a so-called expert system that initially needs to be trained. And this must be done by a person who brings a lot of expertise and experience with the respective machine, as emphasized. Supervised learning algorithms ensure that the system learns quickly and itself becomes an expert capable of reliably recognizing error patterns. This way, the system can be trained on many different machines and production processes. Despite all the success, the AI system is not intended to replace humans but to support them in their work. For companies suffering from a shortage of skilled workers, this means enormous relief. Overall, AI-supported process monitoring helps companies become more competitive.

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Date: 08.12.2025

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AI for retrofit