Hirschvogel integrates AI-based automated testing of closed-die forgings

AI-assisted testing instead of visual checks: The new system utilizes fully automated final inspections of closed-die forgings, thus replacing conventional manual checks.

Working in partnership with Hirschvogel, one of the world’s largest automotive suppliers in the field of solid metal forming, SMS group is setting a new technological milestone in the quality assurance of closed-die forgings. In cooperation with image processing specialist Sightwise, a system for the automated final inspection of closed-die-forged components was developed to replace an existing manual testing station at the Denklingen site in Germany. As an integral part of iForge—SMS group’s digitalization solution for closed-die forging—the system enables fully automatic testing for surface defects and geometrical deviations. Instead of time-consuming manual visual checks, this scalable digital process sustainably enhances Germany’s efficiency as an industrial location.
The centerpiece of this solution is a platform that efficiently trains analysis models using synthetic data. Instead of collecting real defect images on physical parts over the course of weeks, the system uses CAD data or 3D models. Material properties and surface textures are digitally simulated so precisely that they accurately reflect actual conditions. An automated process generates photorealistic image data and virtually applies various types of defects to the components. The result: a ready-to-use analysis model in just six to eight hours.

AI evaluation minimizes the error rate in classification

The inspection process at Hirschvogel includes a fully automated feeding system: a robot removes the forgings directly from the transport crate. High-resolution camera sensors capture the components while the software analyzes them in fractions of a second. The system reliably identifies geometry deviations and surface defects and allocates them precisely to the digital defect catalog. This objective AI evaluation minimizes the error rate in classification, which means that pseudo-scrapping—in other words, the erroneous disposal of good parts—can be almost completely avoided.
According to SMS, the benefits for solid metal forming are measurable: High-level automation reduces dependence on personnel, cuts labor costs, and eliminates human error sources. The high scalability also allows the system to be adapted quickly to new product variants.
Source: SMS group