IoTFlows Docs

Overview

Stamping and punch presses generate distinct vibration spikes with each stroke, making them perfect for precise counting using the Discrete Analysis w/o Merge algorithm. This tutorial shows you how to achieve accurate stroke counting while eliminating micro-stop noise.

What you'll learn:

Why Discrete w/o Merge is perfect for presses
How to combine algorithm (Parts List) with device downtime filter (SenseAi)
Achieving clean data with perfect stroke counts
Handling high-speed vs. low-speed presses

Time required: 30-45 minutes for complete setup

Why Discrete w/o Merge for Stamping Presses?

Stamping presses create distinct, countable events (strokes) that should each be tracked:

✅ Discrete strokes: Each press stroke is a separate, detectable event

✅ High frequency: Can run 30-120 strokes per minute

✅ No merging needed: Every stroke should count individually

✅ Brief micro-stops: Small pauses between strokes should be ignored

The secret: Combine Discrete w/o Merge algorithm (in Parts List) with Downtime Filter setting (on the SenseAi device itself) for perfect results.

The Two-Layer Filtering Approach

Understanding this is key to success:

Layer	Where Configured	What It Does
Algorithm	Parts List (operation settings)	Discrete w/o Merge counts every detected vibration spike as a stroke
Device Downtime Filter	Devices Tab (SenseAi sensor settings)	Converts all downtimes under X minutes to uptime

Combined result: Every stroke is counted, but only meaningful downtimes (longer than X minutes) are captured.

Step-by-Step Setup

Step 1: Install and Calibrate SenseAi

Mount SenseAi on the press frame

Attach close to the ram or drive mechanism where vibration is strongest. Ensure metal-to-metal contact for best sensitivity.

Power and connect

Connect USB-C power and pair to WiFi using the IoTFlows mobile app.

Run test strokes

Manually cycle the press 5-10 times and verify SenseAi is detecting each stroke in the Devices Tab (look for activity spikes).

See the full SenseAi Installation Guide for detailed instructions.

Step 2: Measure Your Stroke Rate

Run the press normally

Start production and let the machine run for 5 minutes

Count actual strokes

Use the press counter (if available) or manually count strokes for 1 minute. Record the number.

Example: 60 strokes in 1 minute = 60 SPM (strokes per minute)

Calculate cycle time

Cycle time = 60 seconds ÷ strokes per minute

Example: 60 seconds ÷ 60 SPM = 1.0 second per stroke

Note typical pauses

Observe any brief pauses between strokes (usually microseconds to 1-2 seconds max).

Step 3: Create Operation in Parts List

Navigate to Parts List

Go to Production Tab → Parts List

Click Add Part

Click + Add Part

Fill in operation details

Operation Name: e.g., "STAMP-BRACKET-100T"
Part/Material: e.g., "Steel Bracket"
Description: e.g., "100-ton stamping press producing brackets"

Select Discrete Analysis w/o Merge

From the Algorithm dropdown, choose Discrete Analysis w/o Merge

Enter cycle time

Input the cycle time you calculated (e.g., 00:00:01 for 1 second per stroke)

Set Quantity Per Cycle

Most common: 1 (one stroke = one part)
If multiple parts per stroke (e.g., progressive die), adjust accordingly

Save the operation

Click Save

Do NOT set a Downtime Filter in Parts List for this algorithm. Leave it at 0% or empty. You'll configure downtime filtering at the device level (next step).

Step 4: Configure SenseAi Device Downtime Filter

This is the critical step that makes everything work perfectly.

Navigate to Devices Tab

Go to Devices Tab

Select your SenseAi sensor

Click on the SenseAi device attached to the stamping press

Open device settings

Click Edit Sensor or similar settings button

Set Downtime Filter (device level)

Find the Downtime Filter setting for the device and set it to 10 minutes (or 5-15 minutes depending on your preference)

Understand what this does

Algorithm counts every stroke/spike
Any downtime under 10 minutes is converted to uptime
Only stops ≥10 minutes are recorded as downtime

Result: Perfect stroke counting with clean downtime data (no micro-stops cluttering your reports)

Save changes

Click Save or Update

Device-level downtime filter vs. Parts List downtime filter are different!

Device level (what you just configured): Filters out ALL short downtimes before any algorithm sees them
Parts List level: Works within the algorithm calculation (not used for Discrete w/o Merge)

For stamping presses, always use device-level filtering.

Step 5: Assign Operation to Machine

Go to Assets Tab

Navigate to Assets Tab → Overview

Click on the stamping press

Open the machine detail view

Click Auto-Detect

Find and click the Auto-Detect button

Select your operation

Choose the stamping operation you just created (e.g., "STAMP-BRACKET-100T")

Confirm selection

The machine will now count every stroke while filtering short downtimes

Step 6: Validate and Monitor

Run for 1-2 hours

Let the press run normally

Compare counts

Check IoTFlows count vs. press counter (if available):

Validation:

Press runs 60 strokes/min for 60 minutes
Expected: 3,600 strokes
IoTFlows should show 3,600 parts (±2-3%)

Review downtime events

Go to Assets Tab → Downtimes:

Should only see stops ≥10 minutes (material loading, die changes, lunch breaks)
Should NOT see brief pauses between strokes

Adjust device downtime filter if needed

Too many micro-stops showing: Increase to 15 minutes
Missing real downtimes: Decrease to 5 minutes

Common Issues & Solutions

Recommended Downtime Filter Settings

Press Type	Strokes/Min	Device Downtime Filter	Why
High-speed stamping	60-120 SPM	10-15 minutes	Eliminates brief pauses; captures only major stops
Medium-speed punching	30-60 SPM	5-10 minutes	Balances detail with noise reduction
Low-speed forming	10-30 SPM	3-5 minutes	More sensitivity needed for slower operations
Manual feed presses	Variable	2-5 minutes	Captures operator-related pauses

Start with 10 minutes and adjust based on your downtime report. If you see too many small events, increase it. If you're missing real stops, decrease it.

Best Practices for Stamping Presses

1. Progressive Dies vs. Single-Hit Dies

Progressive dies (multiple operations per stroke):

Each stroke completes one part through multiple stages
Set Quantity Per Cycle = 1 (one stroke = one completed part)
Focus on stroke count, not individual operations

Single-hit dies (one operation per stroke):

Each stroke = one operation
Set Quantity Per Cycle = 1

2. Die Changes and Setup

Train operators to classify downtime during die changes:

"Die Change" category for planned changeovers
"Setup/Adjustment" for fine-tuning after installation

Typical die change: 15-60 minutes (will be captured with 10-min filter)

3. Material Loading

If coil loading takes 5-10 minutes:

Ensure device downtime filter ≥5 minutes to capture these events
Create auto-classification rule for "Material Loading" based on duration patterns

4. Set Realistic OEE Goals

Stamping operations typically achieve:

Manual feed: 50-65% OEE
Auto feed (coil): 65-80% OEE
Lights-out automation: 80-90% OEE

Start 5-10% above your current baseline.

5. Monitor Stroke Rate Trends

Use Historical Production to track strokes over time:

Declining stroke rate → tooling wear, press degradation
Increasing downtime → material issues, quality problems

Real-World Example

Company: Precision Metal Stamping Co. Machine: 75-ton mechanical press Part: Steel automotive brackets Stroke rate: 45 strokes per minute

Configuration:

Algorithm (Parts List): Discrete Analysis w/o Merge
Cycle Time: 00:00:01.33 (60 ÷ 45 SPM)
Quantity Per Cycle: 1
Device Downtime Filter (SenseAi): 10 minutes

Results:

Before IoTFlows: Unknown press utilization, frequent short stops unnoticed
Week 1: 62% utilization, ~18 downtime events/day (all ≥10 minutes)
Month 1: Identified material loading as #1 downtime (35% of total)
Month 3: Improved material staging process, increased utilization to 74%
ROI: 12% production increase = $38K annual value

Next Steps

Monitor Strokes in Real-Time

View live press activity in Assets Tab

Track Production Goals

Monitor shift stroke targets

Analyze Downtime Patterns

Identify improvement opportunities

Have questions about press monitoring setup? Contact support@iotflows.com for personalized guidance!

Tutorial: Stamping & Punch Presses