Frugal Innovation for Sustainable Manufacturing: Retrofitting Legacy Stamping Presses with COTS Sensors
 
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Department of Production Engineering and Management, Wrocław University of Science and Technology, Poland
 
 
Submission date: 2026-01-26
 
 
Final revision date: 2026-04-01
 
 
Acceptance date: 2026-04-21
 
 
Online publication date: 2026-05-12
 
 
Corresponding author
Dawid Bogdanowicz   

Department of Production Engineering and Management, Wrocław University of Science and Technology, Poland
 
 
 
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ABSTRACT
Small and Medium-sized Enterprises operating legacy stamping presses often lack affordable diagnostics, risking undetected tool damage. This study proposes a frugal vibroacoustic retrofitting methodology using a low-cost piezoelectric sensor and edge processing. Experiments compared normal blanking (0.5 mm brass) with simulated double-hits (0.1 mm spacer). Analyses revealed that abnormal events generate distinct, highly impulsive transients with shorter post-impact signal persistence and elevated broadband energy including mid- and high-frequency components. Unsupervised clustering confirmed reliable detection using simple features despite partial signal overlap. The approach enables cost-effective tool protection and sustainable asset life-extension, supporting Zero-Defect Manufacturing in resource-constrained environments.
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ISSN:1895-7595
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