Roll Forming smart factory

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Eustacia Caitlin Mitchell
5 years ago
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1 Roll Forming smart factory Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, Valley

2 Content EMF What is (3D) roll forming? Role of data M SMS in Roll Forming EMF/LF Flexible Roll Forming data M SMS has been pioneering in 3D Roll Forming Industrial Application of 3D Rollforming Chassis Long Member Industry 4.0 Predictive Maintenance and more

3 What is Roll Forming Video: Dalarana University Borlänge/ Sweden + data M Scandinavia About 40% of steel sheet is being roll formed in Europe

4 What is 3D Rollforming? data M has been working for Cars, Trucks and more

5 Content EMF Flexible Roll Forming What is (3D) roll forming? Role of data M SMS in Roll Forming EMF/LF data M SMS has been pioneering in 3D Roll Forming Industrial Application of 3D Rollforming Chassis Long Member Industry 4.0 Predictive Maintenance and more And how to go for advanced 3D Roll Forming Lines in the (nearest) Future

6 Integrated Role of data M Training, Support R&D Services, COPRA - The leading Tool Design and Simulation Software Quality Control: COPRA RollScanner + Integrated Roll Life Cycle Management Special Apps for Wire Roll Forming, Tubes, Pipes, Sheet Metal and more.. Material Tester for High-End Simulation Roll Forming COPRA Adaptive Motion Control 3D Roll Form Machines Quality Control: COPRA ProfileScan Desktop

7 Process-/ Machine Interaction The CAE tool COPRA FEA RF is able to represent integrated operations in the simulation of the roll forming process like cutting or sweeping of the profiles

8 Process-/Machine Interaction Coupled Simulations FEA programs integrating multibody dynamics RFExpert (

9 Process-/ Machine Interaction Coupled Simulations FEA programs integrating multibody dynamics F M

10 Content EMF What is (3D) roll forming? Role of data M SMS in Roll Forming EMF/LF Flexible Roll Forming data M SMS has been pioneering in 3D Roll Forming Industrial Application of 3D Rollforming Chassis Long Member Industry 4.0 Predictive Maintenance and more

11 3D Rollforming - Where are the Difficulties?

12 3D (flexible) Profile Families variable in width in depth/ height

13 1st R&D Machine 1999 data M pioneering in 3D Roll Forming 1999/2000: data M supplies the first computer control (COPRA Adaptive Motion Control) for 3D Roll Forming to research center PtU in Darmstadt/ Germany

14 data M pioneering in 3D Roll Forming Source: Corus Bausysteme, Internet 2006: COPRA Adaptive Motion Control Software from data M Sheet Metal Solutions (256! axes)

15 data M pioneering in 3D Roll Forming Source: Corus Bausysteme, Internet X-Tail Rollformer 2006: COPRA Adaptive Motion Control Software from data M Sheet Metal Solutions

16 High-End Feasibility Tools data M pioneering in 3D Roll Forming 2006: Truck beam and simulated result from a feasibility study performed for a customer by data M

17 European Research Project PROFORM 2007 data M pioneering in 3D Roll Forming : : European R&D Project PROFORM with 23 project partners (data M, Fiat, Daimler, Tier 1s and Universities; 5,5 Mio Budget)

18 European Research Project PROFORM data M pioneering in 3D Roll Forming 2010 data M provides: * Definition/ Simulation of Forming Steps * Bipod Forming Stands * Computer Control COPRA Adaptive Motion Control

19 New Generation Machine for Automotive 2010 data M pioneering in 3D Roll Forming High end prototyping machine by data M

20 New Generation Machine for Automotive 2010 data M pioneering in 3D Roll Forming POSCO RollForm test facility supplied by data M (source: POSCO) 2 mm DP 780

21 Content EMF What is (3D) roll forming? Role of data M SMS in Roll Forming EMF/LF Flexible Roll Forming data M SMS has been pioneering in 3D Roll Forming Industrial Application of 3D Rollforming Chassis Long Member Industry 4.0 Predictive Maintenance and more

22 3D Profiles (double sided) -Description of Target: Target: Industrial Realisation of a 3D RF System to produce Truck Beams Length: 9-15 m Material thickness: 5-8 mm Material Properties: to 900 MPa Est. 100 holes per meter Double sided asymmetric 3D forming Close tolerances for later assembly 8 geometries Output: 100 tons per day (300 days/year) Target: development of a machine concept

23 Optimisation and Design Process / Profile Forces for dimensioning of mechanics Profile Quality (Process Optimization) Reproducability (Stability of Process) Rotational Speed of single roll tooling Optimisation of sheet trimming

24 The Industrial Application

25 Industrial facility for truck long members (2015) Various Profile-Dimensions and Shapes - With one Tool Set! High number of profile variations Special concept for interface of the computer control Programming of the machine for a new part is completely done by software.

26 Industrial facility for truck long members (2015)

data M SMS is your partner for 3D Roll Forming machine concept and design has an important influence on the geometry/quality of 3D roll formed profiles For the process design and the machine design

27 data M SMS is your partner for 3D Roll Forming machine concept and design has an important influence on the geometry/quality of 3D roll formed profiles For the process design and the machine design new simulation strategies need to be applied - combining FEA simulations, multi-body dynamic simulations, CAD programs and kinematic simulations for workspace and collision investigations data M offers all 3 core competences required: high end simulation techniques (COPRA FEA RF/ MSC.MARC inside) proven hardware components (flexible forming stands) newly developed computer control for 3D roll forming data M offers 3D roll forming machines for trucks and cars

28 Content EMF What is (3D) roll forming? Role of data M SMS in Roll Forming EMF/LF Flexible Roll Forming data M SMS has been pioneering in 3D Roll Forming Industrial Application of 3D Rollforming Chassis Long Member Industry 4.0 Predictive Maintenance and more

29 Change in Production Challenges Efficency Energyand resource efficiency Time-to-Market Complexity Short innovation cycles Flexibility Variants small lot sizes Productivity Quelle: izm.fraunhofer.de Quelle: welser.com

30 Product - Benchmark Industry 4.0 for a 3D Rollforming line

31 Industry 4.0: data processing in production Encoder Wheel: Position and velocity of the sheet for synchronization of the stands Measurement: Current, Voltage, Power Hydraulikaggregat: pressure, temperature, fluid level Pneumatic: Pressure Pusher/Puller: Position and velocity of the sheet for synchronization of the stands LP-Monopods: Position -> Control of the pre-cut blank

PacDrive 3 Motion Controller LMC Pro 2 up to 130 synchronised servo axis High performant Motion Controler reduced space requirement in cabinet due to central

32 PacDrive 3 Motion Controller LMC Pro 2 up to 130 synchronised servo axis High performant Motion Controler reduced space requirement in cabinet due to central multi axis servo amplifier - joint power supply - double drives Maximum modularity due to decentralized integrated servo drives - in Star Layout or Daisy Chain

33 High End Control with Unlimited Number of Axes In the truck long member facility the roll former alone contains more than 90 servo axes Optimized operation concept using an appropriate HMI Indiviual axis drives for forming rolls

34 Cyber physical System Source: open automation.de, Industrie 4.0- eine Einführung, ( )

Data Processing in Production Measurement infrastructure on a rollforming stand level Hydraulics: Monitoring of the extreme positions Drive of the rolls: Velocity and

35 Data Processing in Production Measurement infrastructure on a rollforming stand level Hydraulics: Monitoring of the extreme positions Drive of the rolls: Velocity and torque for optimization of the forming Bipod/Monopod: Position, Velocity, Torque for monitoring the axes Bipod/Monopod: Additional monitoring of the position with a wire rope

36 Data Processing in Production Measurement and Data Concept Data collection field level Simulation und Assessment Visualisation of live-data Cloud Data base Knowlege Generation/ Data mining Machine Learning / Model Generation

37 Industry 4.0 using OPC-UA: Controller to the Cloud Synchronous monitoring and/or Asynchronous analysis ERP MES SCADA/HMI Database Database External Cloud Internal Cloud Factory Floor PLCs Profibus DP CAN Ethernet/IP Profinet

38 Company-wide networking Consistent software solutions Design and Virtual Production Real Production COPRA RF COPRA FEA RF Schneider Electric Wonderware MES COPRA AMC COPRA CRS/CPS Virtual Development of Products Simulation of Production Processes Overview/ Monitoring of Production Processes Control and Validation of Production Steps

39 Company-wide networking Production to SAP Seemless Integration between Shop Floor, MES and ERP on the basis of OPC-UA Execution of manufacturing with a MES System connected by OPC-UA Communication between product and line by OPC-UA Source: OPC Foundation

devices such as smartphones or tablets Direct access to

40 Human Machine Interface (HMI) Use your own device Source: OPC Foundation Application of modern mobile devices such as smartphones or tablets Direct access to the data of the OPC-UA-servers e.g. for diagnostics or maintenance

41 Efficency for Small Lot Sizes Small lot sizes Flexible production line More than 50 different long member geometries with a single setup!

42 Research at data M - ServRoll New servo control, process design and setup strategies for holistic optimization of roll forming SERVROLL aims to create a new process-development and control approach based on three concepts: Improved FE models for prediction of torque and roll wear Servo-drive based control strategies for roll forming lines Development of a roll forming set-up assistant based on simulation results and historic production data This approach is based on driving each roll individually using servo-motors Enables direct measurement of roll torque from each individual roll Possibility to feed real-time data to the machine operator for set-up of the machine and monitoring of the process

43 Research at data M - TroPhy2 TRoPHy2 Thermoplastische, Rollgeformte Profile in Hybridbauweise 2 Quelle: DLR Project duration

44 Many thanks for your attention! data M Sheet Metal Solutions GmbH I Am Marschallfeld 17 I D Valley Germany I Tel.: +49(0)8024/640-0 I Fax: +49(0)8024/ datam@datam.de I I

New concepts for conventional and 3D roll forming: control, forming processes, applications

New concepts for conventional and 3D roll forming: control, forming processes, applications Overview Introduction to 3D roll forming Industrial facility for truck long members Control concept for roll