roll forming „smart factory - maschtech.com€¦ · roll forming „smart factory“ industry 4.0...
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Roll Forming „smart factory“Industry 4.0 with 3D Roll forming
data M Sheet Metal Solutions, 83626 Valley
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Content
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
EMF
EMF/LF
Flexible
Roll
Forming
EMF
EMF/LF
Flexible
Roll
Forming• What is (3D) roll forming?
• Role of data M SMS in 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…
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What is Roll Forming
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
About 40%
of steel sheet is being
roll formed in Europe
Video: Dalarana University Borlänge/ Sweden + data M Scandinavia
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What is 3D Rollforming?data M has been working for Cars, Trucks and more…
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
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Content
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
EMF
EMF/LF
Flexible
Roll
Forming
EMF
EMF/LF
Flexible
Roll
Forming• What is (3D) roll forming?
• Role of data M SMS in 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…
• And how to go for advanced 3D Roll Forming Lines in the(nearest) Future…
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Integrated Role of data M
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
Training, Support
R&D Services,
Roll FormingSpecial Apps for Wire
Roll Forming, Tubes,
Pipes, Sheet Metal and
more…..
Quality Control:
COPRA ProfileScan
Desktop
COPRA® - The leading Tool Design and Simulation SoftwareQuality Control:
COPRA RollScanner
+
Integrated Roll Life
Cycle Management
COPRA® Adaptive
Motion Control
3D Roll Form
MachinesMaterial Tester for
High-End Simulation
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Process-/ Machine Interaction
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
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…
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Process-/Machine Interaction
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
RFExpert (2009-2012
Coupled SimulationsFEA programs integrating multibody dynamics
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Process-/ Machine Interaction
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
Coupled SimulationsFEA programs integrating multibody dynamics
F
M
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Content
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
EMF
EMF/LF
Flexible
Roll
Forming
EMF
EMF/LF
Flexible
Roll
Forming• What is (3D) roll forming?
• Role of data M SMS in 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…
![Page 11: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley](https://reader035.vdocuments.mx/reader035/viewer/2022062318/5fd2804f66bce546df41fe97/html5/thumbnails/11.jpg)
3D Rollforming - Where are the Difficulties?
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
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3D (flexible) Profile Families
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
… variable
in width
… in depth/
height
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1st R&D Machine 1999data M pioneering in 3D Roll Forming
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
1999/2000:data M supplies the first computer control(COPRA Adaptive Motion Control) for3D Roll Forming to research center PtU in Darmstadt/ Germany
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data M pioneering in 3D Roll Forming
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
Source: Corus Bausysteme, Internet
2006: COPRA Adaptive Motion Control Softwarefrom data M Sheet Metal Solutions (256! axes)
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data M pioneering in 3D Roll Forming
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
Source: Corus Bausysteme, InternetX-Tail Rollformer
2006: COPRA Adaptive Motion Control Softwarefrom data M Sheet Metal Solutions
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High-End Feasibility Toolsdata M pioneering in 3D Roll Forming
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
2006: Truck beam and simulated result from a feasibility study performedfor a customer by data M
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European Research Project PROFORM 2007data M pioneering in 3D Roll Forming
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
2007-2010: European R&D Project PROFORM with23 project partners (data M, Fiat, Daimler, Tier 1s and Universities; 5,5 Mio€ Budget)
2007-2010:
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European Research Project PROFORMdata M pioneering in 3D Roll Forming
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
2010
data M provides:
* Definition/ Simulation of Forming Steps
* Bipod Forming Stands
* Computer Control
COPRA Adaptive Motion Control
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New Generation Machine for Automotive 2010data M pioneering in 3D Roll Forming
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
High end prototyping machine by data M
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New Generation Machine for Automotive 2010data M pioneering in 3D Roll Forming
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
2 mm DP 780
POSCO RollForm test facility supplied by data M(source: POSCO)
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Content
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
EMF
EMF/LF
Flexible
Roll
Forming
EMF
EMF/LF
Flexible
Roll
Forming• What is (3D) roll forming?
• Role of data M SMS in 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…
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3D Profiles (double sided) -Description of Target:
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
• 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
Target: Industrial Realisationof a 3D RF System to produceTruck Beams
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Optimisation and Design
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
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
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The Industrial Application
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
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Industrial facility for truck long members (2015)
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
• 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.
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Industrial facility for truck long members (2015)
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
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data M SMS is your partner for 3D Roll Forming
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
•
• 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
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Content
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
EMF
EMF/LF
Flexible
Roll
Forming
EMF
EMF/LF
Flexible
Roll
Forming• What is (3D) roll forming?
• Role of data M SMS in 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…
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Change in Production
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
Efficency
• Energy-and resource efficiency
Time-to-Market
•Complexity
•Short innovation cycles
Flexibility
• Variants– small lot sizes
• Productivity
Challenges
Quelle: welser.com
Quelle: izm.fraunhofer.de
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1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
Product - Benchmark Industry 4.0 for a 3D –
Rollforming line
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Industry 4.0: data processing in production
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
Hydraulikaggregat:pressure, temperature, fluid levelPneumatic:Pressure
Encoder Wheel: Position and velocity of the sheet for synchronization of the stands
Measurement: Current, Voltage, Power
Pusher/Puller:Position and velocity of the sheet for synchronization of the stands
LP-Monopods:Position -> Control of the pre-cut blank
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PacDrive 3 Motion Controller LMC Pro 2 – up to130 synchronised servo axis
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
High performant Motion Controler
reduced space requirement in cabinet due to central multi axis servo amplifier
- joint power supply- double drives
Maximum modularity due todecentralized integrated servo drives- in Star Layout or Daisy Chain
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High End Control with „Unlimited“ Number of Axes
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
In the truck long member facility the roll former alone contains morethan 90 servo axes Optimized operation concept using an appropriate HMI Indiviual axis drives for forming rolls
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Cyber physical System
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
Source: open automation.de, Industrie 4.0- eine Einführung, (16.05.2014)
http://www.openautomation.de/detailseite/industrie-40-eine-einfuehrung.html
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Data Processing in ProductionMeasurement infrastructure on a rollforming stand level
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
Bipod/Monopod:Position, Velocity, Torque for monitoring the axes
Bipod/Monopod:Additional monitoring of the position with a wire rope
Drive of the rolls:Velocity and torque for optimization of the forming
Hydraulics:Monitoring of the extreme positions
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Data Processing in ProductionMeasurement and Data Concept
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
Data collection – field level
Cloud
Visualisation of live-data
Data base Knowlege Generation/ Data mining
Machine Learning / Model Generation
Simulation und Assessment
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Industry 4.0 using OPC-UA: Controller to the Cloud
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
ERP
MES
SCADA/HMI
PLCs
Factory FloorProfibus DP • CAN • Ethernet/IP • Profinet
ExternalCloud
Database Database
Internal ‚Cloud‘
Synchronous monitoringand/or
Asynchronous analysis
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Company-wide networkingConsistent software solutions
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
Design and Virtual Production
COPRA® RFCOPRA® FEA RF
Real Production
Schneider ElectricWonderware MES
COPRA® AMCCOPRA® CRS/CPS
Control and Validation ofProduction Steps
Overview/ Monitoring of Production Processes
Simulation ofProduction Processes
Virtual Developmentof Products
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Company-wide networkingProduction to SAP
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
• 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 byOPC-UA
Source: OPC Foundation
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Human Machine Interface (HMI)Use your own device
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
Source: OPC Foundation
• Application of modern mobile devices such as smartphonesor tablets
• Direct access to the data of the OPC-UA-servers e.g. fordiagnostics or maintenance
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Efficency for Small Lot Sizes
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
Flexible production lineSmall lot sizes
More than 50 different long membergeometries with a single setup!
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Research at data M - ServRollNew servo control, process design and setup strategies for holistic optimization of roll forming
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
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
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Research at data M - TroPhy2
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
TRoPHy2 – Thermoplastische, Rollgeformte Profile in Hybridbauweise 2
Project duration 2016 – 2019
Quelle: DLR
http://open-hybrid-labfactory.de/
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data M Sheet Metal Solutions GmbH I Am Marschallfeld 17 I D-83626
Valley Germany I Tel.: +49(0)8024/640-0 I Fax: +49(0)8024/640-300
e-mail: [email protected] I www.datam.de I www.roll-design.com
Many thanks for your attention!