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Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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Page 1: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

Roll Forming „smart factory“Industry 4.0 with 3D Roll forming

data M Sheet Metal Solutions, 83626 Valley

Page 2: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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 3: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 4: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 5: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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…

Page 6: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 7: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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…

Page 8: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

Process-/Machine Interaction

1.3.2017 Rollforming the Future® © data M SMS, www.datam.de

RFExpert (2009-2012

Coupled SimulationsFEA programs integrating multibody dynamics

Page 9: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

Process-/ Machine Interaction

1.3.2017 Rollforming the Future® © data M SMS, www.datam.de

Coupled SimulationsFEA programs integrating multibody dynamics

F

M

Page 10: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

3D Rollforming - Where are the Difficulties?

1.3.2017 Rollforming the Future® © data M SMS, www.datam.de

Page 12: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

3D (flexible) Profile Families

1.3.2017 Rollforming the Future® © data M SMS, www.datam.de

… variable

in width

… in depth/

height

Page 13: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 14: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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)

Page 15: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 16: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 17: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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:

Page 18: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 19: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 20: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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)

Page 21: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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 22: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 23: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 24: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

The Industrial Application

1.3.2017 Rollforming the Future® © data M SMS, www.datam.de

Page 25: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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.

Page 26: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

Industrial facility for truck long members (2015)

1.3.2017 Rollforming the Future® © data M SMS, www.datam.de

Page 27: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 28: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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 29: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 30: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

1.3.2017 Rollforming the Future® © data M SMS, www.datam.de

Product - Benchmark Industry 4.0 for a 3D –

Rollforming line

Page 31: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 32: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 33: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 34: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 35: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 36: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 37: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 38: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 39: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 40: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 41: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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!

Page 42: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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

Page 43: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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/

Page 44: Roll Forming „smart factory - maschtech.com€¦ · Roll Forming „smart factory“ Industry 4.0 with 3D Roll forming data M Sheet Metal Solutions, 83626 Valley

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!