Upload
others
View
10
Download
0
Embed Size (px)
Citation preview
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…
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
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
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…
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
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…
Process-/Machine Interaction
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
RFExpert (2009-2012
Coupled SimulationsFEA programs integrating multibody dynamics
Process-/ Machine Interaction
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
Coupled SimulationsFEA programs integrating multibody dynamics
F
M
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…
3D Rollforming - Where are the Difficulties?
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
3D (flexible) Profile Families
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
… variable
in width
… in depth/
height
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
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)
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
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
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:
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
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
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)
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…
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
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
The Industrial Application
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
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.
Industrial facility for truck long members (2015)
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
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
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…
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
1.3.2017 Rollforming the Future® © data M SMS, www.datam.de
Product - Benchmark Industry 4.0 for a 3D –
Rollforming line
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
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
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
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
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
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
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
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
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
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
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!
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
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/
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!