3D Roll Forming Center for Automotive Application

>  Introduction to 3D roll  forming
? Industrial facility for truck long members
? Control concept for roll forming lines
? New process and machine concept for general 3D roll forming
? Concept for an industrial line for height-variable profiles

1999/2000:
data M develops the first
control for 3D rollforming
(COPRA? Adaptive Motion Control)
for the research facility at PtU, Darmstadt

POSCO Steel RollForm research line developed and produced by data M

? Introduction to 3D roll forming
> Industrial  facility for truck long members
? Control concept for roll forming lines
? New process and machine concept for general 3D roll forming
? Concept for an industrial line for height-variable profiles

More than 50 different long member geometries with a single setup!

? Introduction to 3D roll forming
? Industrial facility for truck long members
> Control  concept for roll  forming lines
? New process and machine concept for general 3D roll forming
? Concept for an industrial line for height-variable profiles

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

? Control technology
? Individual or group drives with servo motors
? Sensor technology
? Optical inline measurements
? Improved simulation models using comparison with real data
? Monitoring methods for quality control or maintenance
? Enhancing energy efficiency and quality through self-optimization

? Introduction to 3D roll forming
? Industrial facility for truck long members
? Control concept for roll forming lines
> New  process and machine concept for general
3D roll  forming
? Concept for an industrial line for height-variable
profiles

? Development of a production process for complex (automotive) parts using roll forming
? Proof of concept
? Roll forming of high-strength steel
? Great flexibility combined with low tooling costs
? Rapid Prototyping
? Tool for research departments
? Integration of new features into the roll forming process

? At first the pre-cut sheet is clamped between the upper and lower holding die of the core
? The roll forming tools follow 3D trajectories and the flanges are bent step by step around the upper die of the core until the final profile is achieved

? Small series
? Materials research: new materials, UHS, hybrids,….
? Rapid Prototyping for OEMs / automotive suppliers: conventional and 3D geometries
? Process development and optimization
? Development and verification of concepts for industrial lines for mass production
? Roll forming research: Big data for roll forming – industry 4.0
? Further improvement of innovative measuring and sensor technology for roll forming

? Introduction to 3D roll forming
? Industrial facility for truck long members
? Control concept for roll forming lines
? New process and machine concept for general 3D roll forming > Concept  for an  industrial line for height- - variable 

? Roll forming of complex 3D automotive parts
? Control and sensor technology for conventional facilities
? New machine concept for research and development and small series production
? Feasibility studies, prototypes
? Development of industrial production lines for 3D roll forming It‘s now up to you how you want to form the future.