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.