FOCUS ON ROLL FORMING
The newly developed Intelligent Dreistern straightening device , with app screen ( inset ).
The ‘ straightening journey ’ of the profile .
automatic quality detection is usually no longer possible , as the profiles are packaged directly . Dreistern is therefore now introducing a new system that makes it possible to detect profile straightness on the roll forming machine .
The patented system in the straightening device is based on the fundamental idea that although the profile straightness cannot be geometrically detected due to the clamping of the profile in the roll forming machine , the reaction forces required to hold the profile in its constrained position can . For this purpose , the presented straightening device has integrated various force sensors that detect the reaction forces that the profile exerts on the leveller . The sensors are integrated into the axes of the leveller so that they are protected against damage in everyday industrial use .
The measured forces can be taken ? once for a straight profile . If the straightness of the profile ( and therefore the required reaction forces ) change during the next process , the associated application can immediately trigger an alarm and alert operating personnel to the impending quality problem . In this way , the last gap in the closed quality control loop can be closed .
The system works independently of the existing system control and can therefore be integrated into existing roll forming processes .
A connection to the system control is possible in individual cases , so that production can also be interrupted automatically in the event of an alarm . The system is operated via an app that runs on a supplied tablet . Installation on other end devices , such as the system operator ’ s mobile phone , is also possible if required .
The next step
Initial applications of the new system in industrial processes have demonstrated the efficiency of the new concept .
The illustration ( top right ) shows that a change in profile straightness in the vertical direction ( green curve ) leads to a significant change in a load component ( blue columns ). This is impressive as the amount of bowing is still within the permissible product tolerance . The other load components ( red columns ), which correlate with horizontal curvature ( purple curve ), remain virtually unchanged .
This is not the end of the development process . In the next step , DREISTERN is working intensively on further developing the existing alarm function so that operating personnel are made aware of the impending error . This includes diagnosing the cause and guiding them through the solution process . n
About DREISTERN GmbH & Co . KG
Since its foundation in 1949 , DREISTERN GmbH & Co . KG has been setting new benchmarks in global roll forming for a wide range of roll formed products . Now in its third generation , and celebrating its 75th anniversary in 2024 , the family company specialises in roll forming technologies , machines and process execution .
“ Thanks to our intelligent technologies ( Roll Forming 4.0 or RF4.0 ), the forming process is controlled in such a way that the required geometry and dimensional accuracy of the product is achieved . Only the exact forces and torques that are required to achieve the best result are applied . In addition to product quality , this also increases energy efficiency ,” it told ISMR .
“ We use modern drive and control technology , as well as servo technology , to increase the energyefficiency of roll forming production . Functions such as residual strip processing , automatic good and bad part recognition , scrap-optimised cutting or waste-free part changing reduce the proportion of scrap to a minimum . Additional energy-saving functions include intelligent switchon / switch-off functions or reversing optimisation for our flying cut-off machines . Intelligent retrofitting solutions , such as adding a skinpass-station , also make a decisive contribution to increasing the degree of material utilisation ,” it added .
A DREISTERN drive shaft .
www . dreistern . com / en /
ISMR December 2024 / January 2025 | ismr . net | 59