Roll Forming Path Correction Using Reaction Force Feedback
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Solution Overview
Problem
Conventional roll profiling methods are inefficient and costly due to the need for extensive break-in periods, high measuring efforts, and inability to promptly adapt to workpiece properties, often resulting in suboptimal forming results.
Innovation Solution
A method and device that utilize sensors to determine reaction forces during the first forming process, allowing for real-time path corrections and adjustments, enabling faster and more accurate forming with minimal material waste by using a control unit to suggest and implement corrected forming paths, even with unknown workpiece properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional roll profiling methods are used with manual readjustment based on experience, then forming results can be achieved, but setup time and material consumption are considerable
Solution Approach 1:
The system measures process forces during roll forming and uses this feedback to automatically adjust machine parameters. Force sensors monitor the actual forming process in real-time, and the control unit compares measured forces with reference values to automatically readjust roll settings, eliminating manual trial-and-error adjustment and significantly reducing setup time while maintaining forming quality
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated control system that uses force measurement and computer-controlled parameter adjustment. The control unit automatically modifies machine parameters based on force sensor data, substituting the experience-based manual adjustment process with an automated feedback-controlled system that reduces both time and material consumption
2Loss of time
If measurement of process forces is implemented to enable automatic adjustment, then setup time is reduced, but measurement effort becomes disproportionately high
Solution Approach 1:
The system uses the existing force sensors already present in modern rolling mills for their primary purpose of monitoring process forces, and simultaneously leverages this measurement capability for automatic parameter adjustment. The force measurement infrastructure serves dual purposes: process monitoring and adaptive control, eliminating the need for separate complex measurement systems and reducing overall device complexity
Solution Approach 2:
The force measurement system performs multiple functions: it monitors process forces for quality control, provides data for automatic parameter adjustment, and enables adaptive control without requiring additional dedicated measurement equipment. This multi-functional use of existing sensors reduces measurement effort and device complexity while achieving rapid adjustment
3Loss of time
If simulation-based process development is used, then learning phase is accelerated, but only limited acceleration is achieved compared to conventional methods
Solution Approach 1:
The system continuously measures actual process forces during roll forming and uses this real-time feedback to automatically adjust machine parameters. This closed-loop control enables the system to adapt to actual workpiece properties during production, achieving both accelerated implementation and high forming accuracy that simulation alone cannot provide
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables high-quality, cost-efficient forming with reduced break-in times and improved accuracy, allowing for efficient processing of workpieces with variable properties, particularly in single-piece production.
Implementation Method 1
A sensor in the forming device measures the reaction forces of the workpiece resulting from the first forming process step and records them as sensor data
Data Source
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AI summary
The present invention relates to a roll forming process in which a workpiece (1) to be processed is formed, at least in certain areas, by roll forming along a forming path (2) by a processing head (3) of a forming device in a first forming process step. At least one sensor (4) of the forming device determines reaction forces of the workpiece (1) that occur as a result of the forming process step as sensor data, and a control unit (5) of the forming device uses this sensor data to determine a path correction suggestion for a corrected forming path. Based on the determined path correction suggestion, the workpiece (1) is reformed along the corrected forming path in a further forming process step.