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Work Packages

Project Overview

WP1 Project Specifications

The objective of this preliminary WP is to identify the current needs and problems regarding tool and machine components wear, surface defects and set-up difficulties of the industrial roll forming processes. Although preliminary research has been done with ARestant to identify principal critical aspects of the process, during this WP a complete and detailed analysis will be done in order to early identify the critical cases of the project. For that, the experience of the research consortium will be used.

  • data M SMS and data M Scandinavia, as COPRA FEA RF suppliers will finally define the specifications of the new Torque and Wear module
  • data M SMS and Fagor Arrasate will define the technical specifications of the servo-control board and the associated control strategies to be used
  • ARestant will define the laboratory and industrial use-cases and the remote set-up assistant specifications.

WP2 FEA Torque and Wear calculator module for roll forming

The objective of the Work Package is to develop a new Torque and Wear estimation module to be introduced in the COPRA FEA RF software of data M.

For that three steps are envisaged. Firstly, advanced material and contact characterization tests will be performed. With the data obtained, advanced material and contact models suitable to represent the roll forming technology will be developed and compared with classical models to evaluate their precision and choose the most appropriate ones.

In a second step, a complex numerical model will be developed able to estimate tool torques and wear. For that, user subroutines will be used for the computation of the wear and rotation will be added to the rolls (unlike in the current model where the strip is fixed and rolls are moved lineally and without friction to avoid excessive computation time). Being the model validated, for different process conditions (i.e. roll gap influence correction, etc.) new methods to decrease the computational costs will be studied.

Finally, the optimized model will be programmed under COPRA FEA RF language, since the software links the AutoCAD CAD software, the COPRA RF roll optimization software and the final COPRA FEA RF finite element validation software.

Image: data M Sheet Metal Solutions

WP3 Servo-drive based control for roll forming

The objective of WP3 is to design, manufacture a new servo-control board to test new control strategies for roll forming that will:

  • Improve the tool wear
  • Balance the torques along the roll forming line and increase the machine life
  • Increase the energy efficiency
  • Increase the final geometrical accuracy
  • Improve the aspect defects due to friction (i.e. painting scratches, friction lines)
  • Communicate the process key variables and signals to process designers and workshop operators

Four steps will be followed: the design and assembly of the control board using the selected hardware including the wireless communication platform and data storing computer, the programming of the different control strategies to be tested during the experimental testing at laboratory level, the selection of the appropriate strategy or strategies to be applied in roll forming and the final optimization of the control-board and control strategy for its final industrial use.

WP4 Roll former's remote assistant for optimised machine set-up

The workpckage 4 is devoted to create the remote set-up assistant for roll forming.

First step will be to create a friendly and easy to use GUI. This will be the link the workshop operator will use to read and write information in the control board data storing computer. In parallel, the data storing software and structure will be developed and programmed. For these two tasks, specification of workpackage 1 will be used.

Secondly, the wireless communication module will be set. Robust communication between the COPRA FEA RF Torque and Wear module and the operator’s remote set-up assistant (PDA or similar) must be assured.

Finally the whole set-up remote assistant will be tested at laboratory scale, using the 6 forming stand roll forming line available at Mondragon. Communication of the whole systems will be tested to see the robustness of the holistic approach we would like to bring to the industry.

Debugging and optimization tasks will be performed for the final optimization of the system before its industrial testing.

WP5 Industrial validation and first prototyping - proof of products

Workpackage 5 is the industrial validation of the SERVROLL project. The objective is to apply the holistic optimization methodology in ARestant production, using critical profiles that suffer from wear and geometrical quality deviations and are critical from the point of view of set-up time.

Two use-cases are foreseen: a high thickness profile and a high height profile. The first will require high forming torques and the second will be critical from the point of view of tool wear and surface defects.

The optimized COPRA FEA RF Torque and wear module will be used to simulate the profiles forming and key parameters will be sent and stored in the control board database. This numerical data will be communicated via the PDA to the workshop operator for the first time set-up (a conventional set-up will be monitored and the operator will be guided with monitored signals).

With this set-up a representative set of coils will be processed to see study the process variability. The data will be stored in the control board database for future production of this reference and defect detection and overloading protection envelops will be tested for the profiles.

During the industrial production, all the partners will participate and benefits will be quantified to be used in the commercialization of the new products.

Image: Fagor Arrasate

WP6 Marketing of new products, exploitation and dissemination

The objectives of the Work Package 6:

  • To make stakeholders aware of the project and to disseminate the project results
  • To generate plans for the use and dissemination of the knowledge
  • To define a strategy for a proper IPR protection
  • To generate an initial exploitation plan to exploit the project results