TPT November 2012

Technology News

Multifunctional roll forming technology

Multifunctional roll forming from Dreistern

beams require pre- and post-punching operations, which can easily double the investment cost. The same is true for the foot print of the machine, which can double as well. The next product run on this line will most likely require different, possibly with fewer punching operations. Again the machine would be too big and too expensive to operate. This was the starting point for Dreistern to develop a new machine concept, offering product mix flexibility never imagined before. A radical break from existing concepts, based on single purpose line components such as roll forming machine, punching press or cutting machine, only capable to fulfil their assigned function, made this possible. Dreistern’s concept of a multifunctional roll forming machine takes an entirely different approach. The key requirement – operations such as roll forming, punching or welding are to be executed at any position on the machine, only by exchanging components – and this within a time period usually required for a simple tool change. The enormous advantage of such a solution is obvious.

PRODUCT mix flexibility is the ability to produce different products on the same production line and is one of the critical decision factors when investing in new equipment. Shorter innovation cycles and growing product diversity make this issue ever more urgent. In recent years many remarkable developments have advanced the flexibility of roll forming lines. However, this presents an increasing risk to the profile producers. This flexibility does not come for free – it results in much higher equipment costs. The trend towards larger roll forming machines with more and more forming stations can be seen as an example of that. Recently Dreistern supplied a machine with more than 60 forming stations. What if there are not enough complex section orders to fully utilise the machine’s potential? Run simple sections too? Simple sections require fewer forming stations, the 60 pass machine would be far too big and too expensive to run for such jobs. The situation is similar when punching and embossing operations are integrated into the roll forming process. Take an example from the automotive industry. Roll formed longitudinal reinforcement

A multifunctional machine can be configured precisely and rapidly to produce the next part. Compared to conventional technology the foot print of such a machine can be reduced by 30 per cent to 50 per cent. No redundant line components whatsoever will increase the machine’s hourly rate. Exactly this was the objective of the Dreistern development: more flexibility with lower cost and less floor space. The guiding model for this Dreistern development was the quick-change roll- tool cassette, which Dreistern has been supplying for a long time. With the aid of standardised interfaces tools can be exchanged easily and quickly. In the future complete line components, like flying punching units or welding devices, will be exchanged in an equivalent manner. Consequently a 60 station machine could manufacture a highly complex section today, tomorrow it could run a simpler 18-pass section, but also include comprehensive pre- and post-operations. Dreistern GmbH & Co KG – Germany Website: www.dreistern.com

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N ovember 2012