TPT November 2012

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Technology News
November 2012 67
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Multifunctional
roll forming
technology
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
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.
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:
Multifunctional roll
forming from Dreistern