No abstract

No abstract

Abstract. Roll formed profiles are used in automotive chassis production as building blocks for the body-in-white. The ability to produce profiles with discontinuous cross sections, both in width and in depth, allows weight savings in the final automotive chassis through the use of load optimized cross sections. This has been the target of the 3D Roll Forming process.A machine concept is presented where a new forming concept for roll formed parts in combination with advanced robotics allowing freely positioned roll forming tooling in 3D space enables the production of complex shapes by roll forming. This is a step forward into the digitalization of roll forming manufacturing by making the process flexible and capable of rapid prototyping and production of small series of parts. Moreover, data collection in a large scale through the control system and integrated sensors lead to an increased understanding of the process and provide the basis to develop self-optimizing roll forming machines, increasing the productivity, quality and predictability of the roll-forming process. The first parts successfully manufactured with this new forming concept are presented.

Digitalization in the metal forming industry needs to be improved to achieve the goals set by Industrie 4.0. Distributed-Ledger-Technology (DLT) has been identified as a promising foundation for tackling the underlying problem of consistent information exchange. DLT-based solutions have already been developed, but none explicitly covers the roll forming use-case. This paper presents a Hyperledger-Fabric-based blockchain network to fill this research gap. This network is specifically designed for the roll forming industry, while still aiming to meet general information exchange requirements. The roll forming use-case is divided into the material supply chain and a design/simulation workflow. Participants and parameters in these two data transfer chains have been validated with the help of industry experts. Running the conceptualized network on an on-premise server has allowed for a detailed evaluation. Feedback provided by experts of the roll forming industry shows the potential of the presented network. Furthermore, the presented solution covers requirements often neglected by existing approaches like large data handling, compatibility to existing interfaces, secure communication, and access rights definition. In summary, this paper provides a pioneering implementation and evaluation of a DLT-based solution for the roll forming industry and, therefore, a foundation for the next steps towards Industrie 4.0.