1. The Four Basic Machine Applications
World Class Roll Forming 2010
Jaycen Rigger
Technical Support Manager
AMS Controls

2. New Equipment or Retro-fit
• The Best Application with the Best Control Solution for the Production Needs
 Throughput
 Accuracy
 Cost
• Design the Machine (Production Line) with the Finished Part, Mechanical
Possibilities, and Control Solution in Mind
 Project Management Involving the End-user, the Equipment Builder, and the
Controls Provider
 Clear Communications Between All Parties from the Beginning of the Project
Ensures the Best, Most Cost Effective Solution

3. Roll Forming Glossary
• die - tooling assembly that will perform the punching or cutting operation
 punch, blade, slug-die, shear, saw cut, gagged die set, etc.
• flying die - press operations occur while the material is in motion
• feed-to-stop - material stops for press operations
• closed loop - the application incorporates a servo system
• open loop - any roll forming application that doesn’t use a servo system

4. Roll Forming Glossary
• boost - pneumatic or hydraulic cylinder that pushes the die
• kicker - similar to a boost, a kind of mechanical boost
• die accelerator - combination of servo and actuation equipment on a closed
loop flying die system
• actuator - mechanical equipment needed to connect a closed loop servo
system to the die
 ball screw, belt and pulley system, or rack & pinion, linear motor, servo-
hydraulic, etc

5. Mechanical Length Control
Gauge Bar Length Control

6. Mechanical Length Control
Flag Switch Length Control

7. Mechanical Length Control
• Benefits
 Tying Part Length to Press Operation Results in Very Accurate and
Consistent Lengths
• Problems
 Slower Running Speeds
 Length Changes Require Downtime
 Scrap Production
 Punching

8. Mechanical Length Control
Flag Switch Length Control

9. Four Basic Application Types
• Electronic Length Control
 Open Loop Feed-to-Stop
 Open Loop Flying Die
 Closed Loop Feed-to-Stop
 Closed Loop Flying Die

10. Open Loop Feed-to-Stop
Open Loop Feed-to-Stop Post Cut Line

11. Open Loop Feed-to-Stop
• Key Features
 Low Cost
 Low Cycle Rates / Lower Average Line Speeds
 Moderate Accuracy (± 0.032” (0.8 mm) or better)
 Sensitive to Timing / Tracking Variations
 Press Variations Do Not Affect Length
 Easy to Set Up
 Maintenance Required for Consistent Operation

12. Open Loop Feed-to-Stop
Open Loop Feed-to-Stop Pre-Cut Line

13. Open Loop Feed-to-Stop

14. Open Loop Feed-to-Stop

15. Open Loop Feed-to-Stop

16. Open Loop Feed-to-Stop
• Uncompensated Systems
 Produces a Long Part on Startup
 Sensitive to Speed Changes
 Sensitive to Environmental Changes
 Sensitive to Material Changes
• Compensated Systems
 Part Lengths More Accurate from First to Last
 Compensates for Shifts in Machine Timing
 Lower Throughput When Compensating for Machine Timing Changes
 Parameters Must be Set Properly

17. Open Loop Flying Die
Open Loop Flying Die Post Cut Line

18. Open Loop Flying Die
• Key Features
 High Cycle Rates / High Line Speeds (up to 4 hits per second)
 Low Cost
 Moderate Accuracy
 Higher Accuracies Require Regular Maintenance
 Sensitive to Timing / Tracking Variations

19. Open Loop Flying Die
Open Loop Flying Die Post Cut Line

20. Open Loop Flying Die

21. Open Loop Flying Die

22. Closed Loop Feed-to-Stop
Closed Loop Feed-to-Stop Pre-cut Line

23. Closed Loop Feed-to-Stop
• Closed Loop Feed-to-Stop Key Features
 Very High Accuracy (± 0.003” (0.08 mm) or better)
 Higher Cost (Servo System and Associated Components)
 Gagged Dies Allow for Extremely Flexible Punching Operations
 Supports Continuous Press Operations

24. Closed Loop Feed-to-Stop
• Design Concerns
 Unpowered, Material Encoders can Greatly Reduce Length Error Due
to Slip
 Pre-punch Systems Should Include Gagged Tool Specifically Used for
Hole Detect
 Hole Detect Systems Require Careful Placement of Photo-Eye
 Coolant
 Material Control
 Hole Geometry
 Speed

25. Closed Loop Flying Die
Closed Loop Flying Die Post Cut Line

26. Closed Loop Flying Die
• Closed Loop Flying Die Key Points
 High Accuracy
 High Speed
 Not Sensitive to Timing Variations of Equipment
 High Cost
 Very Sensitive to Encoder Tracking Variations
 Requires Higher Expertise for Startup and Troubleshooting

27. Closed Loop Flying Die
Servo Motor and Ballscrew Actuator

28. Closed Loop Flying Die
Belt Driven Actuation System

29. Closed Loop Flying Die
Rack & Pinion Actuation System

30. Closed Loop Flying Die
• Design Concerns
 Die Weight, Friction, Press Type and Speed, Accuracy and Material
Speed Dictate Servo Sizing and Actuation Method
 Tight, Mechanical Couplings Produce the Best Results
 Servo Tuning is Science and Art – Expertise is Required for Best
Results

31. Summary
• Key Points
 Most Roll Forming Systems Fall Into 1 of 4 Major Categories or Some
Combination
 Throughput, Accuracy and Cost Are the Primary Decision Points
When Purchasing New Equipment
 Every Machine is a Set of Variables
 New Equipment or Retro-fit Requires Project Management Including
End-user, Equipment Provider, Controls Provider
 Communication Is Key!