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High quality tooling for better products
But does the actual geometry really meet the original design of the rolls? Even a minor deviation from the original roll contour may result in minor quality tubes or profiles. The COPRA® RollScanner is a fully automatic measuring device for inspecting existing rolls quickly and accurately. It satisfies the rollforming industry’s big demand for a high-quality control system. The COPRA® RollScanner generates an accurate set of data of a roll’s true shape. Scanned rolls can be compared immediately to the originally designed contour. This means no more "fire-fightings" due to unexpected and unnecessary long try-outs – the first step in the optimization of your tooling. |
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The new generation of the COPRA® RollScanner
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Fully automatic scanning and easy to use The COPRA® RollScanner can be handled very easily without any experience with computers: simply put the rolls on the plug. After entering a roll number or another identifier, the roll is being scanned automatically without any additional programming required – contactless and without abrasion. A moving CCD camera follows the roll’s outline and automatically generates an absolutely accurate set of coordinates and geometric elements of the roll. The whole scanning process takes about one minute (depending on roll size). Your digitized actual contour now appears on the screen. The data can be saved in common format, e.g.
DXF, and can be processed and stored by nearly any CAD system. 1. Simply put the roll on the plug – either manually,
by fork lifter or crane
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Quality control at a glance: The COPRA® RollScanner not only allows the user to register existing rolls but also provides continuous quality control. After scanning the roll you will also get an immediate comparison of the measured contour and the originally designed reference contour if available in the COPRA® Database. The deviation is shown in a diagram as the typical "fingerprint" of the roll.
The typical ”fingerprint” of the scanned roll appears on the screen
The horizontal axis represents the unfolded outline of the roll, beginning at the bottom ("0") and ending at the right side of the diagram with the top of the roll ("1"). The vertical axis shows the difference between the measured points vertically to the surface of the original contour. In this way a clear statement about the roll’s quality can be made at a glance. All information about the deviation can be exported to MS Excel for further analysis and printout. The typical “fingerprint” of the scanned roll appears on the screen. The deviation is indicated by red crosses
Deviation between the actual and the measured contour:
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Get the original forming sequence of
stock rolls The production costs for tubes or profiles can be reduced by reusing stocked, discarded or otherwise useless rolls. However, such kind of roll tooling on stock often has unused potential for developing new tubes and profiles. After transferring the scanned data into the COPRA® Database, the original forming sequence (flower pattern) is available and can be used by the designer for new tubes or profiles. With these data the user can now simulate, optimize and draw new roll sets as well as generate NC files as if he had designed his own rolls. |
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Make a profit from used tool sets
Re-working stocked discarded or useless rolls pays back quickly by saving the costs for raw material and working processes such as boring and milling. 70% of the total production costs for a new roll result from costs for raw material and hardening, 30% from design and shaping. Experience shows that by reengineering a used roll total costs can be reduced to about 15% due to the fact that the new roll can usually be produced at a minimum of time required for chip removal. The most effective way of saving costs is to use a highly similar, overdimensional roll. Which roll fulfills these requirements is identified by an intelligent similarity search process of the COPRA® Database. |
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Technical Data | |||||||||||||||||||||||
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Technical data subject to change without notice
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data
M Engineering GmbH . Am
Marschallfeld 17 . D-83626 Valley/Oberlaindern, Germany Internet:
http://www.datam.de .
e-mail: datam@datam.de |
brochure
There are no doubt many advantages of using CAD/CAM software for the layout of tube mill rolls or roll form tooling.
The COPRA® RollScanner is designed for operation in rough industrial environment. The rolls can be handled either manually, by fork lifter or crane. 
A big advantage of using stocked rolls lies in the resulting reduction of costs for manufacturing new tool sets. Why not produce a roll from an already existing one that is no longer needed? 
