Project start RofoInRichtungKI

In September 2023, the research project RofoinRichtungKI (roll forming with intelligent profile straightening by developing process-specific AI models) started at PtU. The project is funded by the German Federal Ministry of Economics and Climate Protection (BMWK) as part of the Central Innovation Program for Medium-Sized Businesses (ZIM). The aim is, in cooperation with Dreistern GmbH & Co. KG, the development, manufacturing and validated industrial use of an intelligent straightener for roll forming processes.

During roll forming, process-related longitudinal residual stresses occur which, depending on the profile geometry and load behavior of the tool rolls, lead to undesirable curvatures in the horizontal and vertical directions as well as torsions. In order to ensure that the accuracy of the finished profiles is maintained, the roll forming process is followed by a downstream straightening process. Nowadays, the straightening parameters are set on the basis of the experience of the line operators by checking the final component geometry.

The unstable personnel situation due to the shortage of skilled workers and demographic change in Germany poses a challenge for the setting and adjustment of analog, experience-based processes such as the straightening of roll-formed profiles. This conflict is further intensified by tighter defect tolerances and an increasing complexity of the manufactured profiles as a result of increasing quality demands of the customers. For this reason, this research project will investigate the use of AI methods based on process data for assisted decision-making by specialists for the straightening of roll-formed profiles.

The goal of the project is to use the intelligent straightener to detect profile errors on the basis of process data and to link them to the correct positioning of the straightening rolls in order to be able to support production specialists during the adjustment process.