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Wednesday, December 02, 2020

High quality tooling for better products 

...The COPRA® RollScanner generates an accurate set of data of a roll’s true shape

COPRA® RollScanner generates an acccurate set of data of each roll's geometry. There are no doubt many advantages of using CAD/CAM software for the layout of tube mill rolls or roll form tooling.

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.

The new generation of the COPRA® RollScanner

...a new design concept of solid built and highest accuracy

The COPRA® RollScanner is designed for operation in rough industry environment. The rolls can be handled either manually, by fork lifter or crane.

Compared to the previous model the new COPRA® RollScanner has been developed with a totally new design concept in mind: the main body consists of a highly precise stone base offering a reference level that is accurate down to a few µm. The linear guide is mounted on the stone body. The new measuring lens displays a considerably higher magnification level than the former model. The vertical guide of the camera is mounted on a high precision normal, which guarantees that the vertical movement is absolutely perpendicular to the body.

Also new is the integrated illumination device that comes as part of the machine body. Reflections that usually occur in standard video inspection systems are now dramatically reduced. By separating the x- and the y-axis (camera up-down, roll back-forth) measurement errors are now reduced to a minimum and there is no more need for calibration. The RollScanner reaches measured values of 1/100 mm accuracy and an optical resolution of 4 µm. A horizontal moveable camera axis (3 axis models only) enables the COPRA® RollScanner to measure more complex roll shapes by adjusting the focus out of the center plane. Being a closed system the COPRA® RollScanner is protected against external influence of ambient light. It operates completely free of vibration and is - thanks to its solid granite block - resistant to thermal deformation.

Fully automatic scanning and easy to use

...contactless measuring with a CCD-camera

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
2. Scanning the roll between a CCD camera and a background illumination
3. The measured contour of the roll appears on the screen
4. The measured contour of the profile appears on the screen

Quality control at a glance:

the roll’s "fingerprint"

...deviation is shown in a diagram

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:

Get the original forming sequence of stock rolls

...simulating, optimizing and drawing of existing roll sets

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.

Make a profit from used tool sets

...reduction of the total costs by recycling

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?

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.

Fast Facts

  • Digitizing and archiving of existing rolls
  • Contactless measuring without abrasion
  • Scans rolls automatically (no extra programming required)
  • Quality control of the roll contour
  • Analysis and reworking of existing roll sets
  • Turntable and measuring software for Pilger Roll optionally available
  • Interface to roll database systems (cost reduction by usage of existing rolls)
  • Early detection of weak points
  • Optimization of your production
  • Continuous quality documentation
  • Available with 2 and 3 axis for automatic focus