COPRA Roll Design and Roll Technology

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COPRA® Roll Design Husk (H1)

COPRA® Roller Technology Husk (H4)

COPRA® CNC Technologie Husk (H5)

COPRA® Roll Design Husk (H1)
An accurate and sound design of roll tooling is - as well as the design of the flower pattern - decisive for the quality and manufacturing costs of a roll formed section. COPRA® is offering in its roll editor a variety of features for an effective roll tool design.
Following some examples of features implemented:
automatic or interactive definition of machine axes
automatic definition of tool contour layout (not just for open shapes but for even complex contours as well as side rolls etc.)
both - interactive or automatic
large number of editing functions
COPRA offers you several methods to generate roll tools for a specific profile shape.
as COPRA is completely integrated in AutoCAD the user can choose from both - COPRA internal or AutoCAD editing commands (best of both worlds...)
For designer who used to work with DOS programs:
COPRA does also have a list editor
Lines are not just drawn as a contour in the CAD system (as usual in CAD systems) but each roll is stored in the COPRA data base - as a separate object
automatic single roll dimensioning
automatic assembly plan dimensioning
design of combination tool sets (in module roller technology)
fully automatic roll design and detailing for hat, U-type or C-Channels
you will hardly find a similar number of roll form specific feature in any other software
COPRA has got a (optional) data base management system which allows for a company wide management of roll tool and profile data - including QM data. data M Software has got a long experience in roll data management - staring from PCs up to midrange server technology. We have got the solution for your needs. Just contact us.

Automatic dimensioning of roll drawings
both - single roll drawings as well as assembly plans
dimensioning strategies can be set by the user

fully automatic dimensioned roll drawing

The parameters required can be defined easily in specific dialogue boxes: Sideroll Parameters
Side roll Parameters

COPRA® Roller Technology Husk (H4)
Once the roll design is finished, the data often has to be processed rapidly so as to avoid time losses. The COPRA -process chain also covers this field.

automatic calculation of roller blank sizes taking into account the additions for diameter and widths

automatic calculation of finished roll weight, taking into account the bore hole details

cutting list and roller weight list can be exported in text format or WINDOWS Excel table format

NC data generation for the final roll contour in ISO format, DXF or full CNC code (module H5 only).

data exchange between different projects for an easy handling of combination tool-sets

Creation of a sawing/ cutting list
The 'COPRA '-module "sawing list" will supply the dimensions of the blanks to be cut within seconds. It takes into account user defined addition for diameter and width of the blanks. Also a diameter list may be used. This will be an automatic run. The sawing list created may directly have a printer output so as to avoid a time-consuming search for the dimensions necessary for production and construction, at this point again, the operator may concentrate on more important tasks. The sawing list contains as well the weight of the stock material.
Optionally the data set can be imported into a spread sheet calculation program like Microsoft Excel. Cutting list generation in COPRA

Saving costs with COPRA Calculation of the final roll weight
The production of a roll set is no low-cost activity. Often it is very difficult for the designer to calculate a realistic price for the rolls as the roll weight cannot be calculated but only estimated. The problem with estimates is always their inaccuracy. COPRA will automatically calculate the final weight of all rolls. Boring, keyway and chamfer of the roll bore will equally be deducted.
On the base of the calculated weight of the final roll set and the total weight of the blanks the volume of the material to be removed may be calculated. This information allows for an exact weight-cost calculation.
The result is also stored to disk and can be exported to spread sheet programs as well.

Generation of NC data files
The NC file format can easily be adapted depending on the specific machine used. The zero point and the working direction can be easily defined as well as the step numbering, the accuracy, the program end and the usage of the G02 and G03 parameters.
NC-data processing in COPRA

no contour tracing necessary any more; all roll tools are already stored in COPRA's data base
all NC data can be processed at one single command - saves a lot of time
all NC data at highest accuracy
NC format can be set in order to adapt it to various machines
optinonally (not in this module): CNC technology providing the full CNC code ready to be processed to the turning mill

Combination tool sets (data exchange between different projects)
The increasing variety of forms of roll-shaped profiles with at the same time decreasing lot sizes will force the manufacturer to take far-reaching measures to streamline production. As the production of roll tools is on the one hand expensive and on the other hand cannot often be integrated into unit prices the application of combination tool sets is the obvious solution.
Manufacturing costs will be allocated to several orders and, thus, the utilization ratio will increase considerably. This might begin with the utilization of a tool set for the production of similar profile forms with different dimensions and in extreme cases lead to exclusive use of standardized shapes.
Each of those applications has its special requirements which COPRA - in relation to the problem -takes into account. COPRA provides the following functions:
Automatic adaptation of an existing profile flower to various dimensions. Profiles similar in form, thus, only have to be unfolded once
Combination of different, already unfolded profile halfs
Automatic combination of the roll tools
Documentation of the required spacer widths
Optimization of the required spacers relative to total length and weigth
Management of the roll stock by a professional database-management-system
Your advantage:
From now on, for a profile section e.g. in three dimensions you will only have to unfold one profile.
By simultaneous visualization (overlapping with different colours) of profile flower and basic dimensions of the roll tools you may detect at once where a roll has to be modified or spacers have to be inserted.

COPRA® CNC Technologie Husk (H5)
The COPRA® NC Technology is a post-processor module to create NC programs for the production of roll tooling. The post-processor module is based on a macro language defining contents and structure of the NC programs. The macro language contains commands allowing to edit the outer roll contour. If the work piece is not completed from the right side, it can also be edited from the left and/or a grooving cycle can be used. Depending on the settings the processing may be done from the left and the right in one chucking or with turning the work piece. The capabilities are:

· Import roll contour via DXF-files

· Import roll contour from COPRA® data base

· Individual or automatic processing of all rolls

· Definition of the blank

· Definition of width and diameter allowance

· Definition of the processing sequence

· Definition of the individual subroutines

· Definition of the turning tool

· Automatic creation of the belonging NC program

· Visualization of the final tool path

· Collision control between tool, tool holder and roll

At the moment Fanuc and Sinumerik controls are being supported. As it is a general postprocessor - the program can be adapted to any kind of control units using the respective G-code. It will be necessary to have a technical manual of the control unit and some typical rolls with the respective G-code used by that control to do the necessary adaptations.
The used macro language allows to very easily adapt the program code to what it should be. As the complete setup is done within the program – including the setup of the program, the definition of the tooling and the adaptation of the process – it is easy to do fast adaptations.
The customer has to make sure that the generated G-code can be loaded into the machine as a text file – either by floppy, serial interface or network connection.
actual list of post processors on request
COPRA CNC Technology


	System requirements What are the requirements for a successful operation of COPRA ? COPRA is available for Windows operating systems and requires AutoCAD or Mechanical Desktop (both registered trademarks of Autodesk). AutoCAD is not included in the COPRA software unless you order a COPRA stand alone option.