Entwicklung eines Anlagenkonzepts zur Vereinzelung von Stahlflachstäben

The singulation of distorted flat steel bars of varying lengths and crossections delivered in bundles has scarcely been investigated to date. Accordingly, there are only a few transferable solutions for the specific application at voestalpine BÖHLER Edelstahl GmbH & Co KG. The aim of this work is to develop a robust, process¿reliable, and adaptable singulation concept that accounts for varying geometries, different bar materials, and curvatures, and that can be integrated into the existing process. The concept comprises the theoretical development of mechanical and control¿engineering principles for singulation. To assess functionality and process behavior, the Discrete Element Method (DEM) is employed. For this purpose, relevant material and contact parameters are determined and suitable simulation settings are defined. Based on the DEM analyses, motion and contact behavior are evaluated, critical states are identified, and design parameters are derived. These results form the basis for a robust concept assessment and the design of a system. As a key result, the basic feasibility of singulation through induced oscillatory motion using a vibratory plate is demonstrated. The underlying mechanism is based on bar¿bar collisions that cause redistribution. In the process, the bars arrange themselves side by side in available gaps. The use of two different bar models and the fine¿tuning of vibration parameters to the specific bundle properties yielded key insights. Real¿world tests confirmed the motion patterns observed in the simulations and served for initial validation. Open issues primarily concern noise emissions and a final validation simulation with parameters calibrated to the real¿world tests. These next steps are recommended for the design, manufacturing, and successful deployment of the system.