Glossary
1 MIN READ
AI-Vision
An intelligent, laser-based vision system that projects thousands of measurement points across a plate's surface to automatically read, analyze, and correct forming radii in real time without operator intervention.
Technical FAQ
Industrial manufacturers need to scale up volume and maintain consistent part quality completely independent of operator skill levels. Autorolling is an autonomous forming process achieved by integrating a fully electric machine, an advanced CNC control system, and a real-time laser measurement system. The system measures the plate radius, adjusts machine axes, and optimizes parameters on the fly, delivering automated precision without human intervention. Developed by Davi, Autorolling combines MCE e-POWER hardware, iRoll eXtreme software, and AI-Vision technology into a self-functioning production line.
Eliminating trial-and-error scrap during the initial setup saves material costs, especially when processing expensive alloys. AI-Vision utilizes high-definition laser scanners to project thousands of measurement points across the plate surface, reading the radius in real time. The system automatically analyzes the actual radius and provides feedback to correct deviations on the fly, ensuring a perfect part on the first sheet without manual templates. Developed by Davi R&D, AI-Vision integrates directly with the control system to eliminate manual inspection downtime.
Relying on heavy physical templates requires operators to repeatedly stop the machine and check the radius manually, creating safety hazards. A digital measurement system uses advanced optical or laser tracking to check the workpiece geometry continuously during the forming process. It improves measuring accuracy, saves time by eliminating constant loading and unloading, and keeps operators at a safe distance from heavy moving parts. Davi's laser measuring systems automate radius tracking, providing a complete digital record of forming tolerances for quality compliance.
Waiting for an on-site technician during an unexpected software or operational issue can delay production schedules. Remote support allows factory-trained engineering teams to access the machine's PLC data securely over the network. It enables technical teams to diagnose faults, adjust parameters, and resolve programming issues in minutes without travel delays. Davi provides dedicated remote engineering support to minimize downtime and maintain production availability.
Manufacturers scaling up production often face a tradeoff between simple manual positioning and fully automated numeric control. Davi bridges this gap by offering scalable control solutions ranging from assisted NC environments to fully automated Industry 4.0 CNC platforms. Standard NC or entry-level iRoll Performance configurations provide digital axis management, phase programming, single-radius templates, and basic diagnostic monitoring for routine jobs. Upgrading to iRoll eXtreme CNC unlocks advanced automation: multi-radius custom shape programming, 3D pre-production simulation, self-learning material spring-back algorithms, an ASME-compliant "Apple-Shape" calculator for re-rolling pre-welded shells, and full integration with OPC-UA network plugins. Furthermore, iRoll eXtreme seamlessly links with the AI-Vision laser measurement system, continuously adjusting axis positions in real time to enable autonomous "Autorolling" without operator intervention.
Traditional plate rolling relies heavily on skilled manual operators to compensate for batch-to-batch material yield variations, resulting in trial-and-error scrap and inconsistent quality. Davi Autorolling© creates a self-functioning rolling cell by combining three proprietary technological building blocks:
- MCE e-POWER: High-precision, fully electric roll positioning controlled down to 0.001 mm (0.00004 in) resolution.
- iRoll eXtreme CNC: Advanced software utilizing a 60-year historical forming database and self-learning material algorithms.
- AI-Vision: A high-definition laser measurement system projecting thousands of data points across the plate surface to read actual curvature radii in real time. By linking these systems, Autorolling© automatically recalculates and adjusts roll axes on the fly without human intervention, achieving exact target dimensions on the very first sheet.
Fabricators investing in heavy capital equipment need assurance that their supplier possesses field-tested expertise across complex manufacturing applications. Over the past two decades, Davi has manufactured and commissioned thousands of plate and angle rolls operating worldwide, maintaining strong market dominance across energy, aerospace, transportation, and heavy job-shop sectors. In the wind energy industry alone, Davi holds approximately 70% of the global market share with over 300 heavy-duty rolling lines operating at major monopile, transition piece, and wind tower fabrication facilities. This massive global reference base powers Davi R&D algorithms with historical data collected across 60 years of real-world forming operations.
Davi CNC systems deliver precise roll positioning feedback down to 0.001 mm (0.00004 in) on fully electric MCE models and sub-millimeter positioning on hydraulic series. However, finished part accuracy depends on raw material variations in yield strength, thickness tolerances, and grain direction. To ensure repeatable tolerances, systems like iRoll eXtreme feature self-learning material algorithms, spring-back compensation software, and direct feedback integration with AI-Vision laser measurement systems to automatically adjust roll axes in real time.
Traditional rolling relies on operator experience to adjust for spring-back and material variations through trial and error. Davi eliminates this dependency through Autorolling©, which merges three core technologies:
- MCE e-POWER: High-precision electric roll positioning.
- iRoll eXtreme CNC: AI software utilizing historical databases and spring-back calculation wizards.
- AI-Vision: Laser system measuring actual shell radii in real time and feeding correction data directly to the CNC. Together, these systems execute precise rolling autonomously, allowing entry-level operators to produce accurate parts on the first attempt.
Davi provides advanced digital and optical measuring devices to replace manual physical templates:
- AI-Vision System: A laser measurement system projecting thousands of data points across the plate to read actual forming radii in real time without stopping the machine.
- Patented HD iRoll Camera: A digital camera system for angle rolls that projects a calibrated template directly onto the operator screen for instant radius verification.
- Automatic Radius & Circumference Measuring Tools: Electronic measuring arms that log dimensional data for quality assurance.
Yes, digital measuring tools (such as wireless radius gauges or the AI-Vision laser system) connect directly with Davi iRoll eXtreme CNC software. When a radius measurement is taken, data transfers via Wi-Fi or network bus to the control system. The iRoll eXtreme software compares actual measured dimensions against the target program and automatically adjusts side roll positioning (X, Y axes) to correct deviations without manual re-calculation.
AI-Vision is designed to operate seamlessly with Davi iRoll eXtreme CNC. While entry-level platforms like iRoll Performance support digital gauge input and template software, full dynamic closed-loop feedback—where AI algorithms continuously modify axis positioning on the fly—requires the advanced computing engine, 3D graphics processor, and real-time interpolation features of iRoll eXtreme.
No, AI-Vision cannot be installed on third-party competitor CNC platforms. The real-time laser measurement system relies on proprietary mathematical algorithms, historical forming databases, and software integration built into the Davi iRoll eXtreme CNC software. However, Davi Service teams can evaluate retrofitting complete control cabinets—replacing legacy competitor CNCs with a full Davi iRoll eXtreme control package—to enable AI-Vision functionality on existing machinery.
Davi CNC control systems—including iRoll Performance and iRoll eXtreme—are developed entirely in-house by the specialized Davi R&D division in Italy. Running on an industrial Windows 10 platform, Davi CNC platforms combine non-proprietary global automation hardware from Siemens and ABB with proprietary software algorithms. These controls feature self-adjusting AI that draws on 60 years of historical forming data to generate multi-pass programs, run offline 3D pre-production simulations, and connect seamlessly with the AI-Vision real-time laser measurement system for autonomous rolling.