Abstract: Several methods and subsystems are provided for aligning a workpiece as it is being loaded into a die space of a bending apparatus, and for performing sensor-based control of a robot as it moves a workpiece from one location to another within a bending apparatus environment. A backgaging mechanism is provided with finger gaging mechanisms having force sensors for sensing forces in directions perpendicular to and parallel to a die. In addition, a robot gripper sensor is provided for sensing either or both of shear forces and normal forces created by movement of a workpiece being held by the gripper.

Abstract: An apparatus and method are provided for integrating an intelligent manufacturing system with an expert sheet metal planning and bending system. The intelligent manufacturing system manages and distributes part design and manufacturing information throughout the locations of a production facility. The expert planning system includes a plurality of expert modules for proposing a bending plan, including bend sequence and tooling selections, and robot motion planning and repositioning. Through the various features and aspects of the present invention, an operator can selectively modify and adapt these integrated systems for particular bend applications, including robot-based and human assisted bending operations.

Abstract: A setup planning technique is provided in which a family of parts to be manufactured is identified, and the setup constraints imposed by the various bending operations in the part family are determined. The setup constraints may define or describe spatial constraints on the sizes and locations of various tooling stages in the setup. After identifying setup constraints, setup plans are generated that satisfy all setup constraints. Any setup plan that satisfies all setup constraints may then be utilized to accommodate every part in the part family. Constraint propagation techniques may be utilized to identify compatible setup constraints and create setup plans. According to the various features and aspects of the invention, dissimilar sheet metal parts can share setups, and the need for extra tooling and fixturing may be minimized. Further, the present invention provides potential savings over state-of-the-art systems, and increases production capability and overall through-put of manufacturing facilities.

Abstract: A fingerpad force sensor system is disclosed which is useful for detecting process variations during manufacturing processes in which a plurality of force sensors are applied to the gripper of a robot in order to monitor shear forces applied to the workpiece held by the robot during, for example, sheet-metal bending manufacturing processes. Each sensor is encapsulated in rubber pads which are secured to the gripper of the robot such that they monitor the status of the workpiece during all phases of automated bending: material acquisition, material handling, machine loading and unloading.

Abstract: A slider of the punch carry out unit is moved in the X-axis direction adjacent a punching section of the punch press machine before or after a plate material is punched into a punched product by a punch press machine. At the same time, a gravity center and a shape of the punched product are calculated and recognized on the basis of the manufacturing data. On the basis of the obtained gravity center and the shape of the punched product, the gravity center of the punched product is moved under the lift arm by the X- and Y-axis locating mechanism. Vacuum pads located just over the punched product are selected or discriminated. Then, the lift arm is lowered and the punched product is held by actuating only the discriminated vacuum pads. During this lift motion, it is preferable to bend one end of the punched product slightly upward to easily separate the punched product from the remaining flat plate material.

Abstract: Several methods and subsystems are disclosed for aligning a workpiece as it is being loaded into a die space of a bending apparatus, and for performing sensor-based control of a robot as it moves a workpiece from one location to another within a bending apparatus environment. A backgaging mechanism is provided with finger gaging mechanisms having force sensors for sensing forces in directions perpendicular to and parallel to a die. In addition, a robot gripper sensor is provided for sensing either or both of shear forces and normal forces created by movement of a workpiece being held by the gripper.

Abstract: An intelligent sheet metal bending system is disclosed, having a cooperative generative planning system. A planning module interacts with several expert modules to develop a bending plan. The planning module utilizes a state-space search algorithm. Computerized methods are provided for selecting a robot gripper and a repo gripper, and for determining the optimal placement of such grippers as they are holding a workpiece being formed by the bending apparatus. Computerized methods are provided for selecting tooling to be used by the bending apparatus, and for determining a tooling stage layout. An operations planning method is provided which allows the bending apparatus to be set up concurrently while time-consuming calculations, such as motion planning, are performed. An additional method or system is provided for positioning tooling stages by using a backgage guide member which guides placement of a tooling stage along the die rail of the bending apparatus.

Abstract: A machine for driving inserts into pieces of sheet metal includes an automatic loading device having a plurality of cartridges containing inserts of different types. Each cartridge can be connected selectively to an insert-supply duct integral with the punch.

Abstract: A computerized method/system is provided for planning motion of a robot within a free space confined by obstacles, from an initial position to a goal position. In executing the method/system, a plan is generated so that the robot can hold and maneuver a workpiece throughout a sequence of bending operations to be performed by a bending apparatus. A plurality of proposed movements to be made by the robot are proposed for an mth movement within a sequence of movements, and at least a portion of the robot and the obstacles that confine the free space are modeled. A determination is made as to whether a collision will occur between the robot and an obstacle for each proposed movement, and a plan is generated including the sequence of movements by choosing for each movement in the sequence of movements, a proposed movement that will not result in a collision and that will bring the robot closer to the goal position.

Abstract: A machine for driving inserts into pieces of sheet metal includes a punch and a die movable relative to one another along an axis along which the inserts are to be driven. The punch and die define a driving zone therebetween, in which a hole in the piece in which an insert is to be driven is positioned. The axis along which the inserts are to be driven is substantially horizontal and the pieces are held in a substantially vertical plane by an automatic handling device.

Abstract: A fingerpad force sensor system is disclosed which is useful for detecting process variations during manufacturing processes in which a plurality of force sensors are applied to the gripper of a robot in order to monitor shear forces applied to the workpiece held by the robot during, for example, sheet-metal bending manufacturing processes. Each sensor is encapsulated in rubber pads which are secured to the gripper of the robot such that they monitor the status of the workpiece during all phases of automated bending: material acquisition, material handling, machine loading and unloading.

Abstract: A computerized method/system is provided for planning motion of a robot within a free space confined by obstacles, from an initial position to a goal position. In executing the method/system, a plan is generated so that the robot can hold and maneuver a workpiece throughout a sequence of bending operations to be performed by a bending apparatus. A plurality of proposed movements to be made by the robot are proposed for an mth movement within a sequence of movements, and at least a portion of the robot and the obstacles that confine the free space are modeled. A determination is made as to whether a collision will occur between the robot and an obstacle for each proposed movement, and a plan is generated including the sequence of movements by choosing for each movement in the sequence of movements, a proposed movement that will not result in a collision and that will bring the robot closer to the goal position.

Abstract: A device for driving inserts into pieces of sheet metal includes a punch having a longitudinal axis of symmetry, a thrust surface and a through hole extending along its longitudinal axis which constitutes a supply duct for the inserts. The through hole extends through the thrust surface. A thrust rod applies a driving force to the inserts to move them into position in front of the thrust surface of the punch. The thrust surface drives the head of the insert into a piece of sheet metal through a hole while plastically deforming the periphery of the hole which interfaces with the head.

Abstract: A machine tool system includes a machine tool and a marking apparatus. The marking apparatus can mark parts-data on workpiece parts at high speed, without occupying any tool mounting station and without having any limitation in the number, the sequence direction, the size and the type font of characters to be marked. A mount base (33) is fixedly attached to a frame (1) of the machine tool. A marking head (51) is mounted on the mount base (37) so as to be movable in the vertical direction. The marking head (51) is provided with a pneumatic stylus (77) movable horizontally both in the X- and Y-axis direction. A parts-data of dot matrix type can be engraved on the workpiece parts by moving the stylus (77) in the X- and Y-axis directions.

Abstract: Several methods and subsystems are disclosed for aligning a workpiece as it is being loaded into a die space of a bending apparatus, and for performing sensor-based control of a robot as it moves a workpiece from one location to another within a bending apparatus environment. A backgaging mechanism is provided with finger gaging mechanisms having force sensors for sensing forces in directions perpendicular to and parallel to a die. In addition, a robot gripper sensor is provided for sensing either or both of shear forces and normal forces created by movement of a workpiece being held by the gripper.