Abstract: In a flexible manufacturing system (FMS), a shelving module of a work cell is fitted with a dedicated lift conveying mechanism so that work materials of desired sizes may be retrieved individually from different shelves of the shelving module for conveyance to the machine of the work cell. By having its own dedicated lift conveying mechanism that operates independently from the transport system that transports raw materials to the wok cells of the FMS, the operation of each cell becomes unaffected by the transport system. As such, materials may be fed to the machine in each cell for fabrication, piece by piece if so desired, by the lift conveying mechanism while the various shelves of the shelving module continue to be stocked by the transport system. Any remnants that prior to the instant invention would have been wasted may be returned to the appropriate shelves of the shelving module for future use by the lift conveying mechanism.

Abstract: To determine whether a tool may be used successfully to fabricate a worksheet in a sheet fabrication machine, data relating to all tools that may be used for the machine as provided by the manufacturers of those tools are stored in a tool database. Dimensional data and characteristics of the worksheets that may be used by the machine are stored in a worksheet database. When a given worksheet is to be fabricated, a determination is made on whether a tool is usable for fabricating that worksheet without causing possible damage to the worksheet, the tool and its die, and/or the machine. The grind life remaining for the tool is used to determine whether the proper clearance between the tool and its die is obtainable by using the tool on the given worksheet. If it is determined that the tool is not useable for a given worksheet, the tool is flagged and reserved for use on worksheets that have a material thickness that is thinner than that of the given worksheet.

Abstract: To determine whether a tool may be used successfully to fabricate a worksheet in a sheet fabrication machine, data relating to all tools that may be used for the machine as provided by the manufacturers of those tools are stored in a tool database. Dimensional data and characteristics of the worksheets that may be used by the machine are stored in a worksheet database. When a given worksheet is to be fabricated, a determination is made on whether a tool is usable for fabricating that worksheet without causing possible damage to the worksheet, the tool and its die, and/or the machine. The grind life remaining for the tool is used to determine whether the proper clearance between the tool and its die is obtainable by using the tool on the given worksheet. If it is determined that the tool is not useable for a given worksheet, the tool is flagged and reserved for use on worksheets that have a material thickness that is thinner than that of the given worksheet.

Abstract: In a manufacturing system that has a plurality of sheet fabrication machines, to enhance the efficiency of the system, there are provided a plurality of databases each for storing particular data relating to the machines, the types of materials to be used, the tooling of the machines, etc. of the system. When a multi-dimensional model of a component part to be produced by the system is input to the system, selective data is retrieved from the various databases so that at least one machine of the plurality of machines of the system is selected to produce the part from a worksheet of a chosen material. Concurrently, or shortly thereafter, a NC part program for programming the selected machine to execute the necessary operations in accordance with a flat drawing generated from the multi-dimensional model to fabricate the component part is generated based on selective data retrieved from the databases.

Abstract: In a manufacturing system that has a plurality of sheet fabrication machines, to enhance the efficiency of the system, there are provided a plurality of databases each for storing particular data relating to the machines, the types of materials to be used, the tooling of the machines, etc. of the system. When a multi-dimensional model of a component part to be produced by the system is input to the system, selective data is retrieved from the various databases so that at least one machine of the plurality of machines of the system is selected to produce the part from a worksheet of a chosen material. Concurrently, or shortly thereafter, a NC part program for programming the selected machine to execute the necessary operations in accordance with a flat drawing generated from the multi-dimensional model to fabricate the component part is generated based on selective data retrieved from the databases.

Abstract: The present invention relates to a system and method therefor of sorting and unloading various pieces cut from sheet blanks which have different dimensions in a sheet metal fabricating environment. To achieve this end, prior to the production run, the various program routines whose operations for effecting the cutting of the sheet blanks are retrieved and the data relevant to the to be cut pieces are grouped and analyzed so that pieces of different dimensions cut in accordance with the different program routines are respectively allocated to the corresponding sorting addresses for unloading. Accordingly, different pieces with the same dimension cut from different program routines during the same production run are unloaded to the same location of the unloader area. Optimization of the unloading process and optimal utilization of the available loading space are thereby achieved.

Abstract: To improve the speed with which a worksheet is positioned in a press brake, and to further eliminate the need for conventional moving back gauge systems, the present invention replaces the conventional back gauge mechanical system with sensors that non-contactedly determine the positioning of the worksheet, with reference to the bending tools. The thus sensed worksheet position is compared with the desired worksheet location preprogrammed into the CNC controller. Any deviation between the sensed, or the actual worksheet position, with the desired worksheet position for each bend of the worksheet is compensated by further moving the worksheet, until there no longer is any discrepancy between the actual and the preprogrammed desired locations.

Abstract: To improve the speed with which a worksheet is positioned in a press brake, and to further eliminate the need for conventional moving back gauge systems, the present invention replaces the conventional back gauge mechanical system with sensors that non-contactedly determine the positioning of the worksheet, with reference to the bending tools. The thus sensed worksheet position is compared with the desired worksheet location preprogrammed into the CNC controller. Any deviation between the sensed, or the actual worksheet position, with the desired worksheet position for each bend of the worksheet is compensated by further moving the worksheet, until there no longer is any discrepancy between the actual and the preprogrammed desired locations.

Abstract: To maximize the production run speed of a sheet fabrication machine such as a turret punch press, and yet at the same time maintaining the requisite accuracy for each part produced from the production run, historical data pertaining to the various parameters for effecting the positioning moves of a worksheet are measured and collected using a reference machine or a prototype machine. For each positioning move to be effected, the CNC controller of the system retrieves the historical data from a database and, using that historical data, calculates the various parameters that affect the positioning move. By using fuzzy logic, the controller becomes, in a sense, self teaching, especially if updated historical data are provided to its database store to enhance the accuracy for later positioning moves. In addition to measuring and collecting historical data from reference or prototype machines, static process control (SPC) tests may be performed for different types of worksheets under different loads.

Abstract: The present invention relates to a system and method therefor of sorting and unloading various pieces cut from sheet blanks which have different dimensions in a sheet metal fabricating environment. To achieve this end, prior to the production run, the various program routines whose operations for effecting the cutting of the sheet blanks are retrieved and the data relevant to the to be cut pieces are grouped and analyzed so that pieces of different dimensions cut in accordance with the different program routines are respectively allocated to the corresponding sorting addresses for unloading. Accordingly, different pieces with the same dimension cut from different program routines during the same production run are unloaded to the same location of the unloader area. Optimization of the unloading process and optimal utilization of the available loading space are thereby achieved.

Abstract: To roll form a worksheet by a turret punch press, at least one pair of coacting tools are mounted to the opposed turrets so that when those tools are rotated to the work location, they could be driven to a predetermined relative distance towards each other to make contact with the workpiece. The depth of the formed shape is determined by the relative distance the coacting tools are driven towards each other. By moving the worksheet at the same time that the coacting tools are making contact with the worksheet, roll forming of the worksheet is effected. By providing the coacting tools in the opposing indexing stations and synchronously rotating those stations, a complex pattern can be roll formed on a worksheet.

Abstract: To determine whether a machine tool is operating effectively, the present invention system, instead of directly measuring the operating parameters of the machine tool, monitors the presence or absence of any holes made by the machine tool and the quality of those holes, if made. The operational effectiveness of the machine tool is then correlated with the data thus monitored.

Abstract: To adapt a punch press to cut work blanks, a cutting mechanism having a freely rotating cutting wheel is provided to a first support of the punch press while a corresponding die having a groove for mating with the cutting wheel is provided to a second support of the punch press. To operate, the cutting wheel is moved toward the die a given distance such that the cutting edge of the cutting wheel slidably mates with the cutting edge of the groove of the die to effect cutting of the workpiece. By synchronously rotating both the cutting wheel and the die to different orientations while maintaining their respective cutting edges aligned and in sliding contact with each other, by moving a worksheet relative to the cutter wheel and die, a multidirectional cut path may be effected on the worksheet.

Abstract: To ensure that a worksheet is effectively operated on, the present invention system monitors the life expectancy of a tool by counting the number of hits the tool has made so that when it is reached, the tool is replaced by a spare tool. Alternatively or in combination therewith, in place of monitoring the life expectancy of the tool, the operational effectiveness of the tool is monitored. Thus, anytime that the operational effectiveness of the tool is deemed to fall below a given standard, the tool is replaced by a spare tool. The replacing of the tool by a spare, and the subsequent replacement of the spare tool by yet another spare can go on ad infinitum. With such a system, severe failure of tools are prevented.

Abstract: To eliminate the need for manually measuring the length of a punch to provide compensation for any shortening of its length in a punch press, a sensor probe is provided at a predetermined height from the punch so that as the punch is driven by its driving ram, it makes contact with the probe. As soon as contact is made between the punch and the probe, the movement of the ram is stopped and its relative position is recorded and compared with a theoretical ram start position for driving, for example, a brand new punch. The difference between the theoretical ram start position and the thus measured position is provided as an offset to reposition the ram so that the wear of the punch is compensated.

Abstract: To move or remove a workpiece from a worktable, as for example a finished workpiece from a work station, an elongate conveyer member, once it has been positioned so that at least a portion thereof is superposed over the finished workpiece, is lowered to contact at least one portion of the finished workpiece. Upon contact, the conveyer member is activated to convey the workpiece away from the work station, and if desired, automatically convey the workpiece to a storage bin or pallet.

Abstract: To enhance the separation of sheet materials from a destacker, an air provider mechanism is attached to a frame of the carriage to bias against the being lifted sheet so as to maintain the air steam provided by an air ejector of the system directed to a location substantially immediately beneath the bottom surface of the being lifted sheet. Accordingly, as the sheet is being picked up, the air ejected from the air ejector system is directed to the gap between the being lifted sheet and its underlying sheets to enhance the separation of the being lifted sheet and the underlying sheets.

Abstract: An automatic sheet metal machining center has a frame, a work table attached immobile to it, a first carriage movable with regard to the frame, a second carriage attached to the first carriage and movable in a direction perpendicular to the path of the first carriage, and a stop pin in the frame. The stop pin is immobile in the directions of the paths of the carriages and is movable to upper and lower positions in a direction perpendicular to the plane of the work table. The position of a work piece, after having been placed on the work table, is determined in relation to the direction of the path of the second carriage, which has clamps for grasping the workpiece. The clamps are movable in the direction of the path of the second carriage and lockable thereto. According to a preprepared program, the respective positions of the clamps, with regard to the second carriage for grasping the workpiece, are automatically recognized and locked onto the second carriage with the aid of the stop pin.