Abstract: The Roll Defect Management Process (RDMP) is a system which is designed to manage, track and evaluate all mill rolls found in use in the hot and cold production of flat rolled metal strip. The RDMP is capable of detection, distinction and differentiation of various defects found in the mill roll using a nondestructive inspection system for generating variable amplitude output voltage signals corresponding to changes in physical properties found in a mill roll and defines corrective action for each roll type, mill, stand and position. The disposition and corrective actions of the RDMP are automated and dependent on the determination of various thresholds identified by roll, mill and stand.

Abstract: A method of finishing like castings wherein the exact dimensions of the casting are not known requires the steps of traversing the casting along a fixed path impinging excess material on a reduction apparatus such as grinder at a fixed location such that a defined witness is produced on the excess material, measuring the difference from the witness to the casting parent material and adjusting the fixed path to remove the excess material to within a specified tolerance.

Abstract: An apparatus and method for generating numerical control information for numerically controlling machine tools. Contents of corrective editing or correction to numerical control information by a processing operator is written and stored in a processing method database as processing knowledge of the processing engineer. When a programmer generates new numerical control information, a suitable processing method can be used from the processing method database. The knowledge included processing conditions by the processing operator. The information in the processing method database is updated at each and every processing.

Abstract: A bending apparatus for bending a workpiece W according to cooperation of a punch P and a die D previously carries out various step bending or makes simulation of step bending, and calculates an approximation formula based on a correlation between a ratio % of a one-sided elongation value &agr; to a plate thickness t and a step bending angle &thgr; based on a relationship among the plate thickness t, the step bending angle &thgr; and the one-sided elongation value &agr; of the workpiece W so as to store the formula as a database. The more accurate one-sided elongation value &agr; of the step bending is calculated by small parameters including only two data including the plate thickness t and the step bending angle &thgr; previously input at the time of actual bending based on the approximation formula in the data base so that the bending is carried out easily.

Abstract: A sheet metal bending machine with a bending unit driven by actuators comprises a data processing system including a technological bending database which is programmed to represent the behaviour of the machine-sheet assembly under the bending process, said database being provided with a predefined stored set of sheet metal angle and thickness data and supplied with nominal angle and thickness data of the sheet metal to be bent, a material characteristic database provided with a predefined set of sheet metal material data and supplied with material type data of the sheet metal to be bent, a machine geometry database provided with a predefined set of geometrical data of the bending machine. A mathematical model calculation algorithm calculates the movements of the bending unit actuators according to processed data provided by said databases and sheet metal length data of the sheet metal to be bent.

Abstract: A numerical control device for a bending machine includes a keyboard, a memory and a processor. The memory stores one or more groups of data, each containing bending conditions, a bend angle and at least one penetration depth. The memory further stores program instructions for searching whether data input with the keyboard is stored in the memory, in a same group of data, and that sends a signal to the bending machine so that the bending machine peforms bending according to the penetration depth included in the group of data. The processor that executes said program instructions.

Abstract: Disclosed are a method and a system for predicting precipitation kinetics in precipitation-hardenable alloys, such as the 7000 series aluminum alloys, and for optimizing conditions for thermal treatment thereof. The method includes the steps of measuring a real-time temperature of an alloy component during the thermal treatment process, and using a signal in dependence upon the real-time temperature to predict, using executable code, a current state of the alloy component. The executable code includes a series of rate equations and initial parameters for a particular alloy. Optionally, the initial parameters for the particular alloy are provided after the code is in execution. The thermal treatment process is terminated when a predetermined state of the alloy component is predicted.

Abstract: A cutting process S1 cuts a wire 1 into cut pieces each having a volume approximately equivalent to that of a desired shoe 11. A forging process S2 sequentially forges cut pieces 2 with forging dies 13, 23, and 33 having three cavities 13c, 23d, and 33e respectively, and obtains a steel sphere 8. A finishing process S3 obtains a shoe-shaped material 10 from the steel sphere 8 without a heat treatment, and carries out a heat treatment to the obtained material 10, thereby to obtain a shoe 11 for a compressor.

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 backstage guide member which guides placement of a tooling stage along the die rail of the bending apparatus.

Abstract: A mobile robot capable of recognizing its location and adjusting its direction in response to an obstacle in its way includes a running device, an obstacle detecting device for detecting the presence of an obstacle, a location recognizing device, a controlling portion, and a power supply. The location recognizing device includes a first vision camera directed toward the ceiling of a room and a first vision board. The first vision camera recognizes a base mark on the ceiling. The first vision board processes an image from the first vision camera and transmits the image data to the controlling portion. The obstacle detecting device includes a line laser for emitting a linear light beam toward the obstacle, a second vision camera for recognizing a reflective linear light beam from the obstacle, and a second vision board for processing image data captured by the second vision camera.

Abstract: A welding machine having an embedded controller with a processor, a network gateway interface device coupled to the embedded controller, an operating program segment stored in a memory of the embedded controller, a gateway communication program segment stored at least partially in the memory of the embedded controller, and a resource sharing program segment stored in the memory of the embedded controller, the resource sharing program segment allocates processing time of the processor between the gateway communication program segment and the operating program segment. The machine may be monitored, controlled, accessed and updated with software over a network from a remote user interface, embodied for example on an Internet browser.

Abstract: A method for automatic conducting of a straightening process for an object to be straightened, such as sheet metal, strips, sections, pipes, and in particular for wire-like or multiwire-like objects that are to be straightened, in a straightening device or a levelling machine with at least one mangle roll which can be adjusted by an actuator. In accordance with this invention, a process simulation model of a straightening process that is to be conducted, and a process simulation program are set up, and the latter gives directly “online” the settings of the adjustable mangle rolls.

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: A method for determining the dimensions of the workpiece that can be roll-formed for preforming. A method for producing suspension parts via preforming the workpiece by roll forming.

Abstract: An exemplary method of designing a manufacturing process comprises the steps of representing a workpiece as a plurality of triangular finite elements, representing the forming tools with mathematical equations which typically include cubic polynomials, simulating a deformation of the workpiece by the forming tools with a finite element model, wherein the finite element model is integrated with explicit integration. The method may be carried out with an apparatus which includes a memory device which stores a program including computer readable instructions, and a processor which executes the instructions. After the deformation of the workpiece has been simulated by the finite element model, the characteristics of the workpiece and forming tools can be modified to improve the final shape of the workpiece. After the finite element simulation produces an acceptable final workpiece shape, an actual workpiece can be formed with actual tools based on the simulation.

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 the bending apparatus.

Abstract: A computer program is provided for developing a bend model of a part to be produced at an intelligent production facility. In accordance with an aspect of the disclosed program, faces of the part are detected based on initial part information, and bendlines of the part are identified based on the detected faces of the part. Further, additional part information is generated by performing a predetermined operation (e.g., a folding operation or an unfolding operation) on the detected faces of the part. The disclosed program also includes other capabilities, such as the capability to perform clean-up operations on initial, 2-D part information and to selectively eliminate part thickness representations in order to facilitate the preparation of a 3-D representation of the part from the modified 2-D part information.

Abstract: A method of generating a robotic process plan for performing a process on a work structure includes a step of receiving input identifying a template corresponding to a plurality of geometric features of the work structure, each geometric feature associated with one or more robotic process elements. The method further includes a step of receiving input associating work structure data with the identified template. The method also includes a step of generating the robotic process plan based on the associated work structure data and the robotic process elements associate with the template.

Abstract: The flowrate of a stream discharged from a drain in a vessel is measured by imaging the stream, measuring a diameter of the stream image, and calculating the flowrate based on the measured diameter. A video camera may be aimed below the drain for imaging the stream. A computer is joined to the camera for measuring the diameter of the stream and calculating a corresponding flowrate therefor.

Abstract: A method (100) for predicting distortion of a sheet metal during a sheet forming process to form the sheet metal into a part. The method (100) of the present invention is for use with a computer including memory and sheet forming tools. The method (100) comprises applying (104-116) the radial return method to compute the total stress for the anisotropic hardening rule of Mroz. The method (100) of the present invention does not divide a given strain increment into hundreds of subintervals as long as the movement of the center of the active yield surface is along a fixed path. If a break occurs, the given strain increment is divided into a few segments (110).

Abstract: An apparatus and method is provided for managing and distributing design and manufacturing information throughout a factory in order to facilitate the production of components, such as bent sheet metal components. In accordance with an aspect of the present invention, the management and distribution of critical design and manufacturing information is achieved by storing and distributing the design and manufacturing information associated with each job. By replacing the traditional paper job set-up or work sheet with, for example, an electronically stored job sheet that can be accessed instantaneously from any location in the factory, the present invention improves the overall efficiency of the factory. In addition, through the various aspects and features of the invention, the organization and accessibility of part information and stored expert knowledge is improved.

Abstract: Automated method and machinery for fabricating a wrought-iron fence panel. The machinery includes (a) automated programmable machinery for welding vertical pickets to horizontal runners to form a fence panel; (b) automated programmable machinery for straightening the fence panel; (c) automated programmable machinery for washing the fence panel; (d) automated programmable machinery for drying the fence panel; (e) automated programmable machinery for painting the fence panel; and (f) automated programmable conveyor machinery for conveying the vertical pickets, the horizontal runners, and the fence panel from station to station.

Abstract: A system combines an open control interface workstation, e.g., a properly configured personal computer, with a networked computer numerical control. The personal computer and CNC are preferably linked to a local area network such as an Ethernet network. The open control interface is configured to utilize Windows DDE, or other protocol, to accomplish process-to-process communications with other DDE-compliant Windows applications. Additionally, the open control interface is designed to allow DDE-compliant Windows applications to communicate with one or more networked computer numerical controls while minimizing data flow over the network.

Abstract: A method of continuously casting and finish-rolling a cast slab within a predetermined finished width tolerance, wherein for the cast slab and any subsequent slab an adjustment of the mold position is carried out particularly in accordance with different rolling conditions for achieving the predetermined finished width within a tolerance strip, initially a preadjustment of the mold position is carried out, inter alia, while considering the extreme strip dimensions of the planned production program, a computation for the optimum use for the mold adjusting units and the adjusting units of the finishing train is carried out for each cast slab and any subsequent slab, and, with an existing entering width of the cast slab into the finishing train, a reoptimization of the finished width by means of the adjusting units of the finishing train is carried out.

Abstract: A system combines multiple man-machine interfaces with multiple computer numerical controls over a network. Typically, each man-machine interface comprises a personal computer with a Windows-based operating system utilizing a standard process-to-process communication protocol, such as Dynamic Data Exchange (DDE). This type of system allows a wide variety of M-to-N topologies in CNC environments. Further, the use of standard personal computer operating systems and common process-to-process communication protocols permits the networking of other types of devices and the use of other third party applications.