Abstract: A power tool system and method of using the same is provided. The system can include a programmable microprocessor device including at least one input mechanism, and a memory having instructions and/or other information. The system can also include a display; at least one power tool having at least one sensor operable for monitoring a parameter associated with operation of the power tool. The system can further include a communications device connectable in signal communication with both the programmable microprocessor device and the at least one sensor and program instructions. The method can include the steps of (i) using stored program instructions to generate power tool related information on at least one display and (ii) collecting power tool related data using a programmable microprocessor.

Abstract: A mobile station for an unmanned vehicle comprises a vehicular storage area for storing a vehicle during transit or at rest. A first wireless transceiver communicates a status or command between the vehicle and the mobile station during at least one of vehicular deployment and rest. A station controller manages a management plan of the vehicle comprising at least one of retooling the vehicle, loading a payload on the vehicle, and recharging or refueling of the vehicle.

Abstract: A method assesses a state of at least one axial joint of an industrial robot, on the basis of data of a mechanical backlash present at the axial joint of the industrial robot, a state of wear of the axial joint being determined. On the basis of data of a torque profile, a first loading state of the axial joint is determined at the axial joint during at a first working cycle of the industrial robot. On a basis of data of a movement sequence at the axial joint during a second working cycle of the industrial robot, a second loading state of the axial joint is determined. An assessment of the state is carried out by pre-assessing the state of wear, the first loading state and the second loading state and a subsequent comparison with an empirically obtained comparison value matrix.

Abstract: A machine condition assessment module may be integrated with standard industrial control and communications networks to receive dynamic operating data from signal processing engines and optionally process data from controlled machinery and to operate on that data according to standard and user customized rule sets to produce an assessment of the presence and severity of specific electrical and/or mechanical faults. The output of the assessment module will be, for each of the one or more machines monitored, and for each of the one or more faults assessed, a single parameter that indicates the presence and severity of the fault. This data, in turn, may be readily communicated to an industrial controller on the network for use in effecting the control process itself.

Abstract: A method is provided for testing the fit or for testing the imbalance of a tool exchangeably accommodated in a tool spindle which is mounted for rotation about a central longitudinal axis and is rotationally driven by a spindle drive motor, including: inserting the tool on the tool spindle; making the tool spindle rotate with a specific rotational frequency fdef about the central longitudinal axis by means of the spindle drive motor; analyzing an actual value of a controlled drive current of the spindle drive motor with respect to a frequency component with the rotational frequency fdef; and determining whether the frequency component with the rotational frequency fdef lies within a threshold value range.

Abstract: A method for extracting parameters of a cutting tool is provided. The method includes obtaining a measurement data set having a point cloud corresponding to a surface of the cutting tool and virtually slicing the point cloud at a pre-determined section to obtain a set of points on the pre-determined section. The method also includes generating a plurality of curves through the set of points and optimizing the plurality of curves to generate optimized fitting curves and extracting the parameters of the cutting tool from the optimized fitting curves. Furthermore, based on the presented rotary angle projection technique, a plurality of parameters can be extracted for the cutting tool.

Abstract: A method for predictive maintenance of a cutting unit of an automatic machine; the method determining, with a given frequency, the value of a characteristic quantity of the cutting unit related to contact between a cutting member and a counter-member; determining a curve for extrapolating the time pattern of the characteristic quantity value, and programming maintenance work on the cutting unit when the curve is outside a given acceptance range.

Abstract: A riveting system is operable to join two or more workplaces with a rivet. In another aspect of the present invention, a self-piercing rivet is employed. Still another aspect of the present invention employs an electronic control unit and one or more sensors to determine a riveting characteristic and/or an actuator characteristic.

Abstract: A method for correcting surface and near surface defects in metal components in which the component is first inspected to identify both the site and size of a component defect. Thereafter, it is determined if the defect is correctable by friction stir processing and, if so, the defect is corrected by performing friction stir processing on the component at the site of the defect. Optionally, one of several different sized friction stir processing tools is selected as a function of the size of the defect.

Abstract: A system and method are provided for real-time measurement of tool forces. A relationship between a sensor characteristic and tool forces is determined by directly measuring tool forces for a standard tool, work piece, and part program. The sensor characteristic for a CNC machine at the user facility is then measured for the standard tool, work piece, and part program, providing a relationship between the sensor characteristic at the user facility and tool forces. If the sensor is not conveniently attached to the work piece or the part program is not sufficiently robust in cutting conditions, the work piece and part program are replaced by a sacrificial work piece and sacrificial part program. The sacrificial work piece and sacrificial part program are selected to accommodate the sensors and to provide sufficient robustness in cutting conditions to accurately determine the process model parameters for the sacrificial work piece.

Abstract: The present invention relates to a method for machining a workpiece 1 by means of a rotating tool 2 provided with at least one cutting edge 3, in which method the machining operation is interrupted at predetermined time intervals, the tool 2 is moved away from the workpiece 1, and a wear measurement is subsequently carried out on the tool 2, characterized in that after the wear measurement the tool 2 is returned at least into the feed position assumed by it before the interruption and the machining operation is continued, and that subsequently within a period of time the tool is continuously fed for compensating the wear measured.

Abstract: In-process non-contact measurement systems and methods for automated lapping systems are disclosed. In an embodiment, a moveable frame can be controllably positioned proximate to a lapped work product. A control component can provide first control signals to control a movement of the moveable frame relative to the lapped work product. A non-contact measuring device can be coupled to the moveable frame measures a surface of the lapped work product and can transmit measurement data of the surface of the lapped work product to the control component. The control component can further provide second control signals to control a movement of the non-contact measuring device relative to the moveable frame.

Abstract: Methods and apparatus to implement techniques for monitoring polishing a substrate. Two or more data points are acquired, where each data point has a value affected by features inside a sensing region of a sensor and corresponds to a relative position of the substrate and the sensor as the sensing region traverses through the substrate. A set of reference points is used to modify the acquired data points. The modification compensates for distortions in the acquired data points caused by the sensing region traversing through the substrate. Based on the modified data points, a local property of the substrate is evaluated to monitor polishing.

Abstract: A machine tool (10) has a Z table (18) sliding in the Z direction in a horizontal plane, a support body (22) provided on the Z table (18) and sliding in the vertical direction, a rotation arm (32) supported at the support body (22) and endlessly rotatable in a vertical plane facing work (W), an arm motor (34) for rotating the rotation arm (32), a processing spindle (36) rotatably supported and placed at a position of a distance R from the center C of rotation of the rotation arm (32), and a spindle motor (38) for rotating the processing spindle (36).

Abstract: There is described a system and method for detecting a geometry of a workpiece for the purposes of processing the workpiece. In order to simplify optimization of a manufacturing strategy for processing a workpiece, the system has at least one camera for producing at least one image of the workpiece before a processing step, a memory area for desired geometry values the workpiece should have after the processing step, determination means for determining workpiece geometry values the workpiece has before the processing step on the basis of the at least one image, and calculating means for calculating differential geometry values describing a difference between the workpiece geometry values and the desired geometry values.

Abstract: A machine tool for chip removing machining operations on workpieces using tools comprises a tool checking device for checking a tool of the machine tool as regards damage or fracture by means of a sensor. There is a provision on the machine tool such that sensor is a contact-free sensor arranged on a movably disposed sensor holder, that the tool checking device possesses a drive for the sensor holder to shift the sensor toward and away from the tool to be checked and that the machine tool or the tool checking device possesses a control module for the control of the drive to perform a measuring excursion so that the drive shifts the sensor for a measurement of a tool to be checked for a measurement toward the tool and after the measurement shifts it away from the tool.

Abstract: By determining a metric for tool utilization in a manufacturing environment on the basis of tool-specific characteristics and a probability distribution for the transport capability of an automated material handling system, the influence of the transport system on the tool performance may be effectively determined. For this purpose, an average delay caused by the automated material handling system may be iteratively calculated on the basis of a respective required carrier exchange time, which depends on tool- and process-specific characteristics. From the corresponding average delay, an appropriate metric, such as a utilization loss factor, may be determined.

Abstract: A process planning apparatus extracts a region to be machined based on the difference of the shape data before and after machining of the workpiece, replaces the extracted region into combinations of the predetermined machining features, allocates a predetermined fixed cycle to each of the replaced machining features, and applies an assessment function relating to a machining time and a life of the end mill to each of the combinations of the machining features to which the fixed cycles are respectively allocated, thereby selecting a group of the fixed cycles which makes an assessment value obtained by the assessment function optimum as the optimal process. By these steps, it becomes possible to design the process for causing the NC machine employing end mills as a cutting tool to perform a predetermined machining of a workpiece without relying on the experience of the designer, and without necessitating complicated work.

Abstract: A numeric control device with a simple structure of a machine tool, capable of detecting a defect of a spindle or a spindle motor of the machine tool and automatically informing an operator of the defect. A numeric control device has a first storing part, a calculating part and a judging part. The first storing part stores master vibration data of the spindle or the spindle motor, the master vibration data being prepared by associating data of the vibration outputted from a vibration sensor arranged on the spindle or the spindle motor with an operation pattern for detecting the defect of the spindle or the spindle motor. When a difference value between the master vibration data and newly obtained data exceeds a predetermined reference value, the judging part determines that the new data is abnormal.

Abstract: The invention is a method of creating greater accuracies for wear compensation of a finishing tool during the finishing of workpieces, in which a reference surface is ablated by initially traversing the finishing tool over the reference surface and determining the actual wear of the finishing tool as a result of this initial feed motion of the finishing tool controlled by an NC feed program of an NC machine. The actual measured wear of the finishing tool as a result of the initial traversing feed motion over the reference surface is compared to a known empirical wear trend line for the workpiece and the feed motion of the NC feed program for the next workpiece is recalculated as a function of the comparative actual wear of the finish tool with respect to the known empirical wear trend line.

Abstract: Various embodiments include a method for providing instructions to a process tool. The method includes emitting an incident light beam at a substrate, receiving a reflected light beam from the substrate and determining a spectrum of the reflected light beam. The method further includes determining a first property of a first layer of the substrate and a second property of a second layer of the substrate, based on the spectrum determination. The method further includes comparing the first property of the first layer to a first reference property and comparing the second property of the second layer to a second reference property. The method further includes determining the instructions based on the first property comparison and the second property comparison; and providing the instructions to the process tool.

Abstract: The method for detecting any clamping malfunction of the work within the machine tool which clamps both ends of the work with clamping mechanisms 23, 24 of a pair of headstocks 19, 29, and processes the work by spinning the work through synchronous rotation of main spindles 21, 22 of the pair of headstocks by servomotors 33, 34, wherein, after clamping the both ends of the work 27 with the clamping mechanisms 23, 24 of the respective headstocks 19, 20, and while both the servomotors 33, 34 of the headstocks are in a servo-ON state, a command for a minute angle ? rotation is given to the servomotor 34 of only one of the headstocks, and at this point, any malfunction in clamping is determined when a current or torque generated within the servomotor of one or the other of the headstocks is smaller than a predetermined value.

Abstract: A method for establishing a dynamic maintenance scheduling tool for a specific part of a machinery based on condensed prior knowledge of the part of the machinery in a population of machineries. The scheduling tool is in turn used in a method for establishing a dynamic maintenance schedule for a specific part of a specific machinery, wherein parameters related to the usage, including relevant parameters representing factors influencing the lifetime of the specific parts, are utilized as input data to the dynamic maintenance scheduling tool for the specific part of the machinery, whereupon a dynamic maintenance schedule for the specific part of the specific machinery is achieved as output data from the scheduling tool. The method is in particular dedicated to industrial robot systems.

Abstract: A system for detecting the presence of a broken tool in a manufacturing line uses a robot device separately positioned along the line. The robot unit has a plurality of probes which are inserted into openings in the item to detect the presence of a broken tool. The robot mounted detector replaces broken tool detectors mounted on index arms that support a plurality of gangheads that perform the machining operations on the item, allowing increased flexibility in the allocation and positioning the gangheads, and providing more effective broken tool detection.

Abstract: After a thermal displacement correcting program has started, a temperature is measured with a temperature sensor in S1, then when a rotational speed of a spindle is changed during the measurement (S2), a counter starts (S3). Then in S4, from a preset relationship between the rotational speed of the spindle and a setting-equivalent heat value, a correction factor that is a difference in setting-equivalent heat value between before and after the change in rotational speed of the spindle is calculated. Subsequently, in S5, a temperature-equivalent heat value is calculated, and then in S6, a compensation amount is calculated from the correction factor and a time elapsed after the change in rotational speed of the spindle. In S7, an equivalent heat value for compensating a dead time is obtained based on the sum of them S8, an estimated calculation for thermal displacement conversion is performed, and a correction process by an NC unit is performed in S9.

Abstract: A riveting system is operable to join two or more workplaces with a rivet. In another aspect of the present invention, a self-piercing rivet is employed. Still another aspect of the present invention employs an electronic control unit and one or more sensors to determine a riveting characteristic and/or an actuator characteristic.

Abstract: A method for determining a polishing endpoint includes obtaining spectra from different zones on a substrate during different times in a polishing sequence, matching the spectra with indexes in a library and using the indexes to determining a polishing rate for each of the different zones from the indexes. An adjusted polishing rate can be determined for one of the zones, which causes the substrate to have a desired profile when the polishing end time is reached.

Abstract: Measurement data collected within a measurement frame of reference is fitted to geometric tolerance zones having regard for the uncertainties of the measurement. Geometric freedoms for fitting the measurement data are exploited to fit uncertainty zones associated with the measurement data within the tolerance zones. Typically, the measurement data is multidimensional and the uncertainty zones have different sizes.

Abstract: A system for performing dimension checkings of mechanical pieces is provided including a contact detecting probe with wireless transmission, for example through a single radiofrequency two-way communication link, to and from a base station connected to an interface unit. The probe includes a logic unit and a memory unit in which reside the values of some operation parameters, for example the transmission frequency and/or the activation mode of the probe. The values of the operation parameters can be modified in a programming phase, according to a method that foresees the wireless transmission of control signals from a manually operated control device—to the probe, for updating of the values among the selectable values of a sequence residing in the probe, and the acquisition of the current value.

Abstract: A method for correcting surface and near surface defects in metal components in which the component is first inspected to identify both the site and size of a component defect. Thereafter, it is determined if the defect is correctable by friction stir processing and, if so, the defect is corrected by performing friction stir processing on the component at the site of the defect. Optionally, one of several different sized friction stir processing tools is selected as a function of the size of the defect.

Abstract: A system for remote maintenance for a machine. The system includes a database having information for a plurality of machines. A customer accesses the database in order to receive an illustration of at least one of said plurality of machines. Thereafter, the customer identifies a portion of the machine illustration and is provided with ordering data for that portion of the machine (e.g., a machine component, sub-component or part). Using this ordering data the customer can order parts of its machine. Additionally, using an imaging device, such as a digital camera, the customer can transmit images of the machine to an off-site expert and receive real-time information related to the assembly, installation, repair or maintenance of the machine.

Abstract: An interactive method and apparatus are disclosed through which a fluid purification system operator inputs the system's parameters and the method then identifies one or more fluid purification equipment packages which will be optimized at the component level to the operator's specific requirements. The invention includes a relational database containing data on fluid purification equipment, the components thereof and ancillary equipment, and associated operational software to which the operator gains access through a computer and which then presents to the operator a series of questions relevant to gas purification equipment and system requirements. The questions are such that the responses elicited from the operator for each question determine what the successive questions will be and what optimal components will be identified. The software and databases may be in memory on the computer, embodied on CDs or DVDs run by the computer, or accessed through the Internet.

Abstract: A machining information generating apparatus includes shape analyzing unit that obtains CAD data, searches a shape database of machining profile information for necessary information based on the CAD data, and performs a shape analysis, thereby creating an equation model for an uncut amount along an intended machining profile based on an uncut amount result from a simulation of a tool and data about the machining profile.

Abstract: A rivet setting tool is provided to provide improved monitoring of riveted connections during rivet setting. The rivet setting tool includes a head piece for holding a rivet, a device for gripping a rivet pin, a pulling apparatus connected to the device for gripping a rivet pin, and a device for measuring the tension of the pulling apparatus. Using the setting implement according to the invention, a cause of a fault can be determined by means of a comparison between measured values and stored values.

Abstract: A method and apparatus for a robotic machining process that gives a controlled removal rate of material from a workpiece when an object, tool or workpiece, held by a robot is brought into contact with a stationary object, workpiece or tool. A signal indicative of the force applied by the held object t the stationary object is used to control the rate at which the robot moves the held object in relation to the stationary object. Associated with the robot is a controller that has tunable proportional and integral gains. The controller determines a command for the feed rate of the tool when the tool engages the workpiece. In response to that command, the proportional and integral gains are tuned to obtain a cutting force to be applied to the workpiece when the tool engages the workpiece that is substantially the same as a desired cutting force.

Abstract: A system includes a process tool for processing a workpiece, a process controller, and a fault monitor. The process controller is configured to determine a control action for updating an operating recipe of the process tool. The fault monitor is configured to determine at least one fault detection threshold based on the control action. A method includes determining a control action for updating an operating recipe of a process tool and determining at least one fault detection threshold based on the control action.

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: A wear amount of a working tool T during the machining of a workpiece is estimated during the machining, and a positional command generated in accordance with a predetermined machining program is sequentially corrected during the machining based on the estimated wear amount of the working tool T. The workpiece W is machined in accordance with the corrected positional command. Also, the wear amount of the working tool T upon the interruption of the machining operation is calculated, and the positional command generated in accordance with the predetermined machining program is corrected based on the calculated wear amount of the working tool so that a tool edge position of the working tool T upon the interruption of the machining operation coincides with the tool edge position of the working tool T upon the restart of the machining operation when the machining operation is restarted at a position where the machining operation has been interrupted.

Abstract: The present invention comprises systems and methods for providing electronic quality control in a process for applying a polyurethane to a substrate. One aspect of the present invention includes a computer-implemented method for providing electronic quality control during manufacturing of a polyurethane coated article. The method can include providing a user interface for a user to input at least one operating characteristic associated with a process for manufacturing a polyurethane coated article. Furthermore, the method can include receiving a selection of at least one operating characteristic from the user, and receiving at least one condition associated with the operating characteristic. Moreover, the method can include monitoring a process for manufacturing a polyurethane coated article, wherein a change to the operating characteristic can be detected. The method can also include generating a notification if the at least one condition is detected.

Abstract: In a monitoring system for the process-accompanying monitoring of machine tool components, it is provided that the same monitoring system, apart from the detection of at least one of the above mentioned conditions in tools, workpieces or processes, is used in other monitoring stages—which at times when no treatment process occurs (i.e. when no tool, workpiece or process monitoring has to occur) are predetermined by the machine control—to perform a detection, monitoring or well-aimed examination of faulty conditions on components of machine tools, such as e.g. damage or wear on the feed slides, on the tool or workpiece spindles or the imbalance on tool or workpiece spindles or on drilling or milling tools.

Abstract: A method for the preparation, editing and maintenance of tool data sets for machining processes in an NC control system has at least one tool data organization that is separate from the control and is stored in the memory of an ADP system. The tool data organization has tool data sets for tools that for each of the tools to be used has the space for static and dynamic data. The tool data organization has separate list data sets of a machining process that can each contain a reference to the associated tool data set, and the required list data sets are taken over and stored in memory, together with the associated tool data sets, for process execution in the NC data processing unit. At least the dynamic data of the tool data sets can be updated in accordance with the current NC machining processes.

Abstract: Systems and methods are disclosed for controlling, diagnosing and prognosing the health of a motorized system. The systems may comprise a diagnostics system, a prognostic system and a controller, wherein the diagnostics system and/or prognostic system employs a neural network, an expert system, and/or a data fusion component in order to assess and/or prognose the health of the motorized system according to one or more attributes associated therewith. The controller may operate the motorized system in accordance with a setpoint and/or a diagnostics signal from the diagnostics system and/or prognostic information.

Abstract: A system and method for monitoring freeplay within an actuator is provided. In accordance with various embodiments, the method includes collecting a plurality of actuator parameter data sets during a predetermined period. During the predetermined time period the actuator drive motor is commanded to extend and retract an actuator output ram operably connected to a movable component of a structural system such as a mobile platform. The method additionally includes selectively isolating various sets of the plurality of actuator parameter data sets that meet specific predetermined criterion. Furthermore, the method includes computing an amount of freeplay value within the actuator based on the isolated actuator parameter data sets.

Abstract: A method of determining a tool geometry and tool orientation for any prescribed path along a workpiece of a cutting tool is described. A parameter set is provided, where parameters of the parameter set include tool geometry and tool orientation relative to a surface of the workpiece. Values of the parameters in the parameter set are determined such that no local interference or global interference occurs, where local interference occurs when a portion of the tool immediately adjacent a cutting edge of the tool contacts a sidewall of a groove already cut by the cutting edge, and global interference occurs when a portion of the tool away from the cutting edge contacts a sidewall of a groove already cut by the cutting edge.

Abstract: The invention describes a method for the inspection of machining tools used in computational numerical control (CNC) machining centers. The invention will observe a machining tool immediately after use to determine if it has been damaged. The invention is based on a machine vision technology that uses one or more image sensors to acquire, locate and compare the tool to a good model. The inspection equipment is designed for implementation in the CNC automatic tool changing system and will alert the operator that tool has been damaged before the next operation. This immediate response of the invention will contain defect components and prevent damage to subsequent components. With the addition of an infrared image sensor the invention is capable of detecting worn or dull tools that may damage a component due to excessive heating.

Abstract: Methods system and apparatus, including computer program products, for monitoring polishing a substrate. A polishing pad mounted on a platen is rotated at a first rotation rate, and a carrier head is rotated at a second rotation rate that is different from the first rotation rate. The carrier head carries a substrate and presses the substrate against the polishing pad. A sequence of data traces is acquired using a sensor mounted in the platen, wherein each data trace results from a separate scan with the sensor along a path across the substrate, and wherein the first and second rotation rates are such that a plurality of paths corresponding to a predetermined number of consecutive scans are substantially evenly radially distributed across the substrate.

Abstract: A method and system (1) for utilizing shaped orifices (e.g., sonic and simple orifices, and divergent nozzles) in the gas inject system (20) as part of a plasma process system. By utilizing the shaped orifices, directionality of gas flow (25) can be improved. This improvement is especially beneficial in high aspect ratio processing.

Abstract: In the method, a tool is tested for an aligning fit or an imbalance in a tool spindle. The tool spindle is set into rotation. A light beam is used to check whether the tool wobbles. The tool spindle and the light beam are moved relative to one another until the light beam impinges on the area covered by the wobbling movement and a received signal generated from the light beam has an intermittent signal path for the first time. The then prevailing relative position between the tool spindle and the light beam is evaluated in respect of a non-aligning fit of the tool or in respect of a tool imbalance.

Abstract: When a trouble occurs in a machine tool (20) sold by a machine tool manufacturer to a customer, a failure analysis apparatus (11) installed in a service center (10) of the machine tool manufacturer remotely controls the machine tool (20) to obtain operation information or alarm information of the machine tool (20) and performs failure analysis based on such information. In the service center (10), a plurality of failure analysis apparatuses (11) comprising personal computers, and a server (12) which are connected to the failure analysis apparatuses (11) for communication and to which a global IP address for the exclusive use is allocated are installed. Machine tools (20) of customers are connectable to the server (12) via the Internet (30).

Abstract: A system and method are provided for real-time measurement of tool forces. A relationship between a motor characteristic and tool forces is determined by first directly measuring tool forces for a standard tool, work piece, and part program in a central facility. A force profile indicative of the tool forces and the standard tool, work piece, and part program are provided to a user at a user facility. The motor characteristic for a CNC machine at the user facility is then measured for the standard tool, work piece, and part program. Based on the force profile determined at the central facility, the relationship between the motor characteristic and tool forces is determined. Thereafter, the motor characteristic of the CNC machine is measured for a desired tool, work piece, and part program and converted to tool forces using the relationship between the motor characteristic and tool forces.