System for creating command and control signals for a complete operating cycle of a robot manipulator device of a sheet metal bending installation by simulating the operating environment

• US 5,642,291 A
• Filed: 12/26/1995
• Issued: 06/24/1997
• Est. Priority Date: 12/22/1989
• Status: Expired due to Fees

• Current Assignee: Amada Company Limited of Japan
• Original Assignee: Amada Company Limited of Japan
• Inventors: Prada, Marco, Prunotto, Gianpaolo
• Primary Examiner(s): Gordon, Paul P.
• Application Number:
  US08/578,383
• Time in Patent Office: 546 Days
• Field of Search: 364/188, 364/191, 364/468.01, 364/468.24, 364/472.01, 364/476.01, 72/7, 72/8, 72/22, 72/23, 72/422
• US Class Current: 700/145
• CPC Class Codes: B25J 9/1671 characterised by simulation, either to verify existing program or to create and verify new program, CAD/CAM oriented, graphic oriented programming systems
• CPC Class Codes: G05B 2219/40054 Supply sheet to bending machine
• CPC Class Codes: G05B 2219/40421 Motion planning for manipulator handling sheet metal profiles

Abstract

A system for the creation of commands and control signals for a complete operating cycle of a robot manipulator device of a sheet metal bending installation by simulating the operating environment, in which various parts of the sheet metal bending installation are presented to the user on a video display in a simplified form and on a reduced scale. The video display and a keyboard are connected to a central processor unit and permit the creation of a complete sequence of signals usable for controlling the operation of the bending installation, and permits the presentation of the simulation of the movement of the parts of the installation on the video.

Claims

1. A system for creating control signals for a complete operating cycle of a robot manipulator device of a sheet metal bending installation, said system comprising:

communication means for communicating with an operator, said communication means being connected to a central processor unit, said central processor unit producing a video simulation of said robot manipulator device including a video representation of a relative positioning and continuous movements of working parts of said bending installation and of a workpiece, and creating said control signals;

wherein said working parts comprise a pair of dies and a head and pincers of said robot manipulator;

said central processor unit including first means for presenting, by means of said communication means, data relating to said working parts of said sheet metal bending installation and the workpiece;

said central processor unit further including second means operable to permit, by means of said communication means, introduction and/or modification of said data into said central processor unit; and

said second means including means operable to permit the introduction and/or modification of said data relating to dimensional information on at least one working part of said bending installation;

said central processor unit further including third means operable to permit the creation and/or modification of control signals for bending cycles;

said third means further comprising means for displaying continuous movements of said video representation of said workpiece and for displaying a video representation of interaction between said workpiece and said working parts, said video representation responsive to said data related to dimensional information.

2. The system according to claim 1, wherein said communication means includes a keyboard and a video display.

3. The system according to claim 1, further comprising means for transferring said control signals from said central processor unit to a control unit of said installation.

4. The system according to claim 1, wherein said data relating to dimensional information comprises information on at least a main gripper member of said manipulator device, a rear position sensor, a pair of dies, a magazine for loading, and a magazine for discharging a metal sheet.

5. The system according to claim 1, wherein said central processor unit further comprises third means operable to command a presentation on a display device of the visual representation which comprises a plurality of working parts of the sheet metal bending installation and the workpiece, the visual representation including both a configuration and a movement of the working parts and the workpiece.

6. A system for creating control signals for a complete operating cycle of a robot manipulator device of a sheet metal bending installation, said system comprising:

communication means for communicating with an operator, said communication means being connected to a central processor unit for producing a video simulation of said robot manipulator device and for creating said control signals, said video simulation including a video representation of a configuration and continuous movements of working parts of said bending installation and of a workpiece;

wherein said working parts comprise a pair of dies and a head and pincers of said robot manipulator;

said central processor unit including first means for presenting, by means of said communication means, data relating to said working parts of said sheet metal bending installation and said workpiece;

said central processor unit further including second means operable to permit, by means of said communication means, introduction and/or modification of said data into said central processor unit;

said second means including means operable to permit the introduction and/or modification of said data relating to dimensional information on said workpiece which is to be bent;

said central processor unit further including third means operable to permit the creation and/or modification of control signals for bending cycles; and

said third means further comprising means for displaying a continuous real-time video representation of said operating cycle, said means for displaying include means for imparting movement to said video representation of said working parts corresponding to said control signals, wherein said video representation of the working parts contact said video representation of the workpiece, and said means for displaying further including means for bending said video representation of said workpiece in accordance with said data relating to dimensional information.

7. A system for creating control signals for a complete operating cycle of a robot manipulator device of a sheet metal bending installation, said system comprising:

communication means for communicating with an operator, said communication means being connected to a central processor unit for producing a video simulation of said robot manipulator device and for creating said control signals, said video simulation including a video representation of a configuration and continuous movements of working parts of said bending installation and of a workpiece;

wherein said working parts comprise a pair of dies and a head and pincers of said robot manipulator;

said central processor unit including first means for presenting, by means of said communication means, data relating to said working parts of said sheet metal bending installation and said workpiece;

said central processor unit further including second means operable to permit, by means of said communication means, introduction and/or modification of said data into said central processor unit;

said second means including means operable to permit the introduction and/or modification of said data relating to dimensional information on bends which are to be formed on said workpiece;

said central processor unit further including third means operable to permit the creation and/or modification of control signals for bending cycles; and

said third means further includes display means for displaying movement of and interaction between said video representation of said workpiece and said video representation of said working parts and for movement of said video representation of said working parts in contacting and bending said video representation of said workpiece.

8. A system for creating control signals for a complete operating cycle of a robot manipulator device of a sheet metal bending installation, said system comprising:

communication means for communicating with an operator, said communication means being connected to a central processor unit for producing a working simulation of said robot manipulator device and for creating said control signals, said working simulation including a visual representation of a configuration and continuous movements of working parts of said bending installation and of a workpiece;

wherein said working parts comprise a pair of dies and a head and pincers of said robot manipulator;

said central processor unit including first means for presenting, by means of said communication means, data relating to working parts of said sheet metal bending installation and said workpiece;

said central processor unit further including second means operable to permit, by means of said communication means, introduction and/or modification of said data into said central processor unit; and

said second means being operable to command presentation, by said communication means, of a configuration of at least one of said working parts of said sheet metal bending installation and of said workpiece.

9. A system for creating control signals for a complete operating cycle of a robot manipulator device of a sheet metal bending installation, said system comprising:

communication means for communicating with an operator, said communication means being connected to a central processor unit for producing a working simulation of said robot manipulator device and for creating said control signals, said working simulation including a visual representation of a configuration and continuous movements of working parts of said bending installation and of a workpiece;

wherein said working parts comprise a pair of dies and a head and pincers of said robot manipulator;

said central processor unit including third means operable to permit, by said communication means, creation and/or modification of said control signals for said operating cycle in said central processor unit; and

said third means including means operable to permit creation and/or modification of said control signals for controlling phases of said operating cycle.

10. The system according to claim 9, wherein said means operable to permit creation and/or modification of said control signals for controlling phases of said operating cycle are activated by elements in said communication means for commanding movement of working parts of said installation.

11. The system according to claim 9, wherein said means operable to permit creation and/or modification of said control signals for controlling phases of said operating cycle are activated by elements in said communication means selectable by an operator and operable to create a complete sequence of said signals for controlling the phases.

12. The system according to claim 9, wherein said means operable to permit creation and/or modification of said control signals for controlling the phases of said operating cycle act to command presentation, by said communication means, of a configuration of working parts of said installation, and a workpiece of predetermined form, relating to a phase selected for the creation and/or modification of said control signals.

13. The system according to claim 12, wherein said means operable to permit creation and/or modification of said control signals for controlling phases of said operating cycle act to command the presentation, by said communication means, of the configuration of said working parts of said installation and said workpiece of predetermined form, relating to bending phases preceding and following the selected phase.

14. A system for creating control signals for a complete operating cycle of a robot manipulator device of a sheet metal bending installation, said system comprising:

communication means for communicating with an operator, said communication means being connected to a central processor unit for producing a working simulation of said robot manipulator device and for creating said control signals;

said central processor unit including third means operable to permit, by said communication means, creation and/or modification of said control signals for said operating cycle in said central processor unit; and

said third means including means operable to command a visual presentation, by said communication means, of a configuration of working parts of the installation and elements of said communication means, operable to permit creation and/or modification of said control signals for controlling phases of the operating cycle;

wherein said working parts comprise the pair of dies and the head and pincers of said robot manipulator.

15. A system for creating control signals for a complete operating cycle of a robot manipulator device of a sheet metal bending installation, said system comprising:

communication means for communicating with an operator, said communication means being connected to a central processor unit for producing a working simulation of said robot manipulator device and for creating said control signals;

said central processor unit including third means operable to permit, by said communication means, creation and/or modification of said control signals for said operating cycle in said central processor unit;

said third means including means operable to define control signals for a phase of withdrawing a metal sheet workpiece from a magazine for loading of said installation by means of said manipulator device, means operable to define control signals for an execution of bending phases of said operating cycle on said workpiece in dependence on data introduced by said communication means, and means operable to define control signals for controlling a phase of discharging said workpiece onto a magazine for discharging from said installation, said means operable to define control signals for an execution of bending phases on said workpiece being adapted to define insertion of one side of said workpiece between a pair of dies of the installation, detection of positioning of said one side between said pair of dies by a pair of sensors located to the rear of said dies, movement of said pair of dies to form a bend, extraction of said one side of a bent workpiece from a region of said dies, and displacement of a head of said manipulator device to present the workpiece between said pair of dies in a position corresponding to forming of a subsequent bend.

16. A system for creating control signals for a complete operating cycle of a robot manipulator device of a sheet metal bending installation, said system comprising:

communication means for communicating with an operator, said communication means being connected to a central processor unit for producing a working simulation of said robot manipulator device and for creating said control signals, said working simulation including a visual representation of a configuration and continuous movements of working parts of said bending installation and of a workpiece;

wherein said working parts comprise a pair of dies and a head and pincers of said robot manipulator;

said central processor unit including third means operable to permit, by said communication means, creation and/or modification of said control signals for said operating cycle in said central processor unit; and

said central processor unit including fourth means operable to command a presentation by said communication means of a configuration of working parts of said installation, an initial form of said workpiece which is to be bent, and successive bending phases of said operating cycle to achieve a desired object in dependence on said control signals determined by said third means.

17. A system for creating control signals for a complete operating cycle of a robot manipulator device of a sheet metal bending installation, said system comprising:

communication means for communicating with an operator, said communication means being connected to a central processor unit for producing a video simulation of said robot manipulator device and for creating said control signals, said video simulation including a video representation of a configuration and continuous movements of working parts of said bending installation and of a workpiece;

wherein said working parts comprise a pair of dies and a head and pincers of said robot manipulator;

said central processor unit including third means operable to permit, by said communication means, creation and/or modification of said control signals for said operating cycle in said central processor unit;

said third means including means adapted to define functions for said control signals defined by said third means operable to permit creation and/or modification of said control signals for controlling phases of said operating cycle; and

said communication means further comprising means for displaying a continuous real-time video representation of said bending program including a video representation of said working parts in motions corresponding to said control signals, wherein said video representation of working parts contact said video representation of the workpiece, and said display means further include means for bending said video representation of said workpiece in a manner consistent with said control signals.

18. The system according to claim 17, said means adapted to define functions for said control signals comprising means acting automatically to determine a preferable grip position of a metal sheet by said manipulator device.

19. The system according to claim 17, said means adapted to define functions for said control signals including means, acting respectively to activate or deactivate a detection, with automatic indication of possible interference in movement of working parts of said installation and a metal sheet.

20. The system according to claim 17, said means adapted to define functions for said control signals including means acting to modify a dimensional scale of presentation by said communication means of a configuration of working parts of said installation and a metal sheet.

21. The system according to claim 17, said means adapted to define functions for said control signals including means acting to modify a sequence of presentation by said communication means of a configuration of working parts of said installation, said manipulator device, and a metal sheet, created by means of said third means.

22. A system for creating control signals for an operating cycle of a sheet metal bending installation that has working parts including a bending press and a robot manipulator;

wherein said working parts comprise a pair of dies and a head and pincers of said robot manipulator;

the bending press having a pair of dies relatively movable toward and away from each other for bending a sheet metal workpiece disposed between the pair of dies, the robot manipulator having a head movable in three-dimensional space and a pair of pincers provided on the head, the system comprising;

a display device;

an input device for inputting parameters concerning the bending press, the robot manipulator and the sheet metal workpiece, the parameters including shapes and dimensions of the dies, dimensions of the sheet metal workpiece, and dimensions of the pincers, the input device further being adapted to input instructions for moving the pair of dies of the press, the head, and the pincers of the robot manipulator;

a central processor unit including means operable to command a presentation on said display device, of the relative configuration of a plurality of working parts of the installation and of the sheet metal workpiece in accordance with said parameters that are input through said input device, said presentation command means being further operable to command a presentation on said display device of continuous movements of said plurality of working parts of the installation in accordance with the instructions input through said input device.

23. The system according to claim 22, wherein said presentation command means include means for detecting possible interference in movement of said plurality of working parts of the installation.

24. The system according to claim 22, wherein the installation comprises two robot manipulators.

25. A system for creating control signals for an operating cycle of a robot manipulator device of a sheet metal bending installation, said system comprising:

a display unit;

a central processor unit connected to said display unit;

said central processor unit permitting creation and/or modification of said control signals for said operating cycle;

said central processor unit producing a first set of signals for controlling said robot manipulator in a number of stages of said operating cycle and producing a second set of signals for presenting, on said display unit, a visual representation of a configuration and movement of working parts of said robot manipulator device and of a workpiece based on said first set of signals; and

said central processor unit further producing an alarm signal when interference occurs between at least two of said robot manipulator device, said working parts, and said workpiece.

26. A system according to claim 25, said alarm signal comprising an acoustic tone.

27. A system for creating control signals for an operating cycle of a robot manipulator device of a sheet metal bending installation, said system comprising:

a display unit;

a central processor unit connected to said display unit;

said central processor unit permitting the creation and/or modification of said control signals for said operating cycle;

said central processor unit producing a first set of signals for controlling said robot manipulator in a number of stages of said operating cycle and producing a second set of signals for presenting, on said display unit, a visual representation of a configuration and movement of working parts of said robot manipulator device and of a workpiece based on said first set of signals; and

said central processor unit further producing an aid signal for showing a preferable grip position on said workpiece by said robot manipulator device.

28. A system for creating control signals for an operating cycle of a robot manipulator device of a sheet metal bending installation, said system comprising:

a display unit;

a central processor unit connected to said display unit;

said central processor unit producing a first set of signals for controlling said robot manipulator in a number of stages of said operating cycle and producing a second set of signals for presenting, on said display unit, a visual representation of a configuration and a movement of working parts of said robot manipulator device and of a workpiece based on said first set of signals; and

said central processor unit further producing a control signal for enlarging a detail of a portion of said robot manipulator device on said display unit.

29. A method of creating control signals for a complete operating cycle of a sheet metal bending installation that includes a bending press, a robot manipulator device positioned in front of the bending press, a magazine with a loader device and discharge table, and communication means, for communicating with an operator, coupled to a central processing unit, the central processing unit for producing a working simulation of the bending press and the robot manipulator device and creating the control signals,

the method comprising the steps of:

(a) displaying a video representation of a cross-section of the bending installation and a sheet metal;

(b) at least one of creating and modifying signals for controlling a bending phase in which bending is performed on the sheet metal by the bending press;

(c) displaying a video representation of movements of the bending press, of the robot manipulator device, and of the sheet metal during the bending phase defined in step (b);

(d) checking whether at least one of the sheet metal and a movable part of the robot manipulator device interferes with a fixed structure of the bending installation; and

(e) repeating steps (b), (c), and (d) to create the complete operating cycle,

wherein the step of checking for interference of at least one of the sheet metal and the movable part of the robot manipulator device with the fixed structure at step (d) occurs immediately after the signals for controlling the bending phase are created at step (b).