Apparatus and method for managing distributing design and manufacturing information throughout a sheet metal production facility

• US 5,864,482 A
• Filed: 07/31/1996
• Issued: 01/26/1999
• Est. Priority Date: 05/06/1996
• Status: Expired due to Fees

• Current Assignee: Amada Company Limited
• Original Assignee: Amadasoft America, Inc.
• Inventors: Sakai, Satoshi, Hazama, Kensuke, Hwang, Yearn-Tzuo
• Primary Examiner(s): Black, Thomas G.
• Assistant Examiner(s): Alam, Hosain T.
• Application Number:
  US08/690,084
• Time in Patent Office: 909 Days
• Field of Search: 364/468.01, 364/468.04, 364/468.14, 364/468.17, 364/368.01, 364/368.04, 707/502, 345/435, 705/29
• US Class Current: 700/95
• CPC Class Codes: G05B 19/4097 characterised by using design data to control NC machines, e.g. CAD/CAM G05B19/4093 takes precedence
• CPC Class Codes: G05B 19/4181 characterised by direct numerical control [DNC]
• CPC Class Codes: G06F 16/00 Information retrieval; Database structures therefor; File system structures therefor
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06T 19/00 Manipulating 3D models or images for computer graphics
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

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.

Claims

1. An intelligent facility for producing parts, said facility comprising:

a database that stores job information relating to the production of at least one part previously produced by said facility, said previous job information for each said previously produced part including previous design data relating to part design features of each said previously produced part;

a system for receiving current job information relating to a current part to be produced by said facility in response to a current job request, said current job information including proposed design data relating to proposed part design features of said current part; and

a system for searching said database to compare said previous job information design data stored with respect to each said previously produced part to said current job information design data, and to determine if said previous job information design data and said current job information design data have at least a predetermined degree of similarity such that a plan can be developed for producing a current part, in response to said current job request, which utilizes at least a part of said previous job information.

2. An intelligent facility according to claim 1, said previous design data and said proposed design data including part design features, said searching system comparing said previous job information design features and said current job information design features to determine whether each said previously produced part includes similar part design features to that of said current part.

3. An intelligent facility according to claim 2, said previous design data and said proposed design data further including part topology data.

4. An intelligent facility according to claim 3, wherein each said previously produced part and said current part comprise sheet metal parts.

5. An intelligent facility according to claim 1, said searching system having the capability to compare said previous job information design features and said current job information design features to determine whether each said previously produced part includes identical, similar, or different features to that of said current part.

6. An intelligent facility according to claim 1, wherein each said previously produced part and said current part comprise sheet metal parts.

7. An intelligent facility according to claim 1, further comprising a system for retrieving, from said database, previous job information determined to have said predetermined degree of similarity, and a system for distributing said retrieved previous job information to various locations throughout said facility so that a plan for producing said current part may be developed based on said retrieved previous job information.

8. An intelligent facility according to claim 7, said distributing system comprising a communications network connected to said database and a plurality of station modules provided throughout said facility, each of said station modules being connected to said communication network to receive said retrieved previous job information from said database.

9. An intelligent facility according to claim 8, each of said station modules comprising a network interface device for interfacing with said communication network and a display device for displaying said retrieved previous job information.

10. An intelligent facility according to claim 8, further comprising a server module connected to said communication network, said server module comprising an input device for entering said current job information and a network interface device for transferring said current job information, entered by said input device, to said database through said communication network.

11. An intelligent facility according to claim 7, wherein each said previously produced part and said current part comprise sheet metal parts, said retrieved previous job information comprising bend sequence and tooling information for producing said previously produced part determined to have said predetermined degree of similarity to said current part.

12. An intelligent facility according to claim 8, wherein said facility locations include a bending station, said bending station comprising one of said station modules and a bending machine for bending sheet metal parts based on a bending code, said retrieved previous job information further including a predetermined bending code for producing, with said bending machine, at least one of said previously produced parts determined to have said predetermined degree of similarity to said current part.

13. An intelligent facility according to claim 9, wherein each said previously produced part and said current part comprise sheet metal parts, said retrieved previous job information comprising bend model data for rendering at least one displayed image of each said previously produced part, said display device of each of said station modules rendering said image based on said bend model data to facilitate the development of said plan for producing said current part.

14. An intelligent facility according to claim 13, said bend model data comprising data for displaying a plurality of displayed images of said previously produced part, including a 2-D image and a 3-D image of said previously produced part, said display devices of each of said station modules being located throughout said facility and being capable of selectively rendering said 2-D image or said 3-D image of said previously produced part.

15. An intelligent facility according to claim 1, wherein said previous job information further comprise manufacturing information relating to each said previously produced part, and wherein said current job information further comprises proposed manufacturing information relating to said current part, said searching system comprising means for comparing said manufacturing information of said previous job information and said manufacturing information of said current job information to determine whether said predetermined degree of similarity exists such that said plan can be developed for producing said current part based on at least a part of said previous job information.

16. An intelligent facility according to claim 15, wherein said manufacturing information comprises machine set-up data, said machine set-up data comprising at least one of machine type data, tool set-up data, and backgaging data.

17. An intelligent facility according to claim 1, further comprising a system for developing bend model data based on said current job information when said searching system determines that said predetermined degree of similarity does not exist, said bend model data comprising 2-D coordinate space data for representing said current part in 2-D coordinate space and 3-D coordinate space data for representing said current part in 3-D coordinate space.

18. An intelligent facility according to claim 17, wherein said current job information comprises said 2-D coordinate space data, said developing system being adapted to develop said 3-D coordinate space data by performing a folding operation on said said 2-D coordinate space data.

19. An intelligent facility according to claim 17, wherein said current job information comprises said 3-D coordinate space data, said developing system being adapted to develop said 2-D coordinate space data by performing an unfolding operation on said 3-D coordinate space data.

20. A method for the intelligent production of parts in a facility, said method comprising:

storing, in a data storage device, job information relating to the production of at least one part previously produced by said facility, said previous job information for each said previously produced part including previous design data relating to part design features of each of said previously produced part;

receiving current job information relating to a current part to be produced by said facility in response to a current job request, said current job information including proposed design data relating to proposed part design features of said current part;

searching said data storage device to compare said previous job information design data stored with respect to each said previously produced part to said current job information design data; and

determining if said previous job information design data and said current job information design data have at least a predetermined degree of similarity such that a plan can be developed for producing a current part, in response to said current job request, which utilizes at least part of said previous job information.

21. A method according to claim 20, said previous design data and said proposed design data including part design features, wherein said searching of said data storage device comprises comparing said previous job information design features and said current job information design features and wherein said determining comprises deciding whether each said previously produced part includes similar part design features to that of said current part based on the results of said searching.

22. A method according to claim 21, said previous design data and said proposed design data further including part topology data.

23. A method according to claim 22, wherein each said previously produced part and said current part comprise sheet metal parts.

24. A method according to claim 20, wherein said searching includes comparing said previous job information design features and said current job information design features and said determining includes determining whether each said previously produced part includes identical, similar, or different features to that of said current part based on the results of said searching.

25. A method according to claim 20, wherein each said previously produced part and said current part comprise sheet metal parts.

26. A method according to claim 20, wherein previous job information determined to have said predetermined degree of similarity is retrieved from said database and distributed to various locations throughout said facility so that a plan for producing said current part may be developed based on said retrieved previous job information.

27. A method according to claim 26, wherein said retrieved previous job information is distributed over a communications network connected to said database and to a plurality of station modules provided throughout said facility, each of said station modules being connected to said communication network to receive said retrieved previous job information from said database.

28. A method according to claim 27, further comprising interfacing each of said station modules with said communication network and using a display device to display said retrieved previous job information.

29. A method according to claim 27, further comprising entering said current job information at a server module connected to said communication network and transferring said current job information, entered at said server module, to said database through said communication network.

30. A method according to claim 26, wherein each said previously produced part and said current part comprise sheet metal parts, said retrieved previous job information comprising bend sequence and tooling information for producing said previously produced part determined to have said predetermined degree of similarity to said current part.

31. A method according to claim 30, wherein said facility locations include a bending station, said bending station comprising one of said station modules and a bending machine for bending sheet metal parts based on a bending code, said retrieved previous job information further including a predetermined bending code for producing, with said bending machine, one of said previously produced parts determined to have said predetermined degree of similarity to said current part.

32. A method according to claim 28, wherein each said previously produced part and said current part comprise sheet metal parts, said retrieved previous job information comprising bend model data for rendering at least one displayed image of each said previously produced part, said display device of each of said station modules rendering said image based on said bend model data to facilitate the development of said plan for producing said current part.

33. A method according to claim 32, said bend model data comprising data for displaying a plurality of displayed images of said previously produced part, including a 2-D image and a 3-D image of said previously produced part, said display devices of each of said station modules being located throughout said facility and selectively rendering said 2-D image or said 3-D image of said previously produced part.

34. A method according to claim 20, wherein said previous job information further comprise manufacturing information relating to each said previously produced part, and wherein said current job information further comprises proposed manufacturing information relating to said current part, said determining comprises comparing said manufacturing information of said previous job information and said manufacturing information of said current job information to determine whether said predetermined degree of similarity exists such that said plan can be developed for producing said current part based on at least a part of said previous job information.

35. A method according to claim 34, wherein said manufacturing information comprises machine set-up data, said machine set-up data comprising at least one of machine type data, tool set-up data, and backgaging data.

36. An intelligent production system, comprising:

a data storage device for storing previous job information of previously produced parts, said previous job information including previous design data relating to part design features of each of said previously produced parts;

means for receiving current job information relating to a current job request to produce a new part, said current job information including proposed design data relating to proposed part design features of the new part of said current job request; and

means for searching said data storage device and for comparing said previous job information with said current job information to identify said previously produced parts that have a predetermined degree of similarity to the new part of said current job request.

37. An intelligent production system according to claim 36, further comprising means for retrieving, from said data storage device, previous job information identified to have said predetermined degree of similarity, and means for distributing said retrieved previous job information to various locations so that a plan for producing the new part of said current job request may be produced based, at least in part, on said retrieved previous job information.

38. An intelligent production system according to claim 37, said means for distributing comprising a communications network connected to said data storage device and a plurality of station modules, each of said station modules being connected to said communication network to receive said retrieved previous job information from said data storage device.

39. An intelligent production system according to claim 38, each of said station modules comprising a network interface device for interfacing with said communication network and a display device for displaying said retrieved previous job information.

40. An intelligent production system according to claim 38, further comprising a server module connected to said communication network, said server module comprising an input device for entering said current job information and a network interface device for transferring said current job information, entered by said input device, to said data storage device through said communication network.

41. An intelligent production system according to claim 36, said searching means comprising means for performing a feature extraction operation on said previous job information and said current job information to determine the existence of predetermined features in each of said previously produced parts and in the new part of said current job request, said means for performing a feature extraction operation producing feature extraction data for each of said previously produced parts and the new part of said current job request.

42. An intelligent production system according to claim 41, further comprising means for comparing the feature extraction data with predefined feature extraction data stored in a feature extraction library to identify fundamental features in each of said previously produced parts and in the part of said current job request.

43. An intelligent production system according to claim 42, further comprising means for performing a feature relation operation to determine the relationship between the fundamental features identified in each of said previously produced parts and in the part of said current job request.

44. An intelligent production system according to claim 43, further comprising means for developing search keys for each of said previously produced parts and search keys for the new part of said current job request based on the fundamental features identified and the determined relationships among the fundamental features of each part.

45. An intelligent production system according to claim 44, said searching means further comprising means for performing a cooperative search of said data storage device to compare the search keys developed for the new part of said current job request and the search keys developed for each of said previously produced parts, said means for performing a cooperative search including means for identifying previously produced parts that have search keys identical to the search keys of the new part of said current job request, and for identifying previously produced parts that have similar search keys similar to the search keys of the new part of said current job request.

46. An intelligent production system according to claim 45, further comprising means for executing a selected parts search to select, among said previously produced parts identified by said cooperative search means, a predetermined number of previously produced parts that have identical or the most similar search keys to the search keys of the new part of said current job request.

47. An intelligent production system according to claim 46, further comprising means for calculating a similarity index to rank each of said previously produced parts selected by said selected parts search means based on the degree of similarity of features and matching search keys with the part of said current job request.

48. An intelligent production system according to claim 36, wherein said previous job information further comprise manufacturing information relating to each of said previously produced parts, and wherein said current job information further comprises proposed manufacturing information relating to said new part, said searching means comprising means for comparing said manufacturing information of said previous job information and said manufacturing information of said current job information to identify said previously produced parts that have said predetermined degree of similarity with said new part.

49. An intelligent production facility according to claim 48, wherein said manufacturing information comprises machine set-up data, said machine set-up data comprising at least one of machine type data, tool set-up data, and backgaging data.

50. A method for performing a similar part search, said method comprising the steps of:

storing previous job information of previously produced parts in a data storage device, said previous job information including previous design data relating to part design features of each of said previously produced parts;

receiving current job information relating to a current job request to produce a new part, said current job information including proposed design data relating to proposed part design features of the part of said current job request; and

searching said data storage device and comparing said previous job information with said current job information to identify said previously produced parts that have a predetermined degree of similarity to the new part of said current job request.

51. A method according to claim 50, further comprising retrieving, from said data storage device, previous job information relating to previously produced parts determined to have said predetermined degree of similarity and distributing said retrieved previous job information to various locations in a production facility so that a plan for producing the new part of said current job request may be developed based, at least in part, on said retrieved previous job information.

52. A method according to claim 51, wherein said distributing distributes said retrieved previous job information over a communications network connected to said data storage device and to a plurality of station modules provided throughout said facility, each of said station modules being connected to said communication network to receive said retrieved previous job information from said data storage device.

53. A method according to claim 50, wherein said previous design data and said proposed design data include part topology data, said part topology data representing the location and geometric relationships of surfaces and bendlines of each part.

54. A method according to claim 50, further comprising performing a feature extraction operation on said previous job information and said current job information to determine the existence of predetermined features in each of said previously produced parts and in the new part of said current job request, said feature extraction operation producing feature extraction data for each of said previously produced parts and the part of said current job request.

55. A method according to claim 54, further comprising comparing the feature extraction data with predefined feature extraction data stored in a feature extraction library to identify fundamental features in each of said previously produced parts and in the new part of said current job request.

56. A method according to claim 55, further comprising performing a feature relation operation to determine the relationship between the fundamental features identified in each of said previously produced parts and in the new part of said current job request.

57. A method according to claim 56, wherein the relationship between the identified fundamental features of a part is defined based on the distance between the identified fundamental features.

58. A method according to claim 57, wherein the distance between two fundamental features of a part is determined based on the number of bendlines between base faces of the two fundamental features.

59. A method according to claim 56, further comprising developing search keys for each of said previously produced parts and search keys for the new part of said current job request based on the fundamental features identified and the determined relationship between the fundamental features of each part.

60. A method according to claim 59, wherein said searching includes performing a cooperative search of said data storage device to compare the search keys developed for the new part of said current job request and the search keys developed for each of said previously produced parts, said cooperative search including identifying previously produced parts that have identical search keys to the search keys of the new part of said current job request and identifying previously produced parts that have similar search keys to the search keys of the new part of said current job request.

61. A method according to claim 60, further comprising executing a selected parts search to select, among said previously produced parts identified by said cooperative search, a predetermined number of previously produced parts that have identical or the most similar search keys to the search keys of the new part of said current job request.

62. A method according to claim 61, further comprising calculating a similarity index to rank each of said previously produced parts selected by said selected parts search based on the degree of similarity of features and matching search keys with the new part of said current job request.

63. A method according to claim 62, further comprising displaying said similarity index so that previous job information relating to said previously produced parts selected by said selected parts search may be selectively accessed from said data storage device to develop a plan for producing the new part of said current job request.

64. A method according to claim 50, wherein said previous job information further comprise manufacturing information relating to each of said previously produced parts, and wherein said current job information further comprises proposed manufacturing information relating to said new part, said searching comprising comparing said manufacturing information of said previous job information and said manufacturing information of said current job information to identify said previously produced parts that have said predetermined degree of similarity with said new part.

65. A method according to claim 64, wherein said manufacturing information comprises machine set-up data, said machine set-up data comprising at least one of machine type data, tool set-up data, and backgaging data.

66. A method according to claim 50, further comprising the step of developing bend model data based on said current job information, said bend model data comprising 2-D coordinate space data for representing said current part in 2-D coordinate space and 3-D coordinate space data for representing said current part in 3-D coordinate space.

67. A method according to claim 66, wherein said current job information comprises said 2-D coordinate space data, said developing including the step of performing a folding operation on said 2-D coordinate space data to develop said 3-D coordinate space data.

68. A method according to claim 66, wherein said current job information comprises said 3-D coordinate space data, said developing including the step of performing an unfolding operation on said 3-D coordinate space data to develop said 2-D coordinate space data.

69. An intelligent facility for producing parts, said facility comprising:

a data storage device for storing previous data representing a plurality of predetermined part design features relating to parts previously produced by said facility;

a data receiving system for receiving proposed data representing a plurality of predetermined part design features relating to a part to be produced by said facility; and

a comparing system for making a comparison of the stored previous data with the received proposed data relating to said part to be produced, and for using the results of said comparison to determine whether at least one of said previously produced parts and said part to be produced are identical, similar, or different.

70. An intelligent facility according to claim 69, further comprising a system for retrieving, from said data storage device, previous data relating to previously produced parts which have been determined to be either identical or similar to said part to be produced, and a system for distributing said retrieved data to various locations throughout said facility so that a plan for producing said part to be produced may be developed based on said retrieved data.

71. An intelligent facility according to claim 70, said distributing system comprising a communications network connected to said data storage device and a plurality of station modules provided throughout said facility, each of said station modules being connected to said communications network to receive said retrieved data from said data storage device.

72. An intelligent facility according to claim 70, wherein when it is determined that at least one of said previously produced parts is identical to said part to be produced, said retrieved system is adapted to retrieve data relating to said at least one identical previously produced part and said distributing system is adapted to distribute said retrieved data so that said retrieved data may be used to produce said part to be produced.

73. An intelligent facility according to claim 70, further comprising a system for editing said previous data, such that when it is determined that at least one of said previously produced parts is similar to said part to be produced, said previous data relating to said at least one similar previously produced part is retrieved and edited by said editing system so that the edited data may be used to produce said part to be produced.

74. An intelligent facility according to claim 70, further comprising a system for developing a plan for producing said part to be produced based on the received data, so that when it is determined that all of said previously produced parts are different from said part to be produced, said received data is used by said developing system to develop said plan for producing said part to be produced.

75. An intelligent facility according to claim 70, wherein said previous data further comprises manufacturing information relating to each of said previously produced parts, and wherein said received proposed data further comprises proposed manufacturing information relating to said part to be produced, said comparing system be adapted to compare said manufacturing information of said previous data and said manufacturing information of said received proposed data to determine whether at least one of said previously produced parts and said part to be produced are identical, similar, or different.

76. An intelligent facility according to claim 75, wherein said manufacturing information comprises machine set-up data, said machine set-up data comprising at least one of machine type data, tool set-up data, and backgaging data.

77. An intelligent facility according to claim 76, wherein the stored previous data and the received proposed data comprise a part reference number, said comparing system comparing the part reference number of the stored previous data and the part reference number of the received proposed data to determine whether at least one of said previously produced parts and said part to be produced are identical or different.

78. A method for use in an intelligent part production facility, said method comprising the steps of:

storing, in a data storage device, previous data representing a plurality of predetermined part design features relating to parts previously produced by said facility;

receiving proposed data representing a plurality of predetermined part design features relating to a part to be produced by said facility;

comparing the stored previous data with the received proposed data relating to said part to be produced; and

determining, through the comparison of said stored previous data and said received proposed data, whether said at least one of said previously produced parts and said part to be produced are identical, similar, or different.

79. A method according to claim 78, further comprising retrieving, from said data storage device, data relating to said previously produced parts determined to be either identical or similar to said part to be produced, and distributing said retrieved data to various locations throughout said facility so that a plan for producing said part to be produced may be developed based upon said retrieved data.

80. A method according to claim 79, wherein said retrieved data is distributed over a communications network connected to said data storage device and to a plurality of station modules provided throughout said facility, each of said station modules being connected to said communication network to receive said retrieved data from said data storage device.

81. A method according to claim 79, further comprising retrieving and using said data relating to said identical previously produced part to produce said part to be produced when it is determined that at least one of said previously produced parts is identical to said part to be produced.

82. A method according to claim 79, further comprising editing said data relating to said previously produced parts, such that when it is determined that at least one of said previously produced parts is similar to said part to be produced, said data relating to said similar previously produced part is retrieved and edited so that the edited data may be used to produce said part to be produced.

83. A method according to claim 79, further comprising developing said plan for producing said part to be produced with new data when it is determined that all of said previously produced parts are different from said part to be produced.

84. A method according to claim 79, further comprising editing said previous data, such that when it is determined that at least one of said previously produced parts is similar to said part to be produced, said previous data relating to said at least one similar previously produced part is retrieved and edited so that the edited data may be used to produce said part to be produced.

85. A method according to claim 78, wherein said previous data further comprises manufacturing information relating to each of said previously produced parts, and wherein said received proposed data further comprises proposed manufacturing information relating to said part to be produced, said determining comprising comparing said manufacturing information of said previous data and said manufacturing information of said received proposed data to determine whether at least one of said previously produced parts and said part to be produced are identical, similar, or different.

86. A method according to claim 85, wherein said manufacturing information comprises machine set-up data, said machine set-up data comprising at least one of machine type data, tool set-up data, and backgaging data.

87. A method according to claim 78, wherein the stored previous data and the received proposed data comprise a part reference number, said method comprising comparing the part reference number of the stored previous and the part reference number of the received proposed data to determine whether at least one of said previously produced parts and said part to be produced are identical or different.

88. A method according to claim 78, further comprising the step of developing bend model data based on said received proposed data, said bend model data comprising 2-D coordinate space data for representing said part to be produced in 2-D coordinate space and 3-D coordinate space data for representing said part to be produced in 3-D coordinate space.

89. A method according to claim 88, wherein said received proposed data information comprises said 2-D coordinate space data, said developing including the step of performing a folding operation on said 2-D coordinate space data to develop said 3-D coordinate space data.

90. A method according to claim 88, wherein said received proposed data comprises said 3-D coordinate space data, said developing including the step of performing an unfolding operation on said 3-D coordinate space data to develop said 2-D coordinate space data.