Expert manufacturing system

• US 5,991,528 A
• Filed: 11/05/1997
• Issued: 11/23/1999
• Est. Priority Date: 11/05/1997
• Status: Expired due to Term

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Reliance Electric Industrial Company
• Inventors: Taylor, Jay A., Swift, Dennis R., Zychowski, Gerard L., Thompson, Dennis R., Kramer, William A.
• Primary Examiner(s): Teska, Kevin J.
• Assistant Examiner(s): Knox, Lonnie A.
• Application Number:
  US08/964,959
• Time in Patent Office: 748 Days
• Field of Search: 364/468.03, 364/486, 395/500.27
• US Class Current: 703/6
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 19/41885 characterised by modeling, simulation of the manufacturing system
• CPC Class Codes: G05B 2219/32104 Data extraction from geometric models for process planning
• CPC Class Codes: G05B 2219/32351 Visual, graphical animation of process
• CPC Class Codes: G05B 2219/35216 Program, generate nc program, code from cad data
• CPC Class Codes: G05B 2219/36181 Input part data, dimensions, without graphical representation of part
• CPC Class Codes: G05B 2219/36237 Prepare nc program for selected, distinct nc machines
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

An expert manufacturing system generates a manufacturing plan for producing a part in an automated manufacturing system. The expert manufacturing system generates a multipurpose manufacturing geometry definitions file. The expert manufacturing system includes a rule-based expert system which uses the manufacturing geometry definitions file to generate the manufacturing plan in the form of a neutral source code file. The neutral source code is converted to machine-specific program code directly executable by a device controller, such as a logic controller or motion controller. The expert manufacturing system also includes a parametric drawing generation program for generating drawing of the part, and a computer simulation program for simulating the manufacturing plan for producing the part.

Claims

1. A system for defining a manufacturing plan for producing a part, comprising:

a user interface to select the part for producing from a plurality of available parts;

a part data file to store basic part defining data associated with each of the available parts;

a manufacturing file generator to generate a manufacturing file for the selected part based on the part data file and in accordance with predefined rules, the manufacturing file specifying part features of the selected part and machining processes for producing the part features;

an expert system to generate a manufacturing plan for producing the selected part based on the manufacturing file, the expert system generating the manufacturing plan in a neutral source code.

2. The system as recited in claim 1, further comprising a program code generator to convert the neutral source code to program code corresponding to the manufacturing plan, the program code being executable by at least one device controller, wherein the device controller provides signals to at least one machine tool to produce the selected part in accordance with the manufacturing plan.

3. The system as recited in claim 1, wherein the expert system specifies processing conditions associated with each machining process.

4. The system as recited in claim 1, wherein the predefined rules include rules specifying retrieval and/or derivation of additional part defining data associated with the selected part.

5. The system as recited in claim 1, wherein the expert system comprises a plurality of expert programs, and the manufacturing file further specifies a particular one of the expert programs which corresponds to each machining process.

6. The system as recited in claim 1, wherein the part data file comprises a plurality of part data files.

7. The system as recited in claim 1, wherein the predefined manufacturing rules include a decision table and/or an expert rule set.

8. An expert manufacturing system for producing a part, the system comprising:

a user interface to select the part for producing from a plurality of available parts;

a part data file to store basic part data associated with the selected part;

a manufacturing file generator to generate a manufacturing file based on the part data file and in accordance with predefined rules, wherein the manufacturing file defines part features and identifies one or more machining operations for producing each respective part feature;

an expert system to define a manufacturing plan for producing the selected part based on the manufacturing file, the manufacturing plan specifying machining operation sequences and process conditions associated with the one or more machining operations;

a program code generator to generate executable program code corresponding to the manufacturing plan;

one or more device controllers to execute the program code and provide a plurality of control signals based thereon; and

one or more machine tools to carry out the one or more machining operations to produce the selected part in accordance with the manufacturing plan in response to the plurality of control signals.

9. The expert manufacturing system as recited in claim 8, wherein the part data file comprises a plurality of part data files.

10. The expert manufacturing system as recited in claim 8, wherein the part features include body elements, detail elements formed on the body elements, surface elements formed on the body elements and primitive geometry elements associated with the selected part.

11. The expert manufacturing system as recited in claim 8, wherein the expert system includes a plurality of expert programs, and the manufacturing file specifies the particular expert program of the plurality of expert programs to invoke to provide the process conditions for each identified machining operation.

12. The expert manufacturing system as recited in claim 8, further comprising a manufacturing simulator to generate a computerized simulation of the manufacturing plan for producing the selected part.

13. The expert manufacturing system as recited in claim 8, further comprising a drawing generator to generate a part drawing based on the manufacturing file.

14. The expert manufacturing system as recited in claim 8, wherein the predefined manufacturing rules include a decision table and/or an expert rule set.

15. The expert manufacturing system as recited in claim 8, wherein the predefined manufacturing rules include rules specifying retrieval and/or derivation of additional part data associated with the selected part.

18. A method for defining a manufacturing plan for producing a part, comprising:

selecting the Dart for producing;

obtaining basic part data associated with the part;

generating a manufacturing file from the basic part data and in accordance with predefined rules, the manufacturing file including manufacturing data associated with the part, the manufacturing data defining body elements, detail elements formed on the body elements, surface elements formed on the body elements, primitive geometry elements, and machining operations to be carried out by one or more machine tools for producing the body elements, detail elements, surface elements, and/or primitive geometry elements;

based on the manufacturing data, invoking one or more expert programs for generating a manufacturing plan for producing the part, the one or more expert programs providing machining conditions and machining sequences associated with the machining operations; and

generating a neutral source code corresponding to the manufacturing plan.

16. The method as recited in claim 18, wherein generating the manufacturing file includes retrieving additional part data from an additional part data source in accordance with the predefined rules and deriving additional part data in accordance with the predefined rules.

17. The method as recited in claim 18, wherein the predefined rules include a decision table and/or an expert rule set.

19. The method as recited in claim 18, further comprising converting the neutral source code to program code corresponding to the manufacturing plan, the program code being executable by one or more machine controllers, the one or more machine controllers providing signals to the one or more machine tools to carry out the manufacturing plan for producing the part.

20. The method as recited in claim 18, wherein obtaining basic part data includes collecting the basic part data from a plurality of part data sources.

21. The method as recited in claim 18, further comprising generating a computer simulation which simulates the manufacturing plan for producing the part.