Machining based on master program merged from parts programs

• US 6,745,098 B2
• Filed: 12/13/2000
• Issued: 06/01/2004
• Est. Priority Date: 12/13/2000
• Status: Expired due to Fees

• Current Assignee: Shapex Solid Image Systems L.P.
• Original Assignee: Shapex Solid Image Systems L.P.
• Inventors: Belanger, Joseph William
• Primary Examiner(s): Picard, Leo
• Assistant Examiner(s): Rapp, Chad
• Application Number:
  US09/736,102
• Publication Number:
  US 20020072823A1
• Time in Patent Office: 1,266 Days
• Field of Search: 700/159, 700/169, 700/179, 700/180, 700/176, 700/184, 700/186, 700/193
• US Class Current: 700/169
• CPC Class Codes: G05B 19/4142 characterised by the use of a microprocessor G05B19/4141 takes precedence
• CPC Class Codes: G05B 2219/50003 Machine simultaneously two workpieces

Abstract

A machining system is described having independently movable cutting instruments configured to simultaneously generate different parts. The cutting instruments are capable of independent motion along a Z-axis and are mounted on a common beam that traverses the parts in an X, Y plane. Merge software modules merge a number of part programs into a single master program. A control unit interprets the master program and controls the machining system to generate the parts. The software modules generate the master program such that all of the Z-axis move commands within the part programs are sequenced along a single X, Y traverse path based on a defined cutting strategy and cutting direction. In this manner, the machining system simultaneously produces a number of different parts.

Claims

1. A method comprising:

merging part programs into a master part program by

identifying Z-axis move commands within the part programs,

modifying an X,Y location for each Z-axis move command, and

inserting updated Z-axis move commands into the master part program, and

controlling a machine according to the master part program to cause independently movable cutting instruments to simultaneously machine different parts defined by the part programs.

2. The method of claim 1, wherein merging the part programs further comprises:

assigning each part program to a corresponding one of the cutting instruments; and

generating move commands for the master part program, wherein each move command specifies an X, Y location that is common to the cutting instruments.

3. The method of claim 2, wherein each move command of the master program specifies a Z location for each cutting instrument.

4. The method of claim 1, wherein merging the part programs comprises generating a set of X,Y move commands to sequentially move the cutting instruments to the modified X, Y locations.

5. The method of claim 4, wherein generating the set of X,Y move commands includes generating the set of X,Y move commands as a function of a selected cutting direction and a selected cutting strategy.

6. The method of claim 4, wherein generating the set of X,Y move commands includes computing an X,Y traverse distance for each X,Y move command.

7. The method of claim 1, wherein merging the part programs comprises defining part groups within the master program.

8. A computer-readable medium having instructions stored thereon to cause a programmable processor to:

merge a plurality of part programs into a master part program, including

identify Z-axis move commands within the part programs,

modify an X,Y location for each Z-axis move commands, and

insert updated Z-axis move commands into the master part program; and

control a machining system according to the master part program to cause independently movable cutting instruments to simultaneously machine different parts defined by the part programs.

9. The computer-readable medium of claim 8, wherein the instructions cause the programmable processor to:

assign each part program to a corresponding one of the cutting instruments; and

generate move commands for the master part program, wherein each move command specifies an X, Y location that is common to the cutting instruments.

10. The computer-readable medium of claim 9, wherein the instructions cause the programmable processor to generate the move commands of the master program such that each move command specifies a Z location for each part program.

11. The computer-readable medium of claim 8, wherein the instructions cause the programmable processor to:

calculate a group starting point; and

compute a new X,Y location for each Z-axis move command relative to the group starting point.

12. The computer-readable medium of claim 8, wherein the instructions cause the programmable processor to generate a set of X,Y move commands to sequentially move the cutting instruments to modified X, Y locations.

13. The computer-readable medium of claim 12, wherein the instructions cause the programmable processor to generate the set of X,Y move commands as a function of a selected cutting direction and a selected cutting strategy.

14. The computer-readable medium of claim 12, wherein the instructions cause the programmable processor to compute an X,Y traverse distance for each X,Y move command.

15. The computer-readable medium of claim 8, wherein the instructions cause the programmable processor to define part groups within the master program.

16. A system comprising:

a machine system having a plurality of independently movable cutting instruments;

software configured to receive a plurality of part programs and merge the part programs into a master program, the software being configured to;

identify Z-axis move commands within the part programs,

modify an X,Y location for each Z-axis move command, and

insert updated Z-axis move commands into the master part program; and

a control unit to interpret a master program to simultaneously control the cutting instruments.

17. The system of claim 16, wherein the control unit controls the machining system to simultaneously produce a plurality of parts.

18. The system of claim 16, wherein the software execute in an operating environment provided byte control unit.

19. The system of claim 16, wherein the software are configured to:

assign each part program to a corresponding one of the cutting instruments; and

generate move commands for the master part program, wherein each move command specifies an X, Y location that is common to the cutting instruments.

20. The system of claim 19, wherein the software are configured to generate the move commands of the master program such that each move command specifies a Z location for each part program.

21. The system of claim 16, wherein the software modules are configured to:

calculate a group staffing point; and

compute a new X,Y location for each Z-axis move command relative to the group starting point.

22. A method comprising:

receiving a plurality of part programs; and

merging the part programs into a master part program to define movements of cutting instruments used to produce parts so that a time period for producing one of the parts overlaps with another time period for producing another of the parts.

23. The method of claim 22, wherein merging the part programs comprises assigning each part program to a corresponding one of the cutting instruments.

24. The method of claim 22, wherein merging the part programs comprises generating move commands for the master part program, wherein each move command specifies an X, Y location that is common to the cutting instruments.

25. The method of claim 24, wherein each move command of the master program specifies a Z location for each cutting instrument.

26. A method comprising:

generating a master part program based on part programs, the master part program comprising commands to move cutting instruments to produce different parts defined by the part programs,

the commands comprising a first command that causes the cutting instruments to move in a common direction dining a first time period,

the commands comprising a second command that causes at least two of the cutting instruments to move in different directions or in a common direction and different distances during a second time period.

27. The method of claim 26 in which the first command comprises sub-commands for controlling movements of each cutting instrument.

28. The method of claim 26 in which the second command comprises sub-commands for controlling movements of each cutting instrument.

29. The method of claim 26 in which the first command also causes the cutting instruments common distance during the first time period.

30. The method of claim 26 in which the commands cause the cutting instruments to alternate between a first mode of movement and a second mode of movement, in the first mode of movement the cutting instruments moving in a common direction, and in the second mode of movement at least two of the cutting instruments moving in different directions or in a common direction and different distances.

31. The method of claim 26 which the first time period does not overlap the second time period.

32. A method comprising:

controlling a machine according to a master part program to cause independently movable cutting instruments to simultaneously machine different parts defined by part programs, the master part program having been merged from the part programs, and controlling the machine includes controlling a first set of independently movable cutting instruments to machine the different parts during a first time period, and controlling a second set of independently movable cutting instruments to machine the different parts during a second time period.

33. The method of claim 32 in which at least some of the first set of cutting instruments have sizes that are different from the second set of cutting instruments.

34. The method of claim 32 in which the first time period does not overlap the second time period.

35. The method of claim 32 in which controlling the machine comprises controlling the cutting instruments to cut along a first direction during a first time period and to cut along a second direction at an angle to the first direction during a second time period.

36. The method of claim 35 in which the first time period does not overlap the second time period.

37. The method of claim 32 in which controlling the machine comprises moving the cutting instruments in a common direction during a first time period, and moving at least two of the cutting instruments in different directions or in a common direction and different distances during a second time period.

38. The method of claim 37 in which the first time period does not overlap the second time period.

39. A computer-readable medium having instructions stored thereon to cause a programmable processor to:

control a machine according to a master part program to cause independently movable cutting instruments to simultaneously machine different parts defined by part programs, the master part program having been merged from the part programs, the instructions causing the programmable processor to control a first set of independently movable cutting instruments to machine the different parts during a first time period, and to control a second set of independently movable cutting instruments to machine the different parts during a second time period.

40. The computer-readable medium of claim 39 in which the instructions also cause the programmable processor to control the cutting instruments to cut along a first direction during a first time period and to cut along a second direction at an angle to the first direction during a second time period.

41. The computer-readable medium of claim 39 in which the instructions also cause the programmable processor to control the machine to move the cutting instruments in a common direction during a first time period, and to move at least two of the cut instruments to move in different directions or in a common direction and different distances during a second time period.