Bending Program Creation Using Topology-Based Tool Length Selection
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Solution Overview
Problem
Existing methods for manufacturing parts using press brakes often fail to accurately bend sheet metals due to lack of owner-specific rules or know-how integration, even when using bending processing programs for similar parts based on topology data.
Innovation Solution
A processing program creation device and method that generates topology data, acquires processing information, and determines the appropriate tool length and tool for bending lines, creating a bending processing program to ensure accurate bending processing by referencing similar parts with matching topology data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a bending processing program for a similar part is used based on topology data, then productivity is improved, but manufacturing precision deteriorates because the part may not be actually bent
Solution Approach 1:
The system performs preliminary actions by pre-calculating the appropriate tool length before bending processing. The tool determination unit calculates the required tool length based on the bending line position and part geometry, ensuring the tool is properly sized before actual bending occurs. This preliminary determination prevents bending failures and ensures manufacturing precision while maintaining productivity through automated selection.
Solution Approach 2:
The system changes the parameter of tool length based on the specific bending line position and part geometry. Instead of using a fixed tool, the tool determination unit dynamically determines the appropriate tool length for each bending operation by analyzing the distance from the bending line to the part end and the bending radius. This parameter adaptation ensures accurate bending for each specific case while maintaining efficient processing.
2Device complexity
If a fixed tool length is used for bending processing, then device complexity is reduced, but manufacturing precision deteriorates due to interference with the part
Solution Approach 1:
The system applies local quality by determining a specific tool length tailored to each bending line's local requirements. The tool determination unit analyzes the local geometry around each bending line, including the distance to the part end and the bending radius, and selects the appropriate tool length for that specific location. This localized tool selection ensures precise bending without interference while keeping the overall system simple through automated determination.
Solution Approach 2:
The system introduces dynamics by making the tool length variable rather than fixed. The tool determination unit dynamically calculates the required tool length for each bending operation based on real-time analysis of the bending line position, part geometry, and bending radius. This dynamic adaptation allows the system to handle various part configurations accurately without requiring multiple fixed tool sets, thus reducing device complexity while improving precision.
Data Source
AI summary
A topology database generates topology data of a plurality of parts. The topology database acquires processing information including a tool name of a use tool and a processing order from a bending processing program of each part, and stores the processing information in association with the topology data. A processing information acquisition unit searches for a similar part with the same topology data as topology data of a processing target part, and acquires the processing information of the similar part. A tool determination unit calculates a range of a tool length which is able to bend each bending line using a tool with a tool name included in the processing information and which does not interfere with the part, and determines the tool with the tool name and a tool length within a range of the tool length as the use tool.