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A PROPOSAL
THE AUTOMATED SHEET METAL SHOP
Sheet metal fabrication has long been considered a hard to
automate field because of the types of machines used and the need to
do a lot of manipulating of material, which can frequently be large
floppy sheets of varying thickness, yield strength and stock
dimension. For prototype manufacture, the setup time of each cutting,
notching, punching, bending or spot welding operation represents
almost the entire cost of manufacture. Automation of these processes
has been limited to numerically controlled punches and stops on hand
fed shears. True automation has been accomplished only in very high
production runs using special purpose dies in cascaded blanking and
stamping transfer presses to replace the traditional short run
methods.
We propose to study and assemble an automated design and
manufacturing system consisting of an interactive graphics display
terminal, our PDP 10, 6 and 11 computers, a design automation
program, a manufacturing planning program, a manufacturing execution
program, and a totally automated manufacturing facility containing a
collection of computer controlled sheet metal working machines and
one or more computer controlled manipulators to set up the machines
and perform all the necessary manipulation of the sheet material.
To execute this project, we will develop new programs and
will utilize existing programs and routines to create a complete
chain of automation. More specifically, we propose to take existing
rapid geometric design (GEOMED) programs and furthur develop and
expand them into new monitor routines to provide interactive design
assistance reflecting the manufacturability of a particular design.
We will also develop programs to interpret the completed design in
terms of manufacturing operations. This manufacturing planning
program will be a set of instructions detailing each operation
required to make the part. Completing the entire system, we will work
to develop a group of computer controlled machines and a manipulator
with suitable grasping devices to handle the material and operate the
machines. Along with this hardware setup, we plan to develop a
workable execution program which would properly interpret the
planning program's output in terms of machine and manipulator
commands.
To make the scope of this project realistic from a standpoint
of both actually working, and being completed in a reasonable period
of time, we propose to limit the acceptable product design to sheet
aluminum chassis and boxes of a generally regular shape. Included in
this category would be degenerate shapes, such as brackets and
sections with simple hole patterns and bends.
Coupled with this programming effort and hardware
development project, we suggest a study of new technology and new
approaches to the execution of some traditional problems. As an
example; laser, electromagnetic, impact, and explosive forming are
other areas where new automatic planning , control and execution
methods can place laboratory demonstrated techniques into viable
roles in industry. We also propose to begin studies in the field of
robot-machine engineering, which we propose as a new area of study,
rather than an extension of man-machine engineering.