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  Control system and method for processing jewelry and the likeUSPTO Application #: 20070264907Title: Control system and method for processing jewelry and the like Abstract: A control system for controlling processing of workpieces such as jewelry has gantry and gimbal units having x, y, z translational and x, y, z rotational degrees of freedom, the units carrying a gripper for holding a piece of jewelry. Drive motors are associated with each translational and rotational degree of freedom and an actuator operates the gripper. A controller is linked to the gantry and gimbal unit motors, the gripper unit actuator, and actuators associated with a series of work stations for carrying out processing operations such as lapping and grinding. The controller controls movement of the gripper unit from a start position to pick up a workpiece and move it along a programmed path between the processing stations, and controls operation of actuators at each processing station to process workpieces according to stored program instructions. A user input device provides optional operator control of the movement and processing for system training purposes. (end of abstract) Agent: Gordon & Rees LLP - San Diego, CA, US Inventor: Vojislav Kalanovic USPTO Applicaton #: 20070264907 - Class: 451005000 (USPTO) Related Patent Categories: Abrading, Precision Device Or Process - Or With Condition Responsive Control, Computer Controlled The Patent Description & Claims data below is from USPTO Patent Application 20070264907. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] The present invention relates generally to control systems and methods for automated processing of parts such as jewelry and the like through a series of work stations, and is particularly concerned with a control system and method for an automated processing apparatus carrying out a material removal process. [0002] Since the jewelry industry evolved into a manufacturing industry rather than a simple hand crafting industry, there has been a need for an automatic method and apparatus for grinding, polishing and repair of jewelry, as well as for initial creation of jewelry without casting. Some of these tasks are still typically carried out by hand, and jewelry making is still a very labor intensive process. For a typical jewelry manufacturer, the initial creation of a jewelry piece is carried out by casting. This involves creating a master model out of steel, creation of wax copies of the master, and then using an investment casting process to create a final jewelry piece out of precious metal alloy. This process creates sprues and requires coarse grinding as well as fine grinding and polishing in order to finish the piece. In this process, over 60% of the labor time is dedicated to finishing the piece of jewelry. These tasks are typically carried out by hand, with each individual piece of jewelry handled separately. The task of grinding and/or polishing of jewelry typically consists of holding a piece of jewelry against a turning grinding wheel. Such a process is monotonous, and also can present a health hazard due to the dust created during the procedure. [0003] The existing jewelry manufacturing processes are time-consuming and labor intensive. In some areas, the quality of the jewelry piece is strongly dependent on the operator. There is therefore a need for automation of at least part of the jewelry manufacturing process in order to produce a more economical, consistent and predictable product with potential savings in precious metal. [0004] Robotic commercial systems have been used in the past to perform some jewelry finishing processes, but typically only in finishing of rings. Such robotic systems, for example the Ring Grinding and Polishing System of Superior Robotics, Inc. of Ontario, Canada, can perform the steps of sprue removal from a ring, grinding the shank on the outside of the ring, pre-polishing the outside of the ring, grinding the inside of the ring, and pre-polishing the inside of the ring. However, this system cannot handle any other types of jewelry and can perform only these limited operations. The robotic control system has distributed software, with part working on the robot's controller and the other part on a separate computer or PC. This means that the software is not readily adaptable to different hardware components. There is therefore a need for an improved automated apparatus for jewelry processing, and for a control system and method for controlling operation of such an apparatus. SUMMARY OF THE INVENTION [0005] It is an object of the present invention to provide a new and improved control system and method for a processing apparatus for processing of parts to perform operations such as material removal, polishing, welding, or the like. [0006] According to one aspect of the present invention, a control system for controlling operation of a processing machine is provided, which comprises a computer programmed with a plurality of program modules for controlling different operations of the machine, a data base for storing piece parameters and styles, program instructions, and machine parameters, an output monitor connected to the computer for displaying data and application windows associated with each machine procedure, and a joystick input device for use by an operator in training the system, the program modules comprising a monitoring module for displaying data on the output monitor, a manual module for manual control of motor movements, set up of parameters, and training of the system, and an auto module for controlling an automatic production process based on instructions stored in the training procedure. [0007] The program modules may further comprise a data base module for updating and organizing data, and a setup module for set up of basic parameters for the system hardware and software. In an exemplary embodiment, the software controls the display on the output monitor to provide a continuous update of various system parameters. The software may be linked to a remote controller for external monitoring of the system operation, allowing a remote site diagnostic to be made. [0008] The software in an exemplary embodiment of the invention includes software drivers for various motors or actuators used in moving workpieces between different work stations and in operating tools at the work stations. A graphical interface may be used for user input to the system, allowing the user to structure a motion of a workpiece as well as to assign specific system commands. [0009] In an exemplary embodiment of the invention, the manual training module comprises means for training operation of a gantry unit having x, y and z translational degrees of freedom and means for training operation of a gimbal unit mounted on the gantry unit and having x, y and z rotational degrees of freedom, the means for training the gantry unit comprising means for associating right and left movements of the joystick with operation of a gantry x-axis motor to move a gantry x-axis carriage in corresponding directions, means for associating up and down movements of the joystick with operation of a gantry y-axis motor to move a gantry y axis carriage in opposite directions, and means for associating actuation of respective buttons on the joystick with operation of a gantry z-axis motor to move a gantry z-axis carriage in opposite directions, and the means for training the gimbal unit comprising means for associating right and left movements of the joystick with operation of a first gimbal motor to rotate in opposite directions, means for associating up and down movements of the joystick with operation of a second gimbal motor to rotate in opposite directions, and means for associating actuation of respective buttons on the joystick with operation of a third gimbal motor to rotate in opposite directions, whereby the system can be trained to move a gripper unit attached to the gimbal unit along a predetermined path with predetermined end points along the path at successive processing stations in the machine. [0010] The joystick based trajectory planner allows the user to readily teach the system desired gantry paths and gimbal paths without requiring any separate control devices hooked to the gantry or gimbal units. [0011] The manual training module may also comprise means for user entry and storing of machine parameters. In the case of a jewelry processing application, these parameters may be gripper force, grind force, polishing force, lapping force, and the speed of the various motors. In an exemplary embodiment of the invention, the manual module further comprises an on-off commands block and a movement command block. The on-off commands block comprises means for user control of operation of a main gripper unit for carrying a piece between a series of processing stations and operation of a flip gripper unit for allowing the grip position of a piece in the main gripper unit to be changed. The movement commands block may comprise means for user entry of commands for moving the gantry and gimbal units to a start position, moving the gripper unit to a pick position above a tray, moving the gantry and gimbal units successively to the work stations where different procedures are carried out, and initiating two different procedures at the two workstations when the work piece is positioned properly at the respective workstations. [0012] This system may be used for control of processing machines for use in various different applications, such as material removal and part shaping, polishing of parts, welding, glue dispensing, laser jet cutting, assembly, palletizing, laser deposition, pick/place, and friction steer welding. [0013] In an exemplary embodiment of the invention, the control system is adapted for use in jewelry processing (grinding and polishing). Where the jewelry to be processed comprises rings, the auto module comprises means for user entry of the style and size of each ring to be processed and the position of each ring on a storage tray. The module includes means for copying a style and size previously entered to additional positions on the storage tray. The auto module further comprises means for user entry of a start command when ring style and size for each tray position has been entered. The ring style and size input includes an empty designation for a tray location carrying no ring. [0014] In an exemplary embodiment of the invention, the system software includes a lapping procedure comprising means for controlling the main gripper unit to hold a ring in a vertical orientation to present a first side face of the ring for lapping, means for controlling the gantry motors to drive the gripper unit and ring to a lapping wheel, means for controlling the drive of the lapping wheel to perform a lapping operation in which sprue is removed from the first side face of the ring, means for detecting when all sprue is removed from the first side face, means for flipping the ring by 180 degrees to be gripped in an opposite vertical orientation to present a second side face of the ring to the lapping wheel, means for moving the gripper unit and ring up to the lapping wheel, and means for controlling the lapping wheel to perform a second lapping operation in which sprue is removed from the second side face of the ring. [0015] The lapping procedure includes means for ensuring that the gripper fingers are level with the outer side face of the vertically oriented ring in the lapping process. The lapping procedure in the exemplary embodiment further comprises means for driving the gantry and gimbal units to move a gripper unit carrying a ring from a start position to a flip station, means for positioning the ring within reach of a flip gripper and actuating the gripper to grip the ring, means for actuating the main gripper unit to release the ring, means for driving the gantry to move the main gripper unit away from the flip gripper, means for controlling the flip gripper unit motor to re-position the ring in a vertical orientation, means for controlling the gantry and gimbal units to move the main gripper unit back to the flip gripper in a horizontal orientation to grip the vertically oriented ring, means for controlling the flip gripper to release the ring, and means for controlling the gantry unit to move the main gripper unit and ring back to the start position. [0016] The software may also include means for keeping track of the average precious metal consumption or removal, and for displaying this information as a production parameter on the output monitor. For a particular style of ring, the same amount of material is removed, on average, for each ring processed. This value is stored in the data base for each ring style, and the computer is programmed to keep track of how many rings of each style have been processed at any point, and the average total amount of material which has been removed as a result of this processing. This allows the user to optimize the material removal process. [0017] The entire software system may be based on an OPC (object linking and embedding for process control) client/server structure, which allows various existing and independent protocols and/or software units to be seamlessly interfaced, added or subtracted. This allows hardware changes, driver changes, and software module changes to be made easily without affecting other components of the system. Existing OPC client/server structures allow any standard software product such as Microsoft Word, Excel, Access, or the like to be added as a client. Thus, the user can monitor or modify any system parameter in real time through tools that are normally used for other applications. [0018] According to another aspect of the present invention, a method of controlling a processing machine to process a plurality of workpieces is provided, in which the processing machine has a gantry unit for x, y and z translational positioning of a workpiece, a gimbal unit mounted on the gantry unit for x, y and z rotational positioning of the workpiece, a main gripper unit for holding the workpiece, and a plurality of spaced work stations for manipulating or processing the workpiece, the method comprising the following steps: [0019] setting up at least one desired trajectory of a workpiece from a storage tray through a selected series of end positions at work stations and then back to an end position, the trajectory being associated with a selected workpiece style; [0020] setting up a series of parameters for processing the workpiece; [0021] setting up a series of workpiece locations on a storage tray; [0022] controlling the gantry and gimbal motors to move the main gripper unit to a first position over a workpiece on the storage tray; Continue reading... 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