F O R M 2

THE PATENTS ACT, 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10; rule 13)

1. Title of the invention: AN AUTOMATED METHOD FOR USE IN MAGNETIC RIVETING DIE DESIGNING

2. Applicant(s):

(a) NAME : LARSEN & TOUBRO LIMITED
(b) NATIONALITY : An Indian Company
(c) ADDRESS : L & T House, Ballard Estate, Mumbai 400 001, State of
Maharashtra, India

3. PREAMBLE TO THE DESCRIPTION

The following specification particularly describes the invention and the manner in which it is to be performed:

TITLE OF THE INVENTION
An automated method for use in magnetic riveting die designing

FIELD OF THE NVENTION

The present invention relates to a riveting press tool assembly. Particularly, the invention is concerned about an automated method for use in magnetic riveting die designing.

BACKGROUND OF THE INVENTION

The design deliverables are crucial inputs for downstream manufacturing activities. But quality of design deliverables suffer due to inconsistencies in design practices, non uniformity of individual domain knowledge and software skills. An undesirable bi-product of this was also some errata in drawings. Moreover, efforts were required at the approval stage for proper checking and release. This all was due to high dependence on the skill and experience of individual designer and manual interventions in design. This was observed even similar construction (repeat designs) and family of tools. Whenever a huge design order comes at a given instance, it is difficult to cope up for timely delivery with limited design resources. Allocation of designers to various jobs and conflicting priorities is a pain area. Coping up with higher customer expectations is a challenge for prompt services.

It has been found that designing of a large number of Magnet Riveting dies was time consuming and difficult because requirement of design features in tools were not uniform. Also, modeling, drafting & checking time for each tool would have increased design lead time if done individually. Design lead time is a function of designer’s domain knowledge, skill and expertise in the software.

Figure 1 shows riveting press tool assembly. The press tool mainly consists of two halves, namely fixed bottom half and a moving top half. The fixed bottom half is secured to the stationary bolster plate of hydraulic press. It comprises arrangement for location of stack of laminations or stampings, sizing the stack, arrangement to remove the magnet assembly after riveting, guide pillars for alignment of both halves etc. The location arrangement for lamination stack consists of two halves – i.e. a moving half on the left side of operator and a moving half on the right side. Both the moving halves are actuated by pneumatic cylinders. The top moving half is clamped to the moving ram of the hydraulic press and it comprises a number of round riveting punches housed in a block clamped to the top bolster. The block moves up and down along with the moving ram of the hydraulic press.

At the beginning, the left moving half of locating arrangement moves in and the stack of laminations (with rivets flared at both ends after insertion in the stack) is kept on the ejector block and located against the locater. During downward stroke, the moving locating parts on right and left hand side are engaged by Guide pins from the top half, the block clamps the stack and pushes it down against a floating block called ejector. The registration of the locating blocks by guide pins from top creates a finite gap in the location arrangement for the lamination stack. The ejector block has a no. of stationary round punches guided in it and held in a plate called punch holder. During downward movement of ejector, there is a relative movement between the stationary round punches and the ejector block which results in upsetting the loose ends of rivets into a rivet head. As the top half moves up, the riveted stack moves up with the floating ejector. The locating moving half on the right side moves away from the riveted stack and the stack is removed manually or by other means. The dieset of a typical magnet die comprises all elements except magnet forming elements. Figure 2 shows the flow diagram of method steps for design cycle of for every new tool.

JP 58041628 (A) discloses that an automation tool of a press when working the respective parts, by arranging the front part of one press die and the rear part of the other press die, which work parts symmetrical on the left and right, respectively, on the pre-position in the parts carrying direction, respectively. The press production line is constituted so that the right door outer panel R is carried by setting its front end as the tip end, and the left door outer panel L is carried by setting its rear end as the tip end. In this way, when the panel R and the panel L which are parts symmetrical to each other are set so as to be carried in reverse, press dies P, Q for pressing these parts R, L have the same section turned in the same direction, respectively. Accordingly, an automation tool T for carrying the parts R, L worked by the dies P, Q, for instance, a work shifting tool provided with an attraction cup can be used in common for the respective parts R, L.

CN 101817046 (A) discloses a punching nut riveting die which comprises an upper die rack (2), a lower die rack (9), an upper die fixing plate (3) and a lower die fixing plate (8), wherein a part positioning pin (7) is arranged on the lower die fixing plate (8); a nut positioning piece (1) with a hole is arranged on the upper die fixing plate (3); a permanent magnet (4) is arranged in the hole of the nut positioning piece (1); the lower die fixing plate (8) is provided with a concave die (5); and a concave die embedding piece (6) is embedded in the concave die (5). By adopting the structure, the invention utilizes the punching nut as the punch head to perform primary punching and riveting, thereby not only ensuring the riveting strength, but also enhances the working efficiency.

US 6,718,527 document teaches an automated techniques to correct certain rule violations with respect to non-design geometries are used, simplifying and automating the design layout of an electronic circuit, whether embodied as a design encoding or as a fabricated electronic circuit. Adding non-design geometries to a design layout is accomplished by adding one or more non-design geometries to the design layout, the design layout including one or more design geometries; and correcting one or more design rule violations by removing a portion of the one or more non-design geometries; wherein correcting the one or more design rule violations includes: deriving non-design wide class objects from the one or more non-design geometries and design wide class objects from the one or more design geometries; wherein at least one of the non-design wide class objects and the design wide class objects have a virtual edge; and using the virtual edge in determining the portion of the one or more non-design geometries to be removed.

The disadvantages of the prior art are long lead times resulted due to modeling of component then building up of assembly, then 2d, checking and release for any kind of tooling even for new order for same kind of tooling. There were non-uniformities & inconsistencies in design deliverables and practices. Many time domain knowledge or prior experience was not captured in design of these dies resulting iterations during trials and priority dies. It was difficult to cope with timely delivery with limited design resources. Previous practices needed 15 days to complete a particular design. Thus, there is a need to overcome the problems or drawbacks of the prior art. Therefore, inventors have developed an automated method for use in magnetic riveting die designing for improving design efficiency and output and reducing design lead time and cost.

OBJECTS OF THE INVENTION

An object of the present invention is to overcome the problems/disadvantages of the prior art.

Another object of the present invention is to provide an automated method for use in magnetic riveting die designing.

SUMMARY OF THE INVENTION

According to one aspect of the present invention there is provided an automated method for use in magnetic riveting die designing, said method steps comprising:
collecting data in the form of predetermined parameters;
categorizing and standardizing said parameters;
a developing phase;
wherein said phase comprising:
customizing of said categorized and standardized parameters;
drafting in 2D based on said customized parameters;
modeling systematic construction of 3D assemblies;
wherein said steps of drafting and modeling being functionally related to each other by means of an appropriate relationship and programming between each other;
a testing and implementing phase;
wherein said phase comprising:
receiving an input value from a user;
regenerating said 3D modeling and said 2D drafting by means of said received input data; and
releasing an output.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

Figure 1 illustrates sectional view of riveting press tool assembly.
Figure 2 illustrates a flow diagram of design cycle for every new tool
Figure 3-7 illustrates a user interface in Pro-e, Mapkeys for use in interactive manner
Figures 8 illustrates a flow diagram of design cycle of the present invention
Figure 9 illustrates a schematic diagram of the present invention.
Figure 10 illustrates a schematic diagram of Study and Analysis phase.
Figure 11 illustrates a schematic diagram of Development and Testing & Implementation phases.
Figure 12 illustrates asking user input by parametric CAD software.

DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS

According to the invention there is provided an automated method for use in magnetic riveting die designing. It is made in such a way that the input values viz. parameters are asked by the system in an interactive manner. Based on these parameters or sizes of component, 3D as well as 2D model of magnet can be generated immediately.

Common parameters (sizes) for each magnet e.g. Length, Width, Thickness, and Rivet head height etc are considered and all these parameters are related to each other to create 3D model of magnet. The numerical value input interactively is assigned to the parameters generated by the system. The relationship of magnet sizes with surrounding part forming elements has influence on the shape & size of the same. Thus, the parametric CAD software will consider d1 equal length to magnet (component) length. Then, there is a need to define same relationship in parametric program as shown in the Programmed & Relationship table. Later on, whenever there is a need to update the same assembly, program will ask input for length by giving a prompt “Please enter the length of component to the end user”. Any user having basic knowledge of parametric CAD software can easily work on it. Similarly every dimension can be defined as a parameter & then programmed. Once relationship & programming is done, there is no need to design tool again & again from scratch. Designer can invest their time on other developments instead of repetitive modeling & drafting same parts again. Programmed & Relationship done as follows in the table:

Parametric Software Dimension

PROGRAMME RELATIONS

INPUT
LENGTH_1 NUMBER
"Please enter LENGTH_1?”
LENGTH_2 NUMBER
"Please enter LENGTH_2?”
LENGTH_3 NUMBER
"Please enter LENGTH_3?”
WIDTH_1 NUMBER
"Please enter WIDTH_1?”
WIDTH_2 NUMBER
"Please enter WIDTH_2?”
RIVET_DIA NUMBER
"What is rivet head diameter?”
RIVET_HEAD_THICKNESS NUMBER
"What is rivet head thickness?"
TOOL_NAME STRING
"What is the TOOL NAME?"
NAME_OF_DESIGNER STRING
"What is the name of designer?"
PRODUCT_NAME STRING
"What is the product name?"
And so on…..
END INPUT

D151:1=RIVET_HEAD_THICKNESS
D0:60=RIVET_DIA
D178:2=RIVET_DIA
D50:4=RIVET_DIA
D158:1=RIVET_HEAD_THICKNESS
D3:56=RIVET_DIA
And so on…..
END RELATIONS

Figure 12 illustrates asking user input by parametric CAD software. Due to parametric nature of CAD software, a change in any parameter in one part will trigger changes in other parts having dimensional relationship with the same. In Press Tool Design, most of the parts forming elements are dependent upon component shape & size. As component shape & size changes, part forming elements change accordingly and rest all the parts remain unchanged. Small changes in component trigger changes in assembly. In the present invention parametric CAD software has been used. However, any other parametric software can be used which is technically equivalent to the CAD software and the invention can be performed. Such use of other software is to be considered within the scope of the present invention.

As shown in figures 3 to 7 illustrate a user interface in Pro-e, Mapkeys for use in interactive manner. A Mapkey is a keyboard macro that maps frequently used command sequences to certain keyboard keys or sets of keys with each macro beginning on a new line. We can define a unique key or combination of keys which, when pressed, executes the mapkey macro. For example, F8 or esc keys or mouse click to select an application on computer are frequently used to automate workflow. The system records our mapkey as we go through the sequence of keystrokes or command executions to define it.

Mapkey operations include the ability to do the following actions:
1. Pause for user interaction.
2. Handle message window input more flexibly.
3. Run operating system scripts and commands.
4. With the help of map keys, this automation will delight (fig.3), help (fig.4), guide (fig.5),
inform (fig.6) and advice (fig.7) the user.

As shown in figure 8, the flow diagram of design cycle of the present invention comprises tool request, user input, fine tuning in 2D drawing, checking & approval and final release of design. This procedure reduces modeling and drafting time drastically and it needs only one day time to finish one die design.

Figure 9 shows an automation method steps for designing magnetic riveting die. The method comprises Study & Analysis phase, Development phase, Testing & Result phase and Implementation phase. As shown in figure 10, the Study & Analysis phase comprises data collection, categorization, standardization and approval of parameters of each magnet.

As shown in figure 11, the Development phase comprises:
a) Finalization of generic parameters of e-shape magnet component as per fig 9.
b) Systematic construction of 3d assembly & 2d drafting in parametric cad software. This includes 3d modeling & 2d drafting of each element.
c) Relationship & programming in parametric cad software. This automates workflow.

The Testing and Implementation phrase comprises:
a) User input for generic component parameter.
b) Regeneration of 3d modeling & 2d drafting with user input. This only needs user input, no need to do modeling again.
c) Design is ready for checking & release with user input

The method as discussed in the present document can be implemented in a computer, or computers connected to a server, or computers connected in a network, or computers connected by internet or intranet. The hardware components which may be or can be used in the implementation of the method of the present invention are discussed hereinbelow.

The method described with respect to the exemplary embodiments may comprise or may be implemented in a machine or an apparatus or other computing device within which a set of instructions, when executed, may cause the machine to perform any one or more of the methodologies discussed above. In some embodiments, the machine operates as a standalone system. In some embodiments, the system may be connected to other systems by way of internet connectivity. In a networked deployment, the system may operate in the capacity of a server or a client user system in a server-client user network environment, or as a peer system in a peer-to-peer (or distributed) network environment. The system may comprise a server computer, a client user computer, a personal computer (PC), a tablet PC, a laptop computer, a desktop computer, a control system, a network router, switch or bridge, or any machine capable of executing a set of instructions (sequential or otherwise) that specify actions to be taken by that machine. Further, while a single system is illustrated, the term “system” shall also be taken to include any collection of systems that individually or jointly execute a set (or multiple sets) of instructions to perform any one or more of the methodologies discussed herein.

The system may include a processor (e.g., a central processing unit (CPU), a graphics processing unit (GPU, or both), a main memory and a static memory, which communicate with each other via a bus. The system may include an input device (e.g., a keyboard) or touch-sensitive screen, a cursor control device (e.g., a mouse), a disk drive unit, a signal generation device (e.g., a speaker or remote control) and a network interface device.

The disk drive unit may include a machine-readable medium on which is stored one or more sets of instructions (e.g., software) embodying any one or more of the methodologies or functions described herein, including those methods illustrated above. The instructions may also reside, completely or at least partially, within the main memory, the static memory, and/or within the processor during execution thereof by the machine. The main memory and the processor also may constitute machine-readable media. While the machine-readable medium can be a single medium, the term "machine-readable medium" should be taken to include a single medium or multiple media (e.g., a centralized or distributed database, and/or associated caches and servers) that store the one or more sets of instructions. The term "machine-readable medium" shall also be taken to include any medium that is capable of storing, encoding or carrying a set of instructions for execution by the machine and that cause the machine to perform any one or more of the methodologies of the present disclosure. The term "machine-readable medium" shall accordingly be taken to include, but not be limited to: tangible media; solid-state memories such as a memory card or other package that houses one or more read-only (non-volatile) memories, random access memories, or other re-writable (volatile) memories; magneto-optical or optical medium such as a disk or tape; non-transitory mediums or other self-contained information archive or set of archives is considered a distribution medium equivalent to a tangible storage medium. Accordingly, the disclosure is considered to include any one or more of a machine-readable medium or a distribution medium, as listed herein and including art-recognized equivalents and successor media, in which the software implementations herein are stored.

Dedicated hardware implementations including, but not limited to, application specific integrated circuits, programmable logic arrays and other hardware devices can likewise be constructed to implement the methods described herein. Applications that may include the apparatus and systems of various embodiments broadly include a variety of electronic and computer systems. Some embodiments implement functions in two or more specific interconnected hardware modules or devices with related control and data signals communicated between and through the modules, or as portions of an application-specific integrated circuit. Thus, the example system is applicable to software, firmware, and hardware implementations.

ADVANTAGES OF THE INVENTION

1. Reduce design lead time from 15 days to 1 day for same type of new tool & try much iteration in a short time.
2. This automation will help a die designer to complete a project with less effort & time in future.
3. Well proven design – has captured all design rules & domain expertise.
4. This development will stimulate more such innovations for other types of tooling.
5. Improvement in productivity of designers.

The invention has been described in a preferred form only and many variations may be made in the invention which will still be comprised within its spirit. The invention is not limited to the details cited above. The structure thus conceived is susceptible of numerous modifications and variations, all the details may furthermore be replaced with elements having technical equivalence. In practice the materials and dimensions may be any according to the requirements, which will still be comprised within its true spirit.

WE CLAIM

1. An automated method for use in magnetic riveting die designing, said method steps comprising:
collecting data in the form of predetermined parameters;
categorizing and standardizing said parameters;
a developing phase;
wherein said phase comprising:
customizing of said categorized and standardized parameters;
drafting in 2D based on said customized parameters;
modeling systematic construction of 3D assemblies;
wherein said steps of drafting and modeling being functionally related to each other by means of an appropriate relationship and programming between each other;
a testing and implementing phase;
wherein said phase comprising:
receiving an input value from a user;
regenerating said 3D modeling and said 2D drafting by means of said received input data; and
releasing an output.

2. Method as claimed in claim 1, wherein said magnet is a substantially ‘E’ shaped magnet.

3. Method as claimed in claim 1, wherein said parameters are selected from length, width, thickness, and rivet head height of said magnet and the like.

4. Method as claimed in claim 1, wherein said step of programming and relationship is adapted to be performed by means of a parametric CAD software.

5. Method as claimed in claim 1 wherein said relationship is a dimensional relationship.

6. Method as claimed in claim 1 wherein change in assembly design corresponds to small change in parameters of 3D model.

7. An automated method for use in magnetic riveting die designing as herein substantially described and illustrated with the accompanying drawings.