Methods and apparatuses for backgaging and sensor-based control of bending operations

A finger gaging apparatus for use in an apparatus for aligning a malleable sheet workpiece with respect to a die of a bending apparatus when loading said workpiece into a die space, before performing a bend operation on the said workpiece, said apparatus comprising:

• a gaging finger having an elongated member with a longitudinal axis parallel to or orthogonal to said die, said gaging finger comprising:
• a contact portion that moves with said elongated member;
• and
• means for measuring forces of contact between said workpiece and said contact portion, said forces of contact comprising both a force parallel to said die and a force orthogonal to said die.

A bending apparatus for performing a bend operation on a malleable sheet workpiece, said bending apparatus comprising:

• a die and a tool punch, said die and tool punch forming a die space;
• a gaging mechanism comprising at least one gaging finger, each gaging finger gaging a position of said workpiece along a first direction orthogonal to said die and along a second direction parallel to said die;
• a robot having a gripper for holding said workpiece;
• and
• means for controlling said robot to bring said workpiece into contact with said at least one gaging finger;
• said robot gripper comprising a gripper force sensor for sensing an amount of force between said workpiece and said robot gripper, and said gaging finger comprising a finger force sensor for sensing an amount of force between said at least one gaging finger and said workpiece contacting said at least one gaging finger.

A method for aligning a malleable sheet workpiece with respect to a die of a bending apparatus, said bending apparatus comprising a finger gaging mechanism, said finger gaging mechanism including a finger tip member mounted on a support base for rotational movement about a pivot point, said method comprising:

• detecting contact forces on said finger tip member based on movement of said finger tip member with respect to said pivot point;
• moving said workpiece toward said finger tip member until said contact force is detected between an edge of said workpiece and said finger tip member;
• and
• adjusting based on said detected contact force, an orientation of said workpiece with respect to said die by rotating said workpiece about said finger tip.

A method for aligning a malleable sheet workpiece with respect to a die of a bending apparatus when loading said workpiece into a die space, said bending apparatus comprising a gaging finger having an elongated member with a longitudinal axis parallel to or orthogonal to said die, said gaging finger comprising a contact portion that moves with said elongated member, said method comprising:

• measuring forces of contact between said workpiece and said contact portion based on movement of said contact portion, said forces of contact comprising both a force parallel to said die and a force orthogonal to said die;
• moving said workpiece toward said contact portion until said contact forces are measured and detected;
• and
• adjusting based on said detected ocntact force, an orientation of said workpiece with respect to said die by rotating said workpiece about said contact portion.

A bending apparatus for performing a bend operation on a malleable sheet workpiece, said bending apparatus comprising:

• a die and a tool punch, said die and tool punch forming a die space;
• a gaging mechanism comprising at least one gaging finger each gaging finger gaging a position of said workpiece along a first direction orthogonal to said die and along a second direction parallel to said die;
• a robot having a gripper for holding said workpiece;
• and
• a control mechanism that controls said robot to bring said workpiece into contact with said at least one gaging finger;
• said robot gripper comprising a gripper force sensor for sensing an amount of force between said workpiece and said robot gripper, and said gaging finger comprising a finger force sensor for sensing an amount of force between said at least one gaging finger and said workpiece contacting said at least one gaging finger.