System and method for making braces for dies

Abstract

A system and method for producing braces for a cavity die having a predetermined shape are disclosed. The system includes an input file containing information about the shape of the cavity die and a bracing program running on a computer. The bracing program produces an output file based on the input file and brace parameters. The output file includes information about the design of the braces. The computer instructs a brace-making machine to produce the braces based on the information in the output file. The method includes the steps of: a) providing input information about the shape of the cavity die and the brace parameters to the computer; b) processing the input information by the computer to produce an output file containing information about the design of the braces; and c) producing the braces in accordance with the information from the output file.

1 . A method of producing a brace for a cavity die having a predetermined shape, the method comprising: 
 a) providing input information to a data processor, the input information comprising information about the predetermined shape of the cavity die and brace parameters;    b) processing the input information by the data processor to produce an output file containing information about the design of the brace; and    c) producing the brace in accordance with the information from the output file.    
   
   
       2 . The method of  claim 1 , wherein the input information comprises an input file containing the information about the predetermined shape of the cavity die.  
   
   
       3 . The method of  claim 2 , wherein the input file comprises a DXF file.  
   
   
       4 . The method of  claim 1  wherein the producing step further comprises: 
 a) supporting a strip of material to be cut on a bed;    b) engaging the strip of material to a material feeder operable to move the strip of material in a first direction;    c) providing a cutting tool movable in a second direction across the strip of material; and    d) coordinating the movement of the material feeder and cutting tool through a control system to make a desired cut in the strip of material.    
   
   
       5 . The method of  claim 4 , wherein the coordinating step utilizes a programmable logic controller, wherein the controller is operatively connected to a cutting tool servo and a material feed servo.  
   
   
       6 . The method of  claim 5 , wherein the coordinating step further comprises the steps of: 
 a) if the strip of material is ready to be cut, cutting a head of a brace from the strip of material;    b) cutting a tail of the brace from the strip of material; and    c) if more than one brace is required, repeating steps (a) to (b) for each brace to be cut.    
   
   
       7 . The method of  claim 1 , wherein, if more than one brace is required for the cavity die, the processing step further comprises calculating the number and location of the braces.  
   
   
       8 . The method of  claim 7 , wherein the calculating step comprises: 
 a) checking for discontinuities in the perimeter of the cavity die;    b) if any discontinuities are located, correcting the discontinuities;    c) orienting the cavity die in a reference direction;    d) determining the location and shape of edge braces;    e) determining the number, location, and shape of interior braces;    f) if required, determining the number, shape, and location of tab braces;    g) if required, determining the number, shape, and location of support braces;    h) if required, determining the number, shape, and location of support braces; and    i) locating mounting holes for each brace.    
   
   
       9 . The method of  claim 1 , wherein the brace parameters comprise brace width, starting brace centre point from edge, minimum brace spacing and maximum brace spacing.  
   
   
       10 . The method of  claim 1  wherein the processing step further comprises: 
 i) drawing a pair of edge braces having parallel centerlines and located at the starting brace center point from edge distance from the furthest points of the die perpendicular to the centerline of the edge braces, the edge braces having a constant width equal to the brace width and end profiles determined by intersection with the shape of the die; and    ii) if the distance between the edge braces is greater than the maximum brace spacing, drawing a number of interior braces having centerlines parallel to the edge braces and regularly spaced between the edge braces, the number being the lowest number such that the regular spacing is between the minimum brace spacing and maximum brace spacing, the interior braces having a constant width equal to the brace width and end profiles determined by intersection with the shape of the die.    
   
   
       11 . A method of producing an output file containing information for the design of braces for a cavity die having a predetermined shape, the method comprising: 
 a) providing input information to a data processor, wherein the input information comprises information about the predetermined shape of the cavity die and brace parameters, the brace parameters comprising brace width, starting brace centre point from edge, minimum brace spacing and maximum brace spacing; and    b) processing the input file and the parameters to produce the output file, wherein the processing step comprises: 
 i) drawing a pair of edge braces having parallel centerlines and located at the starting brace center point from edge distance from the furthest points of the cavity die perpendicular to the centerline of the edge braces, the edge braces having a constant width equal to the brace width and end profiles determined by intersection with the shape of the cavity die; and  
 ii) if the distance between the edge braces is greater than the maximum brace spacing, drawing a number of interior braces having centerlines parallel to the edge braces and regularly spaced between the edge braces, the number being the lowest number such that the regular spacing is between the minimum brace spacing and maximum brace spacing, the interior braces having a constant width equal to the brace width and end profiles determined by intersection with the shape of the cavity die.  
   
   
   
       12 . The method of  claim 11  wherein the input information comprises an input file containing information about the predetermined shape of the cavity die.  
   
   
       13 . The method of  claim 12  wherein the input file comprises a DXF file.  
   
   
       14 . The method of  claim 11  wherein the output file comprises a drawing file of the braces.  
   
   
       15 . The method of  claim 11  wherein the output file comprises computer-readable instructions for a brace-making machine to produce the braces.  
   
   
       16 . The method of  claim 11  wherein the brace parameters further comprise one or more members selected from the group of: (i) start brace center from edge if over support parameter; (ii) internal bracing support length; (iii) brace mounting hole diameter; and (iv) brace mounting distance from edge.  
   
   
       17 . The method of  claim 11  wherein the processing step further comprises: 
 a) checking for discontinuities in the perimeter of the cavity die, and if any discontinuities are located, correcting the discontinuities;    b) orienting the cavity die in a reference direction;    c) if required, determining the number, shape, and location of tab braces;    d) if required, determining the number, shape, and location of support braces;    e) if required, determining the number, shape, and location of support braces; and    f) locating mounting holes for each brace.    
   
   
       18 . A computer readable medium having a computer program recorded thereon for producing an output file containing information for the design of braces for a cavity die having a predetermined shape, the computer program causing the computer to perform the steps of: 
 a) accessing information about the predetermined shape of the cavity die;    b) accessing brace parameters relating to the location of the braces, the brace parameters comprising brace width, starting brace centre point from edge, minimum brace spacing and maximum brace spacing;    c) processing the input file and the brace parameters to produce the output file, wherein the processing step comprises: 
 i) drawing a pair of edge braces having parallel centerlines and located at the starting brace center point from edge distance from the furthest points of the cavity die perpendicular to the centerline of the edge braces, the edge braces having a constant width equal to the brace width and end profiles determined by intersection with the shape of the cavity die; and  
 ii) if the distance between the edge braces is greater than the maximum brace spacing, drawing a number of interior braces having centerlines parallel to the edge braces and regularly spaced between the edge braces, the number being the lowest number such that the regular spacing is between the minimum brace spacing and maximum brace spacing, the interior braces having a constant width equal to the brace width and end profiles determined by intersection with the shape of the cavity die.  
   
   
   
       19 . The computer readable medium of  claim 18  wherein the information about the predetermined shape of the cavity die is stored in an input file.  
   
   
       20 . The computer readable medium of  claim 18  wherein the output file comprises a drawing file of the braces.  
   
   
       21 . The computer readable medium of  claim 18  wherein the output file comprises computer-readable instructions for a brace-making machine to produce the braces.  
   
   
       22 . The computer readable medium of  claim 18  wherein the brace parameters further comprise one or more members selected from the group of: (i) start brace center from edge if over support parameter; (ii) internal bracing support length; (iii) brace mounting hole diameter; and (iv) brace mounting distance from edge.  
   
   
       23 . The computer readable medium of  claim 18  wherein the calculating step comprises: 
 a) checking for discontinuities in the perimeter of the cavity die, and if any discontinuities are located, correcting the discontinuities;    b) orienting the cavity die in a reference direction;    c) if required, determining the number, shape, and location of tab braces;    d) if required, determining the number, shape, and location of support braces;    e) if required, determining the number, shape, and location of support braces; and    f) locating mounting holes for each brace.