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JournalofMaterialsProcessingTechnology88(1999)216–221

Anexpertsystemofprogressivediedesignforelectrongungrid

parts

SangB.Park*

DepartmentofDieandMouldDesign,Dongeui,InstituteofTechnology,San72,Yangjeong-dong,Pusanji-ku,Pusan614-715,SouthKorea

Received14November1997

Abstract

Duetotherequirementofhighprecisionandcomplexityduringthediedesignforelectrongunelements,humanerrorssometimesoccur.Also,inthecaseofnovicedesigners,theyrequiremoretrial-and-errorthanskilledengineers.Toeliminatetheseproblemsandincreaseproductivityinpractice,thereistheneedforthedevelopmentofaCADsystemforelectrongunelementprogressivedie.Inthisstudy,aCADsystemforanelectronelementprogressivedie,whichisusedbyaknowledge-basesystemandmakesuseoftheexperttechnologyofthoseinpractice,hasbeendeveloped.Todevelopthissystem,C-languagehasbeenusedundertheHP-UNIXsystemandCIScustomerlanguageoftheEXCESSCAD/CAMsystem.Theapplicationofthissystemwillprovideaneffectiveaidtothedesignerinthis eld.©1999ElsevierScienceS.A.Allrightsreserved.

Keywords:Diedesign;Electrongun;Gridparts

1.Introduction

Thegridpartsofanelectrongun,whichconsistsofaBrauntube,areusedduringthecontrollingofanelectronbeamthatisextractedfromthecathodeofanelectrontube.Theyhavetheformofasmallholeinthecenterofadisk,cylindricalinshape,whichusesnon-magneticmaterialsothatitwillnotbeaffectedbyexternalmagnetic elds.InthecaseoftheprogressivediedesignofthegridpartoftheelectrongunoftheBrauntube,owingtothedetaileddrawingofitssize,andsothatitwillnotbeaffectedbyexternalcharacter-isticsofitsdesign,alotofdesigntimeisrequired.Inparticular,beginners,whoexperiencegreatertrainingerrorthanskilledworkers,andalsoexperiencedwork-ers,alsofollowacomplicatedsystemthatshouldrepeatthesameprocedureeverytimeforthesameobjects.Withstandardizedshapesthesameprocessinthede-signmethodshouldberepeated,onlybeingchangeableinrespectofthesizeoftheirchangingelements.Insuchaworkingcase,itisdesirabletoapproachtheparamet-ricmethodthatwasdevelopedbyVerroustetal.[1]or

*Fax:+82-51-8603329.

E-mailaddress:psb@dit.ac.kr(S.B.Park)

theparametricprogrammingmethodthatwasdevel-opedbyMcMahonetal.[2].

Inthisstudy,acomputer-aideddesignsystemofaprogressivedieisdevelopedforthegridpartsoftheBrauntubeelectrongunbyapplyingtheparametricautodesignmethodfortheproductionoftheprogres-sivedie,asshowninFig.1.Thesystemdevelopedconsistedof:themainparameterinputmodule;thedetailedbendinginputmodule;theembossing,theswagingandthedetailedinputmodule;thestrip-layoutmodule;theparametercalculatingmodule;theparame-

Fig.1.Theconstructionofanelectrongun.

0924-0136/99/$-seefrontmatter©1999ElsevierScienceS.A.Allrightsreserved.PII:S0924-0136(98)00413-0

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S.B.Park/JournalofMaterialsProcessingTechnology88(1999)216–221217

Fig.2.Thegridofanelectrongun.

terallocatingmodule;andthedrawingmodule[3].Thesystemwillcreatethedesignplanthatwillapplytoproducetheactualelectrongunelementsandwasde-velopedusingCISlanguageundertheenvironmentofthepressdieexclusiveCAD/CAMsoftwareEXCESS,andC-languageonthebasisofUNIXO/S.

2.Diedesigntechnique

2.1.Studyscopeandobjecti6es

Intheequipmentdisplayindustry,effortshavebeendevotedtodevelopmaximizationofscreensizeandhigh-qualityscreendisplay.IntheCRTequipmentindustry,thephenomenonofdecreasingoftheresolu-tionaccordingtothemaximizationofthescreencouldproducehighresolutionwithalargescreenbyimprove-mentoftheelectrongungridparts,whicharethetransportpassageforthe uorescent lmconnectingthebeamofthecathode,whichlatteremitselectrons.Therefore,thisstudyisaimedatthereductionofthemanpoweranddesigningtime,thatareneededfortheproductionofhighqualityelectrongungridparts,andalsohastheobjectiveofstudyingthedevelopmentofacomputer-aideddesignsystemfortheprogressivediefortheproductionoftheelectrongungridpartsfortheBrauntube.

AsshowninFig.2,thepresentstudyconsidersholesthatcanpassthree(red,greenandblue)beams,andtheelectrongungridparts,whichhavethesubmergedregionsbythebeamglass.

2.2.Diestructureanddesign

ThematerialoftheelectrongungridpartsisSUS304LorSUSwire,whichdoesnotoffsetanexternalmagnetic eld.Thebasicdiestructurewillarrange16processshapesofthedieandpunches,suchas‘pilotpiercing’,‘notching’,‘bending’,‘embossing’,‘swaging’,‘trimming’,and‘parting’forthedieoftheelectrongungridparts,andtogetherwithotherdiesetsandaddi-tionaltools.Inparticular,thereneedstobehighaccu-racyofpunchanddiedesignthatrequiresred,green

Fig.3.Thestructureoftheautomaticdrawingsystemforthegridtools.

andblueholes,aswellasofeverypartofthegridandtherealsoneedstobeeaseofattachmentanddisman-tlingofthespeci ctransfertoolsforthegradualtrans-portofthestrip-steelplateoftheprogressivediematerialsandthestrippingmechanismofthethinsheetmetal[3].Themethodfordesigningthedieandthepunchthatformtheelectrongungridpartsemploystwo-dimensionalexclusiveCADsoftwareoramanualdesigningmethod.Recently,ithasbecomeageneraltrendtoselecttheformerfordiedesigningandforthereductionofdesigntimeandoftheprimecostoftheproduct.

2.3.Utilizingtheexpertsystem

Thiselectrongridrequiresthinsheetsofmetal(0.33mm),ofcomplicateshapeattheformingpartandthesubmergedpart,withhighaccuracybeingrequiredat

Fig.4.Inputtableofthegeometricalinformationfortheproduct.

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218S.B.Park/JournalofMaterialsProcessingTechnology88(1999)216–221

Fig.5.Detailedinputfortheregion.

thegridpartand atnessattheplaneregion.Inpartic-ular,theformandwidthofthesubmergedregions,thediameterofneck,theshapeofR.G.B.(red,greenandblue)holesandtheshapeofthestandardhole;theauthorsconsiderthecaseofwhethertheaboverequire-mentsareachieved.Theresultsoftheoutputofthedesignareofvarioustypes.Thus,thestructureofatechnicalsystemmustbedrawnfromdieofthetheBrauntubeelectrongungridpart,providinginputfortheformofthesubmergedregions,thewidthofthesubmergedregions,andthediameterofneck,aswellasinformationfortheR.G.B.holesandstandardholes,onthebasisofinputinformation.Thestriplayoutfortheprogressivedieprocess,thetotalassemblydrawing,thepartdrawingandthedetaildrawingofthedieandpartlistareoutputted.

Inordertoembodythisasasystem,eachmoduleofthesystemmustbeconstructedsoastomakeorganicrelationsbetweentheactualsitedatabasethatrelatetothedrawings,andtheknowledgebasethatisrequiredatthedrawingprocedureanddecision[4].

Fig.6.Detailedinputfortheembossingandswagingregion.

3.Constructionofthesystemandrulebase

3.1.Constructionofthesystem

Fig.3showsthestructureofthesystemthathasbeendevelopedinthepresentstudyforthedrawingofthedieoftheelectrongungridpartbyreceivinginputwiththepick-upmethodforthemainvariablesandthedetaildrawingvariables.Thesevariablesaffectthewholesystem,beingmainparameters,andareadminis-teredwiththedrawingdata le.Thesemainparametersandsub-parametersareassignedtotheorderlycallingmodulebytheneedforthediedrawing,thetotal-as-semblydrawing,thepartdrawingforthedieconstruc-tion,andspecialpartdetaildrawingandparticularitemsthatareneededfordieproduction.Theyaredevelopedasanoutputsystemwiththepartlist.Themoduleofinputofmainparametersassignspicked-updatatothede nedvariablesthatinthesystemreceiv-inginputstandarddrawingdata,suchasform,sizeandpitchoftheelectrongridparts,whichappearinthemainparametertable.Thedetailinputofthebendingregionreceivesinputofembossing,andtheswagingregionwillreceiveinputfromthedetaileddrawingofeachpartofthegridpart,whichisdividedbythefunctionvariablesofthegrid.Themoduleofcalcula-tionofparameterswasoperatedbytheequationthatisrequiredatthedrawingtimethatallocatesparametersatthemainparameterandthedetailinputtable.Italsomanagestheclearancewhichcanaffecttheholemod-ulesofthesystem,thematerialandthedie,escapingamountamongpunches,theformofproducts,infor-mationofholeR.G.B.andstandardholeinformation.Inaddition,itmanagesthesub-parameterforthesizeofletters,thepositionofcomments,anddetaileditemsofsizedescription.

Themoduleofassignmentofparametersallocatesthemainparametersandthesub-parametersthatareneededforthatmodulewheneachmoduleiscalledbytheoperatingofthesystemmanagingrule.Thedrawingmoduleconsistsofthestriplayoutmodule,theassem-blymodule,thepartdrawingmodule,thedetaildraw-ingmodule,thedimensionrecordmodule,andthepartlistmodule.Thestrip-layoutmoduleoutputsthestriplayout,whichisintheorderoftheproductsofeachprocessconsistingofpilotpiercing,notching,bending,swaging,embossing,trimming,andparting.Theassem-bly-drawingmoduleoutputsthetotalassemblydrawingoftheprogressivedie.Thepart-drawingmoduleout-putsthepartdrawingforeachdieelementthatconsti-tutesthemodule.Thedetail-drawingmodulemagni esspeci cpartswhichareindistinguishableontheactual-scaledrawing.Thepart-listmoduleoutputsspeci cde neditems,suchasthearticlenumberofeachdieelement,thenamesoftheparts,thequalityofthematerial,therequiredamountsandtheheattreatment.

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S.B.Park/JournalofMaterialsProcessingTechnology88(1999)216–221219

Fig.7.Outputofthestrip-layoutdrawing.

Thedimensioningmodulerecordsdimensionsauto-matically(byjudgingtheirdirectionandposition)thatarerequiredinthedimensioningatthemoduleinwhichtheshapeandsizeforeachelementofthedieusedatthedesigningtimeareconstructedbyadjustingwiththedatabasethatisapplicablebyquantifying,attheinferenceengine,informationacquiredfromahandbookrelatedtodietechnology,fromdata-booksinpractice,andfromdiscussionswithdieengineersinthe eld[5–7].

3.2.Rulebase

Thisstudyappliedthesystemembodimentbyarrang-ingadrawingrulebasethatwasformalizedsystemati-callyaccordingtotheformalizedrulesofthe eldworker,thedesigner,ofreferences,ofaccumulatedknow-howorinthetechnicaldata.Thestudyallocatedthedrawingdatatothevariablesbythepick-upmethodandbythetableforthedrawingdataoftheelectrongungridparts,shape,andsize.Ifthisisinputted,itwilloutputallpartsofthedrawingsoftheprogressivedie,ofthetotal-assemblydrawings,ofthestrip-layout,andofadetailedassemblydrawing.

Eachmoduleconstructedherewillreceivehelpfromdatabasesthathavebeenconstructedpreviouslyorfromadatabasethathasbeennewlyformingwhilethesystemisproceeding.Thetotal oworprocedurewillfollowthedrawing-rulebasethatwasarrangedthroughinterviewswithpressdieengineers.Sucharulebasehasmadeitsrulequanti edtobeconsistentlogicallywiththebasisof eldtechnicaldata,technicalreports,andbooksthatarerelatedtoplasticworkingor eldengineering.

Fig.8.Frontviewoftheassemblydrawing.3.3.Applicationofthesystemanditsconsideration

http://wendang.chazidian.comingthesystem,theinputtableoftheuser’sinputmodulewasinputtedtheshapeofthesubmergedregion,A-type,wherethewidthofthesubmergedregionwas17mm,thediameterofneckwas20.8mm,thepitchofR.G.B.holewas6.6mm,theshapeofstandardholewasF-type,thepitchofstan-dardholewas2.6mm×2.8mm,andthesizeofthestandardholewas 1.2.

Fig.4showsthe nishedinputinformationoftheproducts.Forthedetailinputtableofthebendingarea,thedetailsizethatisrelatedwithbendingwasselectedasA,B,C,D,EandR,andattheembossingandswagingthedetailsinputtable Da, Db, P, Ed, h, G, Ha, R, St,and Sewereselected.Amongthedetaildrawingsizethatisdividedbythegridpartsfunction,character,andshapeforthestan-dardformation,inthecaseofbendingwasselectedas‘ 2’.

InFig.5thedetaildrawingsizethatisinputtedbythebendingdetailinputtableisshown,andFig.6showsthedetaildrawingsizethatisinputtedbytheembossingandswaging.Thedetailinputtable,andFig.7,showitemsthatareusedasmainparameters.ByinputtingtherelatedinformationoftheproducttothecharacteristicsthataregoingtodrawFigs.4–6,thesystemresultsofFigs.8–13areacquired.

Fig.8showsthestriplayout,whichoutputtedthestriplayoutresultingfromtheproductsof16processes,suchaspilotpiercing,notching,bending,swaging,em-bossing,trimming,andparting.Afterthepartingpro-

Fig.9.Topviewoftheassemblydrawing.

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220S.B.Park/JournalofMaterialsProcessingTechnology88(1999)216–221

Fig.10.Partdrawingofthedie.

cess,thegridpartsthatwereinputtedattheinputpartarenowknownasoutputted,andarecalculated.The owofthestripshowstherelationofthedieassemblyfromtheleftinputandpassesthrougheachprocessuptotheright-handsidepartingprocess.

Fig.9showsthetopviewoftheassemblingdrawingandFig.10showsthepartdrawingofthedie.Theshapeandsizeofthecompleteddrawingofthediecandetecttheshapeandsizeandaccuracyintheprocessingofinputtedproducts.

Fig.11showsthepartdrawingofthepunchandFig.12showsthedetaileddrawingofthestripper.Fig.13showstheoutputtedpartlist.

Throughthesystem,thestudytriestoconsidertheresultofdiedesign.Fromtheoutputteddesignresultofthedie,itispossibletoadjusttheoperatingworkplace.Adjustingthedevelopedsystemenablestheminimiza-tionoftrial-and-errorduringdiedesign,andhasbeencon rmedtoeliminatemistakes.

Inaddition,evenbeginnerscanacquiretheresultsofdesignspecialists,andatthestepofthedesignofproducts,itispossibletodeterminewhetherthepressdieproductioncanserveasatoolofsimulationthatcandistinguishthepossibilityofutilizingpressdieproduction.

Fig.11.Partdrawingofthepunch.Fig.12.Detaileddrawingofthestripper.

4.Conclusions

Thisstudydevelopedacomputer-aideddesignsystemforthepartsofthegridofaBrauntubeelectrongun.Thisisacomputer-aideddesignsystemwhichoutputstheelectrongungridpartsdiedesignanddrawings.Astheinputofthesystemisdataoftheshapeofthegrid,anddataofthedimensions,andastheoutputofthesystem,isthestriplayoutofthegridprogressivedie,thetotalassemblydrawing,thepartdrawing,thedetaildrawing,andthepartlist.

Inordertobuildupthedatabaseofthedesignmethodandthedesignknowledge,themethodofquan-ti cationbyinterviewingdiedesignspecialistsorbyacquiringknowledgefromtheexisting elddatawasused.TheexpressionoftheknowledgeusedC-languageontheUNIXoperatingsystem,andusedCISlanguageontheenvironmentofEXCESSCAD/CAMsoftware.Thecomputer-aideddesignanddrawingsystemthatwasdevelopedbythisstudymayoutputthediedesigndrawingthatisnecessaryfortheproductionofthediebyinputtingfromminimuminformation,thusenablingthedeterminationoftheshapeoftheBrauntubeelectrongungrid.

Fig.13.Outputofthepartlist.