The object of the invention is a computer-assisted method for manufacturing busbars, utilising a computer program and devices for plastic shaping of flat bars, in particular made of copper, aluminium and their alloys, into the form of busbars used, e.g. as the components of switchgears as well as modern electrical enclosures and control cabinets. The object of the invention is also a system of devices for the implementation of this method, and a plastic flat bar shaping device using this method.

Busbars are used in a wide range of ampacities, which translates into considerable diversity of electrically active cross-sections, shapes and sizes, as well as the precision of their manufacturing. The manufacturing of a busbar requires the performance of multiple technological operations, such as punching, cutting, bending and torsion, which are meant to ensure the target size, shape and dimensions of a given bar. Devices for manufacturing busbars perform the required technological operations in a linear system, i.e. one by one, the busbar being each time manufactured from a flat bar segment with a length greater than the length resulting from the sum of the individual segments of the busbar having its target shape. This fact results directly from the difficulty to predict the exact length of the profile, due to local changes in its dimensions (shortenings, thickenings and other changes in form), occurring during multiple bending operations. The currently produced busbars are usually manufactured in a dieless manner, which leads to local changes in the linear dimensions of the profile (shortening or lengthening, which takes place in accordance with the volume conservation law) as well as a change in angular relationships, i.e. a change in their form. The used plastic shaping operations lead to local improvement in the strength properties of the bar material, and as a consequence to deterioration of its plastic properties, and the elastic-plastic nature of matter leads in turn to changes restoring the shape and dimensions within the elastic range, to an extent depending on the size of deformation and the degree of reinforcement of the material. This translates into changes in size by many millimetres, and deviations of the busbar from the input target size (the final bar) by multiple angles.

Therefore, the technical problem is to develop a new method for manufacturing busbars, computer-assisted, provided with an intuitive user interface, which would ensure limiting the involvement of engineering knowledge in favour of intuitive design of ci rcuits by an operator who does not possess the required skills and qualifications.

The essence of a computer-assisted method for manufacturing busbars using a computer, a computer program and at least one plastic flat bar shaping device, is i n that it includes the following, in this order: (A) creating a 3D model of a busbar in the computer program, whose correctness is inspected in an ongoing manner by the computer program, with simultaneous inputting of the material properties of the designed busbar and the technological operations necessary to manufacture it; (B) calculating the extension of the busbar; (C) validating and refitting the plastic flat bar shaping device; (D) transmitting information to the plastic flat bar shaping device; (E) activating the plastic flat bar shaping device and performing the input technological operation; (F) monitoring and inspecting the correct performance of the input technological operation in real time.

Preferably, once the plastic flat bar shaping device has performed the input technological operation, the plastic flat bar shaping device is reactivated, and the next input technological operation is performed.

Preferably, the plastic flat bar shaping device is a busbar cutting and punching device.

Preferably, the plastic flat bar shaping device is a busbar bending device.

Preferably, the generation of a 3D model of a busbar in the computer program is performed on the basis of an input two-dimensional design.

Preferably, the generation of a 3D model of a busbar in the computer program is performed with the use of a touch-screen by means of fingers and/or a stylus and/or a keyboard and a mouse.

Preferably, the computer program comprises windows and the related toolbars, including a drawing and 3D visualisation window, and the data of the 3D model are updated in an ongoing manner.

Preferably, the drawing and 3D visualisation window comprises a 3D view of the designed busbar, a set of tools with multi-touch support, a context menu, a busbar rotation tool in all axes, a set of tools for designing the busbar, and a menu of design properties.

The essence of the system of devices for implementing the computer-assisted method for manufacturing busbars is in that it comprises a computer provided with peripheral devices intended for the user's communication with the computer, a computer program installed on this computer, and at least one plastic flat bar shaping device connected to the computer.

Preferably, communication between the computer and the plastic flat bar shaping device takes place in a wired or wireless manner, by means of Ethernet, and control is implemented by a PLC controller managing the device.

Preferably, the peripheral devices may include a touch-screen, a stylus, a computer mouse, a keyboard and/or an operating panel.

Preferably, the plastic flat bar shaping device is a busbar cutting and punching device provided with an input feeder, an output feeder, a body, a bar with punchers, an operating panel and a device for communication with the computer, preferably a PLC controller.

Preferably, the plastic flat bar shaping device is a busbar bending device provided with a worktop, a body, an operating panel, a bending insert and a device for communication with the computer, preferably a PLC controller.

The essence of the device for plastic shaping of busbars for implementing the computer-assisted method for manufacturing busbars is in that it is adjusted to the implementation of the method according to the invention.

The solution according to the invention is presented in embodiments in the attached drawing, in which:

Fig. 1 presents the method according to the invention as a block diagram,

Fig. 2 presents a 3D drawing of a busbar created in a computer program as seen when inspecting the correctness of technological processes,

Fig. 3 presents a computer program visualisation for calculating the extension of the busbar,

Fig. 4 presents a computer program visualisation for validating and refitting a device for physical manufacturing of the designed bar;

Fig. 5 presents a computer program visualisation for inputting the punching operation;

Fig. 6 presents a diagram of a system of devices for manufacturing busbars using the method according to the invention;

Fig. 7 presents a busbar cutting and punching device in a perspective view;

Fig. 8 presents a busbar bending device in a perspective view. The object of the invention is a method for manufacturing busbars whose implementation requires a computer program for designing flat bars, including flat bars made of copper, aluminium, their alloys, or a combination of these two metals. Preferably, the computer program used to implement the method according to the invention has two operating modes. In the first mode, the computer program cooperates directly with manufacturing devices, assisting the design work (drawing the busbar and dimensioning it in a 3D view), calculating the length of the bar when extended from its bent and/or twisted form, and controlling the process (transmitting information to a PLC controller). On the other hand, in the second mode the computer program is used on a typical PC computer or laptop only for design and computational processes, and in order to generate files which would be openable in a program directly on the manufacturing device.

The computer program is intended to assist devices for manufacturing busbars, starting with the design of a detail in a 3D view in consecutive technological processes, in various configurations, namely: cutting, punching, traditional bending and, in exceptional cases, transverse bending and torsion, in accordance with the input design. The computer program assists the entire process from designing a busbar and controlling a machine to manufacturing the designed bar and monitoring it during manufacturing. The design takes place by using proper peripheral devices, preferably a touch-screen and gestures (movements) performed thereon by means of fingers or a stylus (when designing on a device) or a keyboard and a mouse, or a combination of both methods when using a PC computer or a laptop with the use of a mouse and a keyboard.

The computer program is used directly on two stationary devices for manufacturing a busbar. The first one performs the cutting and punching operations only, the second one— the bending operations only. Both devices use the same software, which depending on the configuration may hide options related to the respective modules in order to manufacture a detail. However, in each case there is a possibility to design a fully functional busbar on each of these devices.

Communication of the computer program with the cutting and punching as well as the bending device takes place by means of Ethernet. Low-level control of the process is provided by the PLC controller itself, managing each of the machines.

The computer program comprises windows and the related toolbars. The main window is the drawing and 3D visualisation window, in which a detail being drawn can be rotated freely for its visual inspection. Rotation of the detail takes place by sliding a finger or fingers across an active window displaying the 3D model (the multi-touch function: zooming in, zooming out and rotating the view), or with the use of tools created for this purpose, used by means of a computer mouse. The rotation takes place spatially. The data i n the 3D model are updated in an ongoing manner.

The computer program inspects the correctness of the elements implem ented in the busbar, such as, e.g. the openings. The following are inspected: the distances between openings, the distances from the openings to the bends, the distances from the openings to the edges of the bar, as well as the applied bend radii and angles.

Example 1: Using a planar technical drawing, an operator created a 3D model of a busbar with the shape and parameters presented in Fig. 2 in a computer program, with the computer program monitoring the correctness of the created model in an ongoing manner, highlighting the elements which may contribute to improper construction of th e bar in yellow. When creating the 3D model, the operator provided data regarding the planned technological operations (cutting, punching and bending) as well as the material properties of the designed busbar; afterwards, they performed calculation of the extension of the busbar (Fig. 3) as well as validation and refitting of plastic flat bar shaping devices (busbar cutting and punching devices as well as bending devices) by means of the computer program, followed by initiating the transmission of data to this device and activation of the first one of them. When performing the input action, the computer program was monitoring the performance of the input operation in real time. Once the cutting and punching operations were completed, the operator moved the bar to the busbar bending device and activated it.

Example 2: An operator created a 3D model of a busbar in a computer program, with the computer program monitoring the correctness of the created model in an ongoing manner, highlighting the elements which may contribute to improper construction of the bar in yellow. When creating the 3D model, the operator provided data concerning the planned technological operations (cutting and punching) as well as the material properties of the designed busbar, following which, by means of the computer program, they performed calculation of the extension of the busbar as well as validation and refitting of the plastic flat bar shaping devices (cutting and punching devices), followed by initiating the transmission of data to this device and its activation. When performing the input action, the computer program was monitoring the performance of the input operation in real time.

The system for implementing a computer-assisted method for manufacturing busbars comprises a computer 19 provided with peripheral devices intended for the user's communication with the computer, a computer program installed on this computer 19, and at least one plastic flat bar shaping device 1, 7 connected to the computer 19. Communication between the computer 19 and the plastic flat bar shaping device 1, 7 takes place in a wired or wireless manner, by means of Ethernet, and control is implemented by a PLC controller managing the device 1, 7. The peripheral devices may include a touch-screen, a stylus, a computer mouse, a keyboard and/or an operating panel 6. The plastic flat bar shaping devices 1, 7 may be a busbar cutting and punching device 1 or a busbar bending device 7. The busbar cutting and punching device 1 is provided with an input feeder 2, an output feeder 3, a body 4, a bar with punchers 5, an operating panel 6 and a device for communication with the computer, preferably a PLC controller. The busbar bending device 7 is provided with a worktop 8, a body 9, an operating panel 10, a device for communication with the computer, preferably a PLC controller, and a bending insert 11.

The main technological processes implemented with the assistance of the computer program are: (i) bending within a target angle range of 5 to 90 degrees (including traditional bending, transverse bending and torsion), (ii) punching with circular punchers, (iii) punching with oval punchers, (iv) punching with special punchers (other than circular and oval), (v) cutting flat bars with a maximum length of 4 metres.

The computer assistance of the method for manufacturing busbars also allows for: a) automatic completion of logical technological operations for plastic shaping of a busbar with the use of algorithms and engineering design support, which contributes to minimising the acceptance of potential geometric errors in busbars resulting from the inexperience of the technical personnel; b) calculating the length of the profile for the input bar model, taking into consideration the type of material, transverse dimensions (the relationship between the width and thickness of the bar), the magnitude of bend angles (position of the neutral plane) and torsion angles; c) the ability to automatically analyse geometric changes in the busbar in areas of the bending and torsion operations, unavailable in previous solutions, taking into consideration the necessary bar length surpluses, guaranteeing the resulting standardised bar size while taking into consideration the material properties of the designed bar; d) the ability to complete technological operations in a logical system opti mised in terms of maintaining the control geometric parameters of the bar, which translates into an increase in the efficiency of the process and a greater dimensional tolerance of the bar; e) determining the limitations and limit states of materials and profiles used for manufacturing the bars, including the indication of limit material parameters at the busbar design process stage, resulting from the input geometry of the final product (mechanical strength, fracturing, minimal bend radii and the risk of 'orange peel'), which was not possible with the use of the previous solutions; f) determining a change in the mechanical properties of the material depending on the magnitude and type of deformation, namely autonomic prediction of the evo lution of local changes in mechanical properties (hardness and tensile strength) of the profile (bar) undergoing shaping, depending on the applied process parameters, and as a result of intelligent identification (internal algorithms) of individual limitations of the material undergoing machining; g) performing the machining of the busbar with a precisely defined length of the input material, using computer-based estimation of the length of the input profile depending on the input shape and size of the busbar, as well as the type and number of technological operations and the type of the profile (the width to height quotient); h) monitoring the selected force parameters of load applied to the elements of the device and its kinematic parameters, which allows for controlling the work of individual elements of the device in terms of kinematics (repetitiveness of the position of the working elements provides additional information about repetitiveness of the geometric parameters of the manufactured bar) and in terms of force, which in turn allows for controlling the quality of the structure and the properties of the applied input materials, and when necessary allows for correcting the process parameters of bar manufacturing and predictions regarding the wear of tools.

The abovementioned advantages prove the uniqueness of the used combination of a computer program with devices for manufacturing busbars. This is because on the date of application there are no known devices with such wide applicability and functionality in terms of assisting the technology and automatic implementation with a guarantee of the shape and size geometry of the busbars desired (assumed at the design stage) by the receiver.

The system of devices for manufacturing busbars uses the ability to shape busbars while taking into consideration individual material limitations, which assists the operator and ensures interaction between the device and the operator, at the same time eli minating the possibility of manufacturing busbars which do not comply with the design.