Method and system for automated earth boring drill bit manufacturing

Abstract

A method and system for manufacturing a earth boring tool, comprising placing a tool in a positioner of an system which then conforms the tool to a model through the performance of a plurality of processing steps thereon. The positioner may move the tool in two axis. The system may include a manipulator which performs each of the processing steps. Alternatively, the system may include a plurality of manipulators, each performing a different one of the processing steps. The processing steps may include various shaping, cleaning, painting, and packaging steps. The processing steps may be performed without removing the tool from the positioner. The tool may be repositioned in the positioner during or between processing steps. For example, performing the processing steps may comprise performing one or more of the process steps, repositioning the tool in the positioner, and re-performing the one or more of the process steps.

1 . A method of manufacturing a earth boring tool, the method comprising the steps of:
 providing at least a partial computer model of at least a portion of finished earth boring tool to an automated manufacturing system;   placing a tool in a positioner of the system;   causing the system to conform the tool to the model through the performance of a plurality of processing steps thereon.   
     
     
         2 . The method of  claim 1 , wherein the positioner moves the tool in at least one axis. 
     
     
         3 . The method of  claim 1 , wherein the system further includes a manipulator which performs the processing steps. 
     
     
         4 . The method of  claim 1 , wherein the system further includes a plurality of manipulators, each performing a different one of the processing steps. 
     
     
         5 . The method of  claim 1 , wherein the performance of the processing steps comprises:
 performing one or more of the process steps;   repositioning the tool in the positioner; and   re-performing the one or more of the process steps.   
     
     
         6 . The method of  claim 1 , the processing steps include:
 removing an outer mold shell from the tool;   removing casting mold material from the tool; and   shaping the tool.   
     
     
         7 . The method of  claim 1 , the processing steps include:
 cleaning the tool;   masking predetermined portions of the tool; and   painting exposed portions of the tool.   
     
     
         8 . The method of  claim 1 , the processing steps include:
 preparing the tool for paint;   painting the tool; and   curing the paint.   
     
     
         9 . The method of  claim 1 , the processing steps include:
 painting the tool;   curing the paint; and   preparing the tool for shipment.   
     
     
         10 . The method of  claim 1 , the processing steps include:
 applying a shank protecting material to a shank of the tool;   applying a label to the tool; and   packaging the tool.   
     
     
         11 . The method of  claim 1 , wherein each of the plurality of processing steps are performed without removing the tool from the positioner. 
     
     
         12 . A method of manufacturing a earth boring tool, the method comprising the steps of:
 providing at least a partial computer model of a finished earth boring tool to an automated manufacturing system;   placing a tool in a positioner of the system;   causing the system to conform the tool to the model through the performance of at least one of a plurality of first processing steps selected from the group consisting of—
 removing casting mold material from the tool, 
 machining the tool, and 
 grinding the tool; 
   causing the system to conform the tool to the model through the performance of at least one of a plurality of second processing steps selected from the group consisting of—
 preparing the tool for paint, 
 painting the tool, and 
 curing the paint; 
   causing the system to conform the tool to the model through the performance of at least one of a plurality of third processing steps selected from the group consisting of—
 applying a shank protecting material to a shank of the tool, 
 applying a label to the tool, and 
 packaging the tool. 
   
     
     
         13 . The method of  claim 12 , wherein the positioner moves the tool in two axis. 
     
     
         14 . The method of  claim 12 , wherein the system further includes a first manipulator which performs the first processing steps, a second manipulator which performs the second processing steps, and a third manipulator which performs the third processing steps. 
     
     
         15 . The method of  claim 12 , wherein the system further includes a plurality of manipulators, each performing a different one of the processing steps. 
     
     
         16 . The method of  claim 12 , wherein the performance of the processing steps comprises:
 performing one or more of the process steps;   repositioning the tool in the positioner; and   re-performing the one or more of the process steps.   
     
     
         17 . The method of  claim 12 , wherein each of the processing steps of each of the plurality of processing steps are performed without removing the tool from the positioner. 
     
     
         18 . A method of manufacturing a earth boring tool, the method comprising the steps of:
 providing a computer model of a finished earth boring tool to an automated manufacturing system;   placing a tool in a two axis positioner of the system;   causing the system to conform the tool to the model through the performance of at least one of a plurality of first processing steps selected from the group consisting of—
 removing casting mold material from the tool, 
 machining the tool, and 
 grinding the tool; 
   wherein performing at least one of the first processing steps comprises—
 performing one or more of the process steps, 
 repositioning the tool in the positioner, and 
 re-performing the one or more of the process steps; 
   causing the system to conform the tool to the model through the performance of at least one of a plurality of second processing steps selected from the group consisting of—
 preparing the tool for paint, 
 painting the tool, and 
 curing the paint; 
   wherein performing at least one of the second processing steps comprises—
 performing one or more of the process steps, 
 repositioning the tool in the positioner, and 
 re-performing the one or more of the process steps; 
   causing the system to conform the tool to the model through the performance of at least one of a plurality of third processing steps selected from the group consisting of—
 applying a shank protecting material to a shank of the tool, 
 applying a label to the tool, and 
 packaging the tool.