WO1999044764A1 - Formation method and device for curved plates - Google Patents
Formation method and device for curved plates Download PDFInfo
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- WO1999044764A1 WO1999044764A1 PCT/KR1999/000093 KR9900093W WO9944764A1 WO 1999044764 A1 WO1999044764 A1 WO 1999044764A1 KR 9900093 W KR9900093 W KR 9900093W WO 9944764 A1 WO9944764 A1 WO 9944764A1
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- plates
- heating
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- forming
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- 238000000034 method Methods 0.000 title claims abstract description 108
- 230000015572 biosynthetic process Effects 0.000 title claims abstract description 38
- 230000008569 process Effects 0.000 claims abstract description 51
- 238000005452 bending Methods 0.000 claims abstract description 45
- 238000013528 artificial neural network Methods 0.000 claims abstract description 22
- 238000005259 measurement Methods 0.000 claims abstract description 11
- 238000004364 calculation method Methods 0.000 claims abstract description 8
- 238000010438 heat treatment Methods 0.000 claims description 71
- 238000004458 analytical method Methods 0.000 claims description 30
- 238000004519 manufacturing process Methods 0.000 claims description 18
- 238000001816 cooling Methods 0.000 claims description 14
- 238000012549 training Methods 0.000 claims description 12
- 238000004891 communication Methods 0.000 claims description 11
- 238000009826 distribution Methods 0.000 claims description 11
- 239000000463 material Substances 0.000 claims description 11
- 238000012545 processing Methods 0.000 claims description 8
- 238000005096 rolling process Methods 0.000 claims description 7
- 238000013461 design Methods 0.000 claims description 5
- 238000010276 construction Methods 0.000 claims description 4
- 238000007726 management method Methods 0.000 claims description 4
- 238000012805 post-processing Methods 0.000 claims description 4
- 238000004088 simulation Methods 0.000 claims description 3
- 239000002699 waste material Substances 0.000 claims description 3
- 230000010354 integration Effects 0.000 claims description 2
- 210000002569 neuron Anatomy 0.000 description 6
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- 238000007792 addition Methods 0.000 description 1
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- 238000003466 welding Methods 0.000 description 1
Classifications
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/4097—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by using design data to control NC machines, e.g. CAD/CAM
- G05B19/4099—Surface or curve machining, making 3D objects, e.g. desktop manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D11/00—Bending not restricted to forms of material mentioned in only one of groups B21D5/00, B21D7/00, B21D9/00; Bending not provided for in groups B21D5/00 - B21D9/00; Twisting
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/33—Director till display
- G05B2219/33018—Adaline network, n inputs with n weights, sum, one output
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/33—Director till display
- G05B2219/33036—Error back propagation
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/33—Director till display
- G05B2219/33037—Learn parameters of network offline, not while controlling system
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/36—Nc in input of data, input key till input tape
- G05B2219/36284—Use of database for machining parameters, material, cutting method, tools
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/45—Nc applications
- G05B2219/45143—Press-brake, bending machine
Definitions
- This invention relates to formation method and device for curved plates.
- Hot forming method which uses residual thermal elastic- plastic deformation to be caused in heating, is mainly used as a second method to form doubly curved plates or a method to remove residual welding deformation in ship blocks.
- Hot forming method has been called line-heating process as plates are heated up in constant direction. This line-heating process needs a lot of forming information such as heating positions, heating speed, cooling positions, cooling speed, etc. In the former process, skillful workers have decided this forming information. To make things worse, some technical systems and some databases have not yet been built in relation with this process.
- Some researches are implemented to improve this defect. They are roughly divided into two categories. One is to derive simple formula from relationship between heat input and the corresponding residual deformation, which is obtained from many experimental data. This has advantages in not spending much time compared with the thermal elastic-plastic analysis. The other is to use a simple model in the thermal elastic-plastic analysis. Recently in the simplified analysis, to improve an initial beam model some models are developed: there are a 2-dimensional strip model, a 2-dimensional elastic- plastic theory for a round plate under spring constraint, and a modified strip model. This approach has some difficulties in assuming the accurate structural behavior and this also spends much time in practically simulating the line-heating process.
- this invention is intended to improve the productivity in shipbuilding and automae a formation process of curved plates, specially, a line-heating process by establishing a new forming process to make better former ones in which inexact forming information is used only considering bending strain and developing some techniques corresponding to this process.
- Such techniques are divided into two: one is a component technique to yield accurate forming information and the other is a system technique to utilize the information efficiently.
- This invention is made to provide workers with accurate forming information and to form curved plates more close to their objectives specially in the hot forming process, e.g., line-heating in which curved plates are formed by locally heating one side of plates with a torch.
- this invention makes forming process be automated.
- Such purposes are accomplished by constructing a database on various data and forming information systematically, which are formerly experiences of workers, by inferring new information from this database through the artificial neural network method, and by calculating in-plane and bending strains from relationship between initial flat plates or any initially-curved plates and their objective plates.
- This invention adopts three main component techniques to obtain an accurate forming information. One is to calculate in-plane and bending strains. Another is to simulate the formation process of curved plates by developing a numerical model. And the third is to calculate and infer the forming information.
- this invention includes the following techniques:
- a ship hull-piece forming method including steps of (a) constructing a product database by using a relational database management system and by building product model on a basis of information modeling about formation data and processes; (b) measuring the shape of a plate and processing data; (c) performing numerical analyses on a basis of thermal elastic-plastic theory, which have forming information on the above measured plate and information on heating position as a off-line training or programming; (d) inferring forming information that is applied to new plates with multilayer artificial neural network from the product database which has many data obtained by numerical simulations and measured in the previous works; and (e) generating information on heating paths and heat condition by calculating in-plane and bending strains from relationship between flat plates and the objective curved plates and from relationship between the objectives and plates partially formed in the middle of formation; wherein said method can measure the difference between any shaped plate partially formed in the middle of formation and their objective plates during the process and numerically calculate the in-plane and bending strains with that difference to provide
- the ship hull-piece forming method having abilities of offering forming information to workers through monitors and worksheets, sending it to the automatic device for line-heating process, and storing intermediate forming information from this device to the product database.
- the information-generating step (e) has abilities of providing heating paths for the transverse formation, which are determined perpendicularly to maximum principal directions of bending strains by calculating the ratio between maximum principal bending strains and minimum ones, and providing heating paths for the longitudinal formation, which are determined perpendicularly to maximum principal directions of in-plane strains by calculating the ratio between maximum principal in-plane strains and minimum ones.
- the numerical analysis step (c) comprises steps of (c-1) setting up parameters such as sizes of plates, initial curvature of plates, speed of a torch, the clearance between a torch and a cooler, film coefficient, the number of finite elements; (c-2) setting up material properties like conduction coefficient and specific heat quality, to model a heat source and a cooling method, calculating temperature distribution in each time step, and making post-process to show the calculating results effectively; and (c-3) setting up material properties like conduction coefficient, elastic coefficient, thermal expansion coefficient, yield stress, determining boundary conditions, calculating strains and stresses with temperature distribution, and making post-processing to effectively show calculating results.
- an information-generation system for ship hull-piece formation consisting of measurement module in which the shape of plates in process and forming information is measured with some devices; numerical analysis module in which heating conditions are calculated and verified, and this process is simulated, using a numerical program for thermal elastic-plastic 8
- display module in which much information is displayed in a monitor of a personal computer (PC) and is printed out through a printer; data access module in which measuring and forming information is stored to and retrieved from a product database and a STEP physical file that has measuring and forming information is available; inference module in which forming information and heating conditions about a plate to newly form are predicted from data of the product database by an artificial neural network method; information-generating and control module in which each module previously described is controlled by a program of this module and forming information is obtained through calculation of in-plane and bending strains in the processing stages, wherein heating paths or locations to heat on are determined, comparing in-plane strains and bending strains with each other; communication module through which the information-generating and control module transmits forming information, heating conditions and heating paths to numerical control machine based on PC (PC/NC) an through which the measured and the formation results are transmitted and stored to the product database.
- PC personal computer
- Figure 1 is a diagram which shows the system of a formation method of curved plates suggested in this invention
- Figure 2 is a chart which shows some kinds of information and their manufacturing flow on data production, handling and storage suggested in this invention
- Figure 3 is a diagram which shows a method to generate forming information from any flat plate suggested in this invention. In other words, this is kinematics between any flat plate and the corresponding objective plate;
- Figure 4 is a drawing which shows a method to generate forming information from any partially-formed plate suggested in this invention. In other words, this is kinematics between any initially-curved plate and the corresponding objective plate.
- FIG. 1 is a diagram which shows the system of a formation process of curved plates suggested in this invention. As shown in Figure 1, this formation process is composed of seven parts: a main module and six sub- modules.
- the measurement module (10) the shape of plates in process and forming information is measured with some devices (11) .
- the numerical analysis module (20) heating conditions are calculated and verified, and this process is simulated, using a numerical program (21) for thermal elastic-plastic analysis.
- the display module (30) much information is displayed in a monitor of a personal computer (PC) (31) and is printed out through a printer.
- PC personal computer
- the data access module (40) measuring and forming information is stored in a product database (41) and retrieved from it, and this data is the 10
- a STEP STandard for the Exchange of Product model data
- the inference module (50) forming information and heating conditions about a plate to newly form are predicted from data of the product database by an artificial neural network method.
- the information-generating and control module (60) each process previously described is controlled by a program of this module and forming information is obtained through calculation of in-plane and bending strains in the processing stages. Also heating paths or locations to heat on are determined, comparing in-plane strains and bending strains with each other.
- This module (60) transmits forming information, heating conditions and heating paths to numerical control machine (71) based on PC (PC/NC) through the communication module (70) .
- FIG. 1 is a chart which shows some kinds of information and their manufacturing flow on data production, handling and storage suggested in this invention.
- this formation process is composed of four sub-processes as follows.
- CAD Computer-Aided Design
- S100 - S104 In which necessary data like surface model and expanded shapes are calculated on a basis of objective plates and they are stored in the product database (41)
- Roller bending process S201 - S205
- that rolling information such as the rolling quantity and the measuring information is retrieved from the database (41), roller bending is implemented, and 11
- Offset data of objective plates that are obtained from the ship design step are modeled into NURBS (Non- Uniform Rational B-Spline) surfaces (S101) in order to calculate bending and in-plane strains in this system and then the modeled surfaces are stored in the product model database (41).
- NURBS Non- Uniform Rational B-Spline
- S104 developed shapes of the objective curved plates (S104) are calculated with such data and are also stored in the product database (41) .
- the roller bending is carried out on a basis of rolling information
- the forming information is determined to fabricate flat plates or plates that has initial curvature (S302) . If the plates are prefabricated by the cold forming, the line-heating will be applied to curved plates as the second process.
- the forming information for line heating (S401) is yielded in the same way as that of roller bending. That is, it is obtained from relationship between the objective curved plates and the initial plates. After the line heating is proceeded (S402), the formed plates are measured (S404) and it is evaluated whether the desired shapes is got. If the desired shapes are not made, the previous steps are repeated. And the information which occurs in this process is continuously stored in the product database (41).
- Inference devices e.g., an artificial neural network method are adopted to estimate forming information in roller bending and line-heating.
- the new information is determined through the database (41) in which many data have been accumulated.
- the information-generating step in which bending and in-plane strains are calculated to generate initial forming information and intermediate information, and to decide locations of heating lines through the information-generating and control module (60) .
- the shapes of plates in process and the process information are measured.
- a numerical model is composed. It involves the shape information like sizes and initial curvature of a plate, the forming information like velocity of a torch, cooling conditions, heat input, etc., and the meshes of the plate that affect on the numerical analysis.
- the heat transfer problem is solved.
- the plate In heating, the plate has the temperature distribution caused by the heat conduction in the transverse and longitudinal direction and in cooling, the plate gets cooled only by heat convection ignoring the 15
- the heat source is treated as the shape of Gauss distribution, moving over the plate with fixed velocity.
- the heat source is modeled as the following equation.
- the third step is the procedure in which the thermal elastic-plastic analysis is preformed with the temperature distribution which is found in the second step.
- the yield stress of a plate decreases as the temperature of the plate increases.
- the heated surface has the compressive stress as the surface expands in heating. If this compressive stress gets lower than the yield stress, the material yields locally. Owing to that, 16
- the plate has the bending effect during the cooling process.
- the heated surface has the tensional stress as the surface contracts in cooling.
- various parameters are established. These parameters involves the size of the plate, the initial curvature of the plate, the velocity of the torch, the distance between the torch and the cooling device, film coefficient, the number of the finite element, etc.
- four procedures are performed in the heat conduction problem. The first is setting the conduction coefficient and specific heat quantity. The second is modeling the plate, a torch, and a cooling. The third is calculating the temperature distribution in each time step. And the fourth is post-processing which shows the results efficiently.
- the third step previously described four procedures are also performed in the thermal elastic- plastic problem.
- the first is setting up the material properties like the transfer coefficient, the elastic coefficient, the thermal expansion coefficient, the yield stress, etc.
- the second is applying the boundary condition.
- the third is calculating the deformation and the stress from the temperature distribution which is obtained in the second step.
- the fourth is postprocessing which shows the calculation result efficiently.
- the displaying step This is the step of showing determined information through a monitor. 17
- this step we build and use the design data on the shapes of curved plates and the forming information.
- the information contains measuring values and the results of the numerical analysis.
- this invention carries out a information modeling using an object oriented concept in the forming process on ship hull pieces and defines a product data model.
- This product model defines all information generated during a whole lifetime from the design and production of a specified product to the waste.
- RDBMS relational database management system
- Measuring points Measuring sequence, Heating line set, Heating sequence, Communication method, ANN model.
- a product database shown in Figure 2 is constructed on the basis of the definition and constraints of the attributes and relationships of these objects. 18
- the fabrication information can be obtained though a multilayer artificial neural network (ANN) with a backpropagation algorithm, which requires the information database built by the simulation of the numerical analysis and the measurement.
- ANN artificial neural network
- the ANN consists of the input layers, the hidden layers and the output layers.
- w 2 n are updated values of the weights
- wf is the old values of the weights
- R is the output values of the correspondent variables
- / / is the training rate
- f ' is the derivative of the active function f
- T is the target value.
- the training rate ; / is a constant between 0.01 to 1.0.
- the weights between the hidden layers and the input layers are also controlled in the similar way. And then, with the newly updated weights, ANN system calculates the output. If that result is within the tolerance range, it ceases the training, but if not, continues the training until the accuracy of output enters the tolerance range.
- the training is performed with the variation in the number of the hidden layers and of neurons in each hidden layer. From the results, if ANN system has enough neurons in two hidden layers, it studies the example problems with ease. The inference from the training gives reasonable solutions, which presents relatively small error. This means that when the rich data sets are examined and trained in the problem domain, the ANN system will serve the results close to the real practice. And it will efficiently utilize the results of the structural analysis. To verify this possibility, examples are shown for the implementation of the numerical analyses and the inference of new information. The numerical analyses are performed with variation of the thickness, initial curvature of plates and the moving speed of the heating torch. When the results of the examples are regarded as the training set, ANN system infers the maximum deformation for new inputs.
- (1) is obtained from the ANN system with 2 hidden layers and 4 neurons in each layer and the training is performed 162900 times.
- (2) is done with the system with 2 hidden layers, 6 neurons in each layer and 227700 times training.
- Table 2 when the number of neurons increases in each layer, the time needed for training also increases with the remarkable error. This means that adequate number of hidden layers and neurons should be 21
- TCP/IP is adopted as a protocol for the communication of manufacturing data between physical devices and the database management system. This is currently being used as an internet protocol.
- the information-generating step Strains are adopted as a primary factor to determine the heating paths and forming conditions to apply initial plates. In this step, such fabrication information is generated through the calculation of in- plane and bending strains.
- the Green-Lagrangian strain tensor is in main use as follows.
- ⁇ ⁇ is the strains and u, means the deformation in x, y, and z direction.
- the method 1 is shown about the information generation for flat plates in Figure 3, which shows kinematics between any flat plate and the corresponding objective plate.
- Figure 3 shows kinematics between any flat plate and the corresponding objective plate.
- the total strains are divided into the bending strains * and in-plane strains ⁇ "' .
- the information generation for partially formed plates namely the plates which are initially deflected is shown as the method 2 in Figure 4, which is kinematics between any initially-curved plate and the corresponding objective plate.
- du ⁇ counter ⁇ ft 2 d ⁇ dw d-w
- ⁇ v represent components of the strains, divided into in-plane strains ⁇ "' and bending strains ⁇ .
- the strains can be calculated numerically on a basis of derived equations in each method. Bending strains represents curvatures at that point. Thus, they can be replaced with the curvature of the interpolated surface. And in-plane strains can be calculated by an isoparametric finite element formulation. In this 24
- a plate element is utilized for obtaining in-plane strains.
- the forming information like heating paths and heating order, etc., is determined. Firstly, the ratio of the maximum bending strains and the minimum bending strain is calculated and then heating paths for the transverse formation are determined perpendicular to maximum principal bending strains. Secondly, the ratio of the maximum in-plane strain and the minimum in-plane strain is calculated, and then heating paths for the longitudinal formation are determined perpendicular to maximum principal in-plane strains.
- this invention in the formation process of ship hull pieces, makes a database with forming information, inferred new information by an artificial neural network system, and fabricates the optimal plates by continuously comparing with the objectives during process. So it can be possible to fabricate a flat plate into the correspondent objective even if not best workers and actually all processes can be automated in the formation of ship hull pieces.
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE69911382T DE69911382T2 (en) | 1998-03-05 | 1999-03-02 | METHOD AND DEVICE FOR MOLDING CURVED PLATES |
JP2000534353A JP2002505194A (en) | 1998-03-05 | 1999-03-02 | Method and apparatus for forming curved plate |
DK99906561T DK1060037T3 (en) | 1998-03-05 | 1999-03-02 | Method and device for forming curved plates |
US09/623,228 US6560498B1 (en) | 1998-03-05 | 1999-03-02 | Formation method and device for curved plates |
EP99906561A EP1060037B1 (en) | 1998-03-05 | 1999-03-02 | Formation method and device for curved plates |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
KR1998/7332 | 1998-03-05 | ||
KR1019980007332A KR100244582B1 (en) | 1998-03-05 | 1998-03-05 | Method and apparatus for surface processing of the outer plate of a ship body |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1999044764A1 true WO1999044764A1 (en) | 1999-09-10 |
Family
ID=19534286
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/KR1999/000093 WO1999044764A1 (en) | 1998-03-05 | 1999-03-02 | Formation method and device for curved plates |
Country Status (8)
Country | Link |
---|---|
US (1) | US6560498B1 (en) |
EP (1) | EP1060037B1 (en) |
JP (1) | JP2002505194A (en) |
KR (1) | KR100244582B1 (en) |
CN (1) | CN1165391C (en) |
DE (1) | DE69911382T2 (en) |
DK (1) | DK1060037T3 (en) |
WO (1) | WO1999044764A1 (en) |
Cited By (3)
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WO2002051564A1 (en) * | 2000-12-23 | 2002-07-04 | Simone Rubbert | Method for shaping flat bodies to give irregular multi-dimensional curved objects |
US7431780B2 (en) | 2001-08-03 | 2008-10-07 | Norsk Hydro Asa | Method and apparatus for distorting a workpiece |
CN102371293A (en) * | 2010-08-20 | 2012-03-14 | 陈广永 | Automatic plate bending machine |
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Also Published As
Publication number | Publication date |
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DE69911382D1 (en) | 2003-10-23 |
KR19990074013A (en) | 1999-10-05 |
DK1060037T3 (en) | 2004-02-02 |
DE69911382T2 (en) | 2004-06-24 |
JP2002505194A (en) | 2002-02-19 |
CN1165391C (en) | 2004-09-08 |
EP1060037B1 (en) | 2003-09-17 |
EP1060037A1 (en) | 2000-12-20 |
CN1292737A (en) | 2001-04-25 |
KR100244582B1 (en) | 2000-03-02 |
US6560498B1 (en) | 2003-05-06 |
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