Several methods and subsystems are provided for aligning a workpiece as it
is being loaded into a die space of a bending apparatus, and for
performing sensor-based control of a robot as it moves a workpiece from
one location to another within a bending apparatus environment. A
backgaging mechanism is provided with finger gaging mechanisms having
force sensors for sensing forces in directions perpendicular to and
parallel to a die. In addition, a robot gripper sensor is provided for
sensing either or both of shear forces and normal forces created by
movement of a workpiece being held by the gripper. Several sensor-based
control modules are disclosed, including a bend-following control module,
a speed control module, a module for actively damping vibrations in a
workpiece, a module for controlling active compliance/contact between a
workpiece and an obstacle, a module for performing a guarded move to
intentionally bring a workpiece into contact with an obstacle, and a
module for detecting unintentional impacts between a workpiece and an
obstacle. Several droop sensing methods and systems are also provided,
including methods for performing droop sensing and compensation with the
use of a vision-based droop sensor, a compound break-beam droop sensor,
and a single break-beam droop sensor. In addition, an angle sensor is
provided, along with a springback control method utilizing the disclosed
angle sensor.