Automatically adjustable system for cutting with variable notch angles

Abstract

A tool assembly for cutting a substrate during relative motion between the tool and the substrate, the assembly comprising a tool having a distal tool blade and a proximal tool shaft attached to a holder, the holder being rotatable about a first axis perpendicular to the substrate to define a cutting direction angle. The holder is also configured to rotate the tool blade about a second axis perpendicular to the first axis to form a notch angle relative to the first axis. The notch angle is preferably automatically infinitely adjustable within an angle range. Optionally, the holder may also be configured to rotate the tool blade about a third axis perpendicular to a plane defined by the tool blade to adjust the angle of attack of the tool blade relative to the substrate.

Description

Background Art

[0001] In the process of processing thicker materials that need to be folded, such as plastic or paper fluted core boards (single wall, double wall and triple wall), such as corrugated board, paper or plastic honeycomb boards, foam boards, flexible printed boards (flexographic clichés), solid cardboard and display boards, special tool assemblies that can produce inclined cuts in the material can be used. For example, as depicted in Figure 1, a single-wall fluted core board (e.g., corrugated board) 100 includes flutes 130 arranged between liners 110, 120. Performing two cuts with an inclined blade from two opposite directions just above the bottom liner 110 will produce a V-shaped groove 140, also called a V-notch or V-cut, in the material after the cut portion is removed. Therefore, by cutting two 45° lines, a 90° fold can be achieved in the final product.

[0002] Commercial cutting systems, such as the Esko Kongsberg C series system, the details of which are incorporated herein by reference, are configured to cut a substrate during relative motion between the cutter and the substrate. Such systems may include optional V-notch cutter assemblies, each of which is configured to cut at a specific angle (e.g., 15°, 22.5°, 30°, and 45°). Thus, the aforementioned cutters allow the user to form corresponding (e.g., 30°, 45°, 60°, and 90° angles). However, if more than one angle is required in a job, the operator must pause production and manually change the adapter from one angle to another. In addition, the available angles are usually predetermined and cannot be selected arbitrarily.

[0003] Therefore, there is a need for an improved cutting system that provides greater flexibility in cutting angles and / or makes it easier / faster to change from one cutting type or cutting angle to another. Summary of the invention

[0004] One aspect of the present invention includes a tool assembly for cutting a substrate during relative motion between the tool and the substrate. The assembly includes a tool having a tool blade and a proximal tool shaft attached to a tool holder. The tool holder can rotate around a first axis perpendicular to the substrate to limit the cutting direction angle. The tool holder is also configured to rotate the tool blade around a second axis perpendicular to the first axis to form a notch angle relative to the first axis. The notch angle is preferably infinitely adjustable within an angle range, such as symmetrical from -60 degrees to +60 degrees about the first axis. The tool assembly is preferably adjustable in the Z direction perpendicular to the substrate. The tool holder can also be optionally configured to rotate the tool blade around a third axis perpendicular to the plane defined by the tool blade, and the rotation around the third axis adjusts the angle of attack of the tool blade relative to the substrate to a desired range.

[0005] The cutting system may include a tool assembly and a control system as described herein, the cutting system having a device for causing relative motion between the tool assembly and the substrate, the control system being used to control the direction of the relative motion, the cutting direction angle and the notch angle. The control system may be programmable to position the distal end of the tool blade relative to the thickness of the substrate, operable to completely penetrate or incompletely penetrate the thickness of the substrate from the top surface and the bottom surface of the substrate and form a zero notch angle and a non-zero notch angle, including performing multiple cutting operations at a non-zero notch angle, thereby forming a V-shaped notch that does not completely penetrate the substrate in the substrate. The control system may be configured to allow selection of a tool angle pivot point at a desired distance from the top surface of the substrate as a constant reference point for kinematics associated with the tool, with the second and third rotation axes intersecting at the tool angle pivot point. The pivot point may be selected within a range including at least a first point located on the top surface of the substrate and at least a second point located on the bottom surface of the substrate, so that the cutting line in the substrate relative to the reference point is independent of the tool notch angle.

[0006] In some embodiments, the control system can also be configured to control the operation of the tool assembly based on information in the 2D design file, including selecting a cutting direction angle and a relative motion direction of the tool assembly based on the position of the line in the 2D design file, and selecting a value of a notch angle, an angle of attack, or a combination thereof based on line properties (such as line type, line color, or line width) in the 2D design file. One or more 2D design file line properties can be associated with a custom angle value, and other line properties can be predefined for multiple common values ​​(e.g., 0°, 15°, 22,5°, 30°, and 45°).

[0007] In other embodiments, the control system can be configured to control the operation of the tool assembly based on information in a 3D design file, wherein the cutting direction angle, relative motion direction, and notch angle are derived from a 3D cutting shape defined in the 3D design file, and the attack angle is defined by cutting surface characteristics represented in the 3D design file.

[0008] In one configuration, the holder includes a worm gear assembly including a worm drive attached to a motor and a circumferential portion of the worm gear. The proximal end of the tool shaft is attached to the circumferential portion of the worm gear such that a predetermined rotation of the worm drive provides a corresponding adjustment of the notch angle.

[0009] In another configuration, a first relatively proximal connection point on the tool shaft is connected to a linearly movable portion of a first linear actuator, and a second intermediate connection point located between the first connection point and the distal end on the tool shaft is connected to a linearly movable portion of a second linear actuator. The first linear actuator and the second linear actuator cooperate to provide adjustability of the notch angle while maintaining the second vertically translatable rotational axis of the blade along the first axis. Each of the first linear actuator and the second linear actuator may include a linear motor, a ball screw device, or a piezoelectric device.

[0010] One aspect of the present invention includes a method for cutting a substrate. The method includes providing a cutting system having an adjustable tool assembly, the adjustable tool assembly including a tool blade having a distal tool blade and a proximal tool shaft attached to a tool holder. The tool holder (i) can rotate around a first axis perpendicular to the substrate to define a cutting direction angle, (ii) is configured to rotate the tool blade around a second axis perpendicular to the first axis to form a notch angle relative to the first axis, wherein the notch angle is infinitely adjustable within an angle range, (iii) is adjustable in the Z direction perpendicular to the substrate, and (iv) optionally, is configured to rotate the tool blade around a third axis perpendicular to a plane defined by the tool blade, wherein the rotation around the third axis adjusts the angle of attack of the tool blade relative to the substrate to a desired range. The method includes causing relative motion between the tool assembly and the substrate, including automatically controlling the relative motion direction, the cutting direction angle, and the notch angle. Automatically controlling the notch angle includes using the adjustable tool assembly to automatically change the notch angle from a first notch angle to a second notch angle. The method may include a computer processor of the cutting system reading information from a design file and controlling operation of a cutter assembly and relative movement between the cutter assembly and the substrate based on the information in the design file.

[0011] In embodiments where the design file is a 2D design file, the computer processor may select the cutting direction angle and the relative motion direction of the tool assembly based on the position of the line in the 2D design file, and select the values ​​of the notch angle and the angle of attack based on the line characteristics in the 2D design file. In embodiments where the design file is a 3D design file, the computer processor may select the cutting direction angle, the relative motion direction, and the notch angle based on the 3D cutting shape as defined in the 3D design file, and select the angle of attack based on the cutting surface characteristics represented in the 3D design file.

[0012] Yet another aspect of the present invention includes a non-transitory computer readable medium encoded with instructions, which are implemented in a design file readable by a computer processor, for controlling a control system of a cutting system. The cutting system includes an adjustable tool assembly, the adjustable tool assembly including a tool having a distal tool blade and a proximal tool shaft attached to a tool holder, the tool holder (i) rotatable about a first axis perpendicular to the substrate to define a cutting direction angle, (ii) configured to rotate the tool blade about a second axis perpendicular to the first axis to form a notch angle relative to the first axis, wherein the notch angle is infinitely adjustable within an angular range, (iii) adjustable in a Z direction perpendicular to the substrate, and (iv) optionally, configured to rotate the tool blade about a third axis perpendicular to a plane defined by the tool blade, wherein rotation about the third axis adjusts the angle of attack of the tool blade relative to the substrate to a desired range. The cutting system also includes means for causing relative motion between the tool assembly and the substrate, including automatically controlling the relative motion direction, the cutting direction angle, and the notch angle. The instructions include instructions for controlling the operation of the tool assembly and the relative movement between the tool assembly and the substrate based on information in the design file, including instructions for causing the control system to automatically change the notch angle from a first notch angle to a second notch angle using the adjustable tool assembly.

[0013] In an embodiment where the design file is a 2D design file including instructions corresponding to a plurality of lines, each line has one or more line properties, wherein at least one line property corresponds to a selected value of a notch angle, at least one line property corresponds to an angle of attack, or a combination thereof. The line properties are selected from the group consisting of line type, line color, and line width. One or more line properties may be associated with a custom angle value, and a plurality of other line properties may be predefined for a plurality of common values. In an embodiment where the design file is a 3D design file, the cutting direction angle, relative motion direction, and notch angle may be represented by a 3D cutting shape defined in the 3D design file, and the angle of attack may be defined by cutting surface properties represented in the 3D design file.

[0014] Another aspect of the present invention includes a method for creating a design file processed by a cutting system. The method includes creating a design file that implements instructions readable by a computer processor, which are used to control a control system of the cutting system. The cutting system has an adjustable tool assembly, the adjustable tool assembly including a tool having a distal tool blade and a proximal tool shaft attached to a tool holder, the tool holder (i) being rotatable about a first axis perpendicular to the substrate to define a cutting direction angle, (ii) being configured to rotate the tool blade about a second axis perpendicular to the first axis to form a notch angle relative to the first axis, wherein the notch angle is infinitely adjustable within an angular range, (iii) being adjustable in a Z direction perpendicular to the substrate, and (iv) optionally, being configured to rotate the tool blade about a third axis perpendicular to a plane defined by the tool blade, wherein the rotation about the third axis adjusts the angle of attack of the tool blade relative to the substrate to a desired range. The cutting system further includes a device for causing relative motion between the tool assembly and the substrate, including automatically controlling the relative motion direction, the cutting direction angle, and the notch angle. The instructions include instructions for controlling the operation of the tool assembly and the relative movement between the tool assembly and the substrate based on the information in the design file, including instructions for causing the control system to automatically change the notch angle from a first notch angle to a second notch angle using the adjustable tool assembly. In an embodiment where the design file is a 2D design file including instructions corresponding to a plurality of lines, each line may have one or more line characteristics, wherein at least one line characteristic corresponds to a selected value of the notch angle, at least one line characteristic corresponds to an angle of attack, or a combination thereof. In an embodiment where the design file is a 3D design file, the cutting direction angle, the relative movement direction, and the notch angle may be represented by a 3D cutting shape defined in the 3D design file, and the angle of attack may be defined by cutting surface characteristics represented in the 3D design file. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 is a cross-sectional view schematically depicting a substrate having a V-shaped notch.

[0016] Figure 2A is a perspective view schematically depicting an exemplary knife blade for cutting a substrate.

[0017] Figure 2B It is schematically depicted Figure 2A A top view of an exemplary knife blade having an adjustable cutting direction angle about an axis C.

[0018] Figure 2C It is schematically depicted Figure 2A Front view of an exemplary knife blade having an adjustable notch angle about axis A.

[0019] Figure 2D It is schematically depicted Figure 2A Side view of an exemplary tool blade having an adjustable angle of attack about axis B.

[0020] Figure 3A is a front view schematically depicting an exemplary mechanism for providing an automatically adjustable notch angle.

[0021] Figure 3B is used for Figure 3A Schematic diagram of an exemplary control system for an exemplary mechanism.

[0022] Figure 3C is a front view schematically depicting another exemplary mechanism for providing an automatically adjustable notch angle.

[0023] Figure 4 is a front view schematically depicting another exemplary mechanism for providing an automatically adjustable notch angle.

[0024] Figure 5 is a perspective schematic diagram of an exemplary cutting system.

[0025] Figure 6 is a schematic flow chart depicting the steps of an exemplary workflow using the exemplary cutting system described herein.

[0026] Figure 7 is a perspective schematic diagram of an exemplary tool mounted on a carriage.

[0027] Figure 8 Is installed in Figure 7 A perspective schematic side view of a tool on an exemplary Z-shaped cart depicted in FIG. 1 , showing additional elements of the mechanical system.

[0028] Fig. 9A yes Figure 8 A perspective schematic diagram of an exemplary Z-shaped cart.

[0029] Fig. 9B is located in Fig. 9A A perspective diagram of an exemplary translation system behind a Z-shaped cart.

[0030] Fig. 10A yes Figure 7 An isolated perspective schematic diagram of the exemplary tool depicted in .

[0031] Fig. 10B yes Fig. 10A A perspective schematic diagram of the exemplary tool depicted in FIG. 1 with the housing removed.

[0032] Fig. 10C yes Fig. 10BA perspective schematic diagram of the exemplary tool depicted in FIG. 1 as seen from the front side with additional elements removed to illustrate elements of the mechanical system.

[0033] Fig.11A yes Figure 7 An isolated perspective schematic side view of an exemplary tool depicted showing a mechanism for varying the angle of attack.

[0034] Fig. 11B yes Fig.11A An enlarged perspective schematic side view of the exemplary tool depicted in , with a portion of the tool cut away to illustrate an exemplary mechanism for changing the angle of attack.

[0035] Fig. 11C yes Fig. 11B Schematic side view of a mechanism for changing the angle of attack, showing a first angle of attack.

[0036] Fig.11D yes Fig. 11C Schematic side view of a mechanism for changing the angle of attack, showing a second angle of attack.

[0037] Fig. 12A is a schematic diagram of a 2D design in which line features are used to provide notch angle information, depicting embodiments in which each dashed line format represents a different notch angle.

[0038] Fig. 12B is a schematic diagram of a 2D design in which line features are used to provide notch angle information, depicting an embodiment in which each line thickness represents a different notch angle.

[0039] Fig. 12C is a schematic diagram of a 2D design where line features are used to provide notch angle information, depicting an embodiment where each line color represents a different notch angle.

[0040] Fig.12D is a schematic diagram of a 3D design in which the cut shape information provides notch angle information, including an embodiment in which the color of the cut surface is mapped to the notch angle. DETAILED DESCRIPTION

[0041] FIG. 2A to FIG. 2D An exemplary tool tool is schematically depicted, which is configured to change the angle of the tool blade about axes A, B and C. Rotation about axis C (perpendicular to the material being machined) gives a transverse cutting direction. Figure 2BAs shown in the top view of FIG. 1 , when the system moves the tool in the direction of arrow X1 (which changes to the direction of arrow X2) on a first path, the tool rotates about axis C so that the tip of the tool blade is oriented in the direction of travel. Axis A is parallel to the horizontal / lateral motion vector of the tool, giving the tool inclination angle, referred to herein as the "notch angle". Axis B is perpendicular to the plane defined by the tool blade, giving the angle between the tool edge and the material being cut, referred to herein as the "angle of attack" or "attack angle".

[0042] In an exemplary embodiment, the tool blade is preferably configured to rotate around axis C to any angular position to achieve maximum flexibility in the cutting direction. The system is preferably configured to allow the notch angle of the tool blade to vary infinitely within a range around axis A, such as + / -60°, including a 0° (vertical) angle, so that the tool blade is suitable for both inclined cutting and vertical / straight cutting. The pivot point P (at least where axes A and B intersect) is preferably a certain distance H from the distal end of the tool blade, usually half the thickness T of the material being processed. Such a configuration balances the reaction forces F1 and F2 exerted on the tool blade by the material around the C axis, so that the moment of the reaction force is preferably zero, which improves the quality / straightness of the cutting. Axis C may also coincide with the pivot point, or may be located at another position on the plane of the tool blade. As further described herein, a control system for controlling the notch angle may be configured to allow selection of a tool angle pivot point at a desired distance from the top surface of the substrate as a constant reference point for kinematics associated with the tool. In a preferred embodiment, the pivot point can be selected within a range including at least a first point on the top surface of the substrate and at least a second point on the bottom surface of the substrate so that the cut line in the substrate relative to the pivot point is independent of the tool notch angle. Figure 3A Such a position of P is depicted in .

[0043] Reference now Figure 3A and Figure 3B, a first exemplary mechanism for adjusting the blade notch angle is shown. In this embodiment, a partial worm gear transmission 300 includes a worm drive 302 that meshes with a partial worm wheel 304, and a tool blade holder 308 is mounted on the partial worm wheel. The self-locking characteristics of this gear mechanism minimize the potential forces exerted on the tool blade by the cutting material to cause unexpected changes in the blade notch angle. Encoders 352, 354 can be used to detect the position of the worm drive and the worm wheel, respectively, which are connected to a controller 350 and configured to provide feedback to the controller. The encoder can be an absolute encoder or a relative encoder, and can include an optical, magnetic, inductive or capacitive position sensor. A motor 306 coupled to a shaft 307 can drive the shaft 307 directly or via a gearbox / reducer, a belt or other transmission mechanism, and the worm drive gear 302 is mounted on the shaft. A predetermined rotation of the worm drive provides a corresponding adjustment of the notch angle. When the angle of the blade is adjusted, the distal end (tip) 307 of the blade deflects in two directions, i.e., dZ (vertical) and dY (lateral), which are calculated and compensated in the control system by correspondingly changing the position of the tool assembly relative to the substrate. Therefore, the tool assembly is also preferably adjustable in the Z direction perpendicular to the substrate, as further described herein. As depicted, the tool shaft 308 is shown in a first position of zero notch angle and a second position of non-zero notch angle. The tool shaft 308 has a proximal portion 309 attached to a partial worm gear. The worm drive and partial worm gear can be located in a housing, as further depicted and described herein.

[0044] Preferably, the range of notch angles achievable by the system includes a symmetrical range (eg, -60 degrees to +60 degrees relative to the first position).

[0045] Accordingly, Figure 3A The circumferential portion of the worm wheel depicted in is merely a schematic representation and is not intended to depict the entire partial worm wheel or a representative spacing between the substrate and the partial worm wheel. In a preferred arrangement, the tool shaft is mounted in the center of the partial worm wheel, and the size of the worm wheel and the spacing from the substrate are set to allow the full 120 degree range of motion required to move the wheel from -60 degrees to +60 degrees without the opposite end of the wheel contacting the substrate.

[0046] Despite Figure 3A and Figure 3B 302 and a portion of a worm gear 304, but the invention is not limited to any particular implementation. Figure 3CAs depicted in , in an alternative embodiment, the worm drive mechanism may include a non-enveloping worm drive 362, and the worm wheel may include a full 360 degree gear 364, wherein the tool shaft 368 is connected to the wheel 364 at a pivot point P1 aligned with the axis of rotation of the wheel. It is worth noting that in this embodiment, the pivot point P1 is located directly above the surface of the material. Although combined with Figure 3A and Figure 3B The embodiment depicted in FIG. 1 has the pivot point located relatively low, which increases the forces on the tool blade and does not provide a static pivot point that can be used as an invariant reference point for the kinematics associated with the tool, but this arrangement has the advantage of allowing the worm gear to use standard bearings.

[0047] Reference now Figure 4 , depicts another exemplary mechanism 400 for adjusting the rotational pivot point P of an exemplary knife blade, which also minimizes the effects of moments generated by unequal reaction forces when cutting material. The mechanism 400 includes two parallel linear guide elements 402, 404, on which respective carriages 412, 414 are connected to a knife shaft 408. The respective linear positions of the carriages 412, 414 are coordinated to change the angle of the knife blade, thereby providing adjustability of the notch angle, while also vertically translating the pivot point P of the knife blade to coincide with the rotational axis C. The carriage 412 is connected to a first relatively proximal connection point on the knife shaft, while the carriage 414 is connected to a second intermediate connection point located between the first connection point and the distal end 407 of the knife blade.

[0048] As depicted, the tool axis 408 is shown in a first position of zero notch angle and a second position of non-zero notch angle. Similarly, for a cut having a desired depth in the thickness t of the substrate 450, the substrate to be cut is shown to be at a first relative height corresponding to the first position of the tool axis and a second relative height corresponding to the second position of the tool axis. The carriage can be driven by any type of actuator known in the art (e.g., a linear motor, a ball screw device (not shown) operated by a motor, or a piezoelectric device). The electric actuator can include two motors (one for each linear guide element) or a single motor and a specific gear arrangement between the two actuators. The actuator can be controlled by a controller 420 based on feedback from encoders 422, 424 regarding the position of each carriage 412, 414.

[0049] Figure 4 It is intended to provide only a schematic diagram of the mechanism. Preferably, the range of notch angles achievable by the system includes a symmetrical range (e.g., -60 degrees to +60 degrees relative to the first position). Accordingly, the linear guide element preferably extends symmetrically to the left and right of the first position to provide a full range of motion.

[0050] In one embodiment, the tool angle of attack (i.e., rotation about axis B) can be implemented using an actuator mechanism configured to infinitely rotate the tool holder within a desired range, or by providing a feature in the tool holder that enables the tool blade to be manually adjusted / mounted in one of a set of possible discrete positions.

[0051] In a preferred embodiment, information embedded in the design file can be used to define the desired angle of the tool mechanism. FIG. 12A to FIG. 12C In the exemplary embodiment depicted in FIG. 1 , any line property of the 2D design file may be used to represent an angle, including but not limited to a line type (e.g., Fig. 12A The dashed line type depicted in , indicating the notch angle), line thickness (e.g. Fig. 12B , indicating angle of attack), line color (e.g. Fig. 12C , denoting the notch angle), where each line feature is associated with a given angle. The foregoing is merely exemplary and is not intended to be limiting in any way. A commonly used angle may have a preset information descriptor, while another line feature (e.g., Fig. 12A The dot-dash format in Fig. 12C ) can be used for custom angles, where the desired angle is set in a dialog box with the tool operator or in a user-defined table.

[0052] The desired angles can also be derived from information embedded in the 3D CAD design file, where the 3D shape is converted into the desired cutting direction and notch angle, such as Fig.12D The angle of attack can be related to the cutting surface characteristics (such as but not limited to Fig.12D The color of the cut surface depicted in digits)) that are mapped by the user to a desired angle of attack in a job setup dialog box. Thus, for example, the color of surface 1200 may represent a first angle of attack, while the color of surface 1202 may represent a second angle of attack. As described in claim 12D, the term "notch angle" generally refers to the angle of one half of a notch with respect to the vertical. Thus, for example, a 45 degree notch angle formed by opposing cuts inclined at a 45 degree angle (to the horizontal or vertical direction) produces a notch with a 90 degree internal angle. A 30 degree notch angle formed by opposing cuts at 30 degrees from the vertical direction (60 degrees from the horizontal direction) produces a notch with a 60 degree internal angle. A "through cut" refers to a cut that completely penetrates the thickness of the substrate being cut, while a V-shaped notch penetrates less than the entire thickness. The notch angle settings and mechanisms as described herein may be used to produce through cuts or V-shaped notches without limitation.

[0053] Applications of the disclosed system include utilizing high speed through cuts perpendicular to the surface of the material or obliquely relative to the perpendicular, such as for separating product from waste. The oblique cuts may be used for design / aesthetic purposes, such as for "picture framing". The automated tool may also be used to perform folding, such as by performing two oblique partial (i.e., not completely through the material) cuts (forming a V-shaped mark in the material) to facilitate the folding of thicker paper and plastic based materials. An advantage of the disclosed device over prior art devices is that the same automated tool is suitable for all of the above applications without requiring any operator intervention.

[0054] like Figure 6 As depicted in , an exemplary method for cutting a substrate may include the following application workflow. In step 700, a 2D or 3D design file is created, which contains information about each line to be cut, including what tool to use on each line (a tool blade for cutting, a crease wheel for forming a crease, etc.) and the relevant tool angle for cutting each line using an automatic tool when cutting. In step 710, the design file is then read by a processor connected to a controller of a cutting machine, and the processor is programmed with software, which includes instructions for interpreting the design file information and converting the design file information into a language readable by the controller, including converting the geometry of the cut into tool coordinates. Lines converted using different tools and / or using automatic tools at different angles can be represented in a separate conversion layer in the design file. Based on predefined settings and design file information, the machine software can automatically assign a corresponding tool configuration to each layer. In step 720, the machine operator starts production, causing the machine to automatically select between installed tools to convert the assigned layers, and automatically adjust the angle of the automatic tool to convert different tool cutting layers.

[0055] Reference now Figure 5 , an exemplary cutting system 600 is shown. The system 600 includes: a base 602 for receiving a substrate to be cut; a gantry 604 configured to move back and forth along a guide rail 608 in the X direction; and a cutting tool 630 on a slide or cart (in Figure 5), the cutting tool is configured to move back and forth on the support in the Y direction. The system for providing relative motion between the substrate and the cutting tool may include any configuration known in the art, and is not limited to the configuration shown in the drawings. The exemplary control system 620 may include an integrated computer processor and computer memory, a user interface 622, and a display 624. The computer processor is configured to read information embedded in a design file located in the computer memory and convert the embedded information into commands for operating the cutting system. The control system may include one or more positioners 606, which are used to move the gantry to a desired position along the X-axis along the guide rail 608, and one or more positioners are embedded in the cutting tool 630, which are used to move the slide with the cutting tool mounted thereon to a desired position on the Y-axis of the gantry. Exemplary mechanisms for controlling the XY motion of the gantry and the cutting tool slide are well known in the art and are not described in further detail here. The control system further includes as described in reference to this article Figure 3B or Figure 4 The controller and encoder for controlling the tool angle described in the mechanism described in the . The cutting tool can be connected to the control system wirelessly or wired through a physical connection (such as a flexible conduit 610), which can also be connected to a power source (not shown) for powering all automatic functions of the cutting tool as described herein.

[0056] Figure 7 and Figure 8 An exemplary tool system 630 is depicted in greater detail. The cutting tool 730 is mounted on a Z-shaped cart 735 configured to move back and forth in the Z direction and a carriage 740 configured to move back and forth in the Y direction along a rail 745. A motor 850 rotates a shaft 852 on which is mounted a pulley 854 configured to drive a timing belt 856. A housing 760 covers various internal components, which will be discussed in greater detail below. Figure 7 and Figure 8 As depicted in FIG. 7 , the mechanism 770 for adjusting the notch angle of the blade is similar in structure to Figure 3A and Figure 3B The institutions depicted in Ref. FIG. 10A to FIG. 10C Discussed in more detail in Figure 8 The reference is depicted in FIG. 11A to FIG. 11D Mechanism 870 for adjusting the angle of attack is discussed in more detail. Z-wagon 735 is configured to move back and forth along the Z direction, as depicted by the corresponding arrows.

[0057] Fig. 9A and Fig. 9BAdditional parts of the mechanism for driving the Z-cart 735 are depicted. The Z-cart mounting plate 902 is attached to a carriage 904, which may include a roller screw assembly by which movement of the timing belt 856 rotates a timing gear 858 connected to a roller screw shaft 906. Male threads (not shown) on the roller screw shaft 906 engage with female threads in the carriage 904 to convert the rotation of the roller screw shaft into movement of the carriage in the Z direction. The plate 902 is fastened to the carriage 904, such as with bolts 908. The plate 902 also has a rear guide 912 located on a rail 914 to maintain the correct orientation of the plate 902 and provide smooth movement. The present invention is not limited to any particular mechanism for providing Z-cart movement; accordingly, the mechanism depicted herein is merely one possible example.

[0058] FIG. 10A to FIG. 10C An exemplary mechanism for adjusting the cutting angle and the notch angle is depicted in more detail. The housing 760 is mounted on the frame 1000. The frame is mounted with a mechanism for adjusting the cutting angle rotation, such as Fig. 10B The mechanism for adjusting the cutting angle rotation includes a motor 1002 which rotates a shaft on which a pulley 1004 is mounted, thereby rotating a timing belt 1006 connected to a timing gear 1008, thereby rotating a cutting angle shaft 1010. A sensor 1012, such as a Hall sensor, is used to send the position of a collar 1014 relative to the sensor, which calibrates the positioning system by detecting the neutral orientation of the tool passing the Hall sensor each time the machine is started. Fig. 10C As depicted, a bearing 1050, such as a ball bearing, supports the cutting angle shaft 1010 and is coupled to a bearing housing on the frame 1000. The shaft 1010 may be covered by a housing 1011. Thus, the aforementioned exemplary mechanism may be used to position the blade 1016 at any cutting angle orientation along the cutting angle axis of rotation (CAA), but the mechanism is not limited to any particular embodiment.

[0059] like Fig. 10CAs shown in more detail in , the notch angle mechanism may include a motor 1030 connected to a worm drive 1032 via a pulley 1034, a timing belt 1036, and a timing gear 1038. The threads of the worm drive 1032 mesh with the teeth of the worm wheel 1040 so that rotation of the worm drive positions the worm wheel and allows the blade 1016 to move along the notch angle rotation axis (NAA). An end stop sensor 1044 may be provided on the opposite side of the worm wheel to prevent the worm wheel from over-extending in either direction. The worm wheel 1040 may include a geometry including semicircular guides 1041 on the opposite side of the gear that extend along a track defined by semicircular inserts 1060 that are held in place by a worm wheel housing plate 1070 on the opposite side and secured by bolts 1062. Thus, the aforementioned exemplary mechanism may be used to position the blade 1016 at any notch angle orientation along the rotation axis NAA, but the mechanism is not limited to any particular embodiment. In the example of Figure 3C In the embodiment depicted in which an integral worm gear is provided, a standard ball bearing (not shown) may be provided between the housing plates 1070 (or attached to only a single housing plate) to receive the shaft 366 upon which the worm gear 364 is mounted.

[0060] FIG. 11A to FIG. 11D An exemplary angle of attack adjustment mechanism is shown in more detail in FIG. Fig. 11B As best depicted, the worm gear 1040 may have a central hole 1110 (which may be formed by mating a semi-cylindrical recess in a two-piece construction) in which a motor (not shown) is mounted to drive a pinion 1102 which drives an angle of attack rack 1104 connected to the blade 1060. Thus, the motion pinion 1102 and rack 1104 set the angle of attack along the angle of attack rotation axis (AAA). Positioning the pinion and rack as shown in FIG. Fig. 11C The first position shown can provide a neutral angle of attack, wherein the inclined blade meets the substrate 1100 to be cut at a blade angle β relative to the horizontal. Fig.11DAs shown, positioning the pinion and rack in the second position can provide an angle of attack that forms an angle β' that is sharper than angle β between the inclined blade and the surface of the substrate. A neutral position can be selected so that the angle of attack can change between a larger acute angle and a smaller acute angle. Although a specific blade angle is depicted, the blade angle is not limited to any specific angle. Although depicted with a rack and pinion mechanism, the mechanism for changing the angle of attack is not limited to any specific mechanism. Other mechanisms can include, for example, a piezoelectric linear actuator, which can use less space than the rack and pinion embodiment. Other embodiments can have an angle of attack that is not adjustable or can only be manually adjusted. Although shown as an infinitely adjustable angle of attack within the angle range implemented in the rack and pinion, the angle can be adjustable only in a more limited set of discrete angles, such as manually replacing the first blade with a first blade angle by utilizing a blade with a second blade angle.

[0061] Although the exemplary system described herein is for providing an automatically adjustable notch angle, the invention is not limited to the mechanism shown and may be implemented using any combination of elements known in the art for producing the functionality described herein.

[0062] Aspects of the present invention include features that provide several benefits, including:

[0063] Allows cutting of any angle between 0° and 60° (e.g., a 36° cutting angle produces a 72° notch for a pentagonal box, allowing designers more creative freedom;

[0064] Automatically adjusts angle based on job setup, allowing operators to be more productive; and

[0065] Replace the oscillating cutter for 0° straight cutting, further improving productivity by enabling cutting at higher speeds.

[0066] Although the invention has been illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the range and range of equivalents of the claims and without departing from the invention.

Claims

1. A cutting system, comprising a tool assembly for cutting a substrate (450; 1100) during relative movement between the tool and the substrate (450; 1100), means for causing relative movement between the tool assembly and the substrate (450; 1100), and a control system (620) for controlling the direction of the relative movement, the cutting direction angle and the notch angle, the tool assembly comprising: A tool having a distal tool blade (1016; 1060) and a proximal tool shaft (308; 408), the holder can be rotated around a first axis perpendicular to the substrate (450; 1100) to define a cutting direction angle, the holder is configured to rotate the tool blade (1016; 1060) around a second axis perpendicular to the first axis to form a notch angle relative to the first axis, wherein the notch angle is infinitely adjustable within an angle range, wherein the holder comprises a worm gear assembly (300) including a worm drive (302) attached to a motor and a circumferential portion of a worm gear (1040), wherein a proximal end of the tool shaft (308; 408) is attached to the circumferential portion such that a predetermined rotation of the worm drive (302) provides a corresponding adjustment of the notch angle; The cutting system further comprises a computer processor connected to the computer memory, the computer processor being configured to read a design file located in the computer memory, wherein the computer processor is configured to cause the control system (620) to control the operation of the cutter assembly based on information in the design file, It is characterized in that the design file is a 2D design file, and the control system (620) is configured to select the cutting direction angle and the relative movement direction of the tool assembly based on the position of the line in the 2D design file, and select the value of the notch angle based on the line characteristics in the 2D design file.

2. A cutting system, the cutting system comprising a tool assembly for cutting a substrate (450; 1100) during relative movement between the tool and the substrate (450; 1100), means for causing relative movement between the tool assembly and the substrate (450; 1100), and a control system (620) for controlling the direction of the relative movement, the cutting direction angle and the notch angle, the tool assembly comprising: A tool having a distal tool blade (1016; 1060) and a proximal tool shaft (308; 408), the holder can be rotated around a first axis perpendicular to the substrate (450; 1100) to define a cutting direction angle, the holder is configured to rotate the tool blade (1016; 1060) around a second axis perpendicular to the first axis to form a notch angle relative to the first axis, wherein the notch angle is infinitely adjustable within an angle range, wherein a first relatively proximal connection point on the tool shaft is connected to a linearly movable portion of a first linear actuator, and a second intermediate connection point located between the first connection point and the distal end of the tool shaft is connected to a linearly movable portion of a second linear actuator, wherein the first linear actuator and the second linear actuator coordinate to provide adjustability of the notch angle while maintaining a second vertically translatable rotational axis of the tool along the first axis; The cutting system further comprises a computer processor connected to the computer memory, the computer processor being configured to read a design file located in the computer memory, wherein the computer processor is configured to cause the control system (620) to control the operation of the cutter assembly based on information in the design file, It is characterized in that the design file is a 2D design file, and the control system (620) is configured to select the cutting direction angle and the relative movement direction of the tool assembly based on the position of the line in the 2D design file, and select the value of the notch angle based on the line characteristics in the 2D design file.

3. The cutting system according to claim 1 or 2, wherein: The holder is further configured to rotate the tool blade (1016; 1060) about a third axis perpendicular to a plane defined by the tool blade (1016; 1060), wherein the rotation about the third axis adjusts the angle of attack of the tool blade (1016; 1060) relative to the substrate (450; 1100) to within a desired range.

4. The cutting system of claim 3, wherein: The control system (620) is configured to select the cutting direction angle and the relative movement direction of the tool assembly based on the position of the line in the 2D design file, and to select a value of one of the following based on line characteristics in the 2D design file: the notch angle, the attack angle, or a combination thereof.

5. The cutting system according to claim 1 or 2, wherein: The angle range of the notch angle is symmetrical about the first axis from -60 degrees to +60 degrees.

6. The cutting system of claim 1, wherein: The tool shaft (308; 408) is connected to a rack having teeth that mesh with a pinion (1102), wherein the position of the pinion (1102) provides a corresponding angle of attack.

7. The cutting system of claim 6, wherein: The worm gear (1040) has a hollow portion in which a pinion drive connected to the pinion gear (1102) is installed.

8. The cutting system of claim 2, wherein: Each of the first linear actuator and the second linear actuator includes a linear motor, a ball screw device, or a piezoelectric device.

9. The cutting system according to claim 1 or 2, wherein: The cutter assembly is adjustable in a Z direction perpendicular to the substrate (450; 1100).

10. The cutting system of claim 9, wherein: The substrate (450; 1100) includes a thickness between a bottom flat surface and a top surface, and the control system (620) is programmable to position the distal end of the tool blade (1016; 1060) relative to the thickness of the substrate (450; 1100) and cause relative movement between the tool assembly and the substrate (450; 1100), the relative movement being operable to fully penetrate or partially penetrate the substrate (450; 1100) and produce a zero notch angle and a non-zero notch angle, including performing multiple cutting operations at a non-zero notch angle to form a V-shaped notch in the substrate (450; 1100) that does not fully penetrate the substrate (450; 1100).

11. The cutting system of claim 10, wherein: The second and third axes of rotation intersect at a tool angle pivot point, and the control system (620) is configured to allow selection of a tool angle pivot point at a desired distance from the top surface of the substrate as an invariant reference point for kinematics associated with the tool.

12. The cutting system of claim 11, wherein: The pivot point can be selected within a range including at least a first point on the top surface of the substrate (450; 1100) and at least a second point on the bottom surface of the substrate (450; 1100) such that a cutting line in the substrate (450; 1100) relative to the reference point is independent of the notch angle of the tool.

13. The cutting system according to claim 1 or 2, wherein: The line property is selected from the group consisting of line type, line color, and line width.

14. The cutting system according to claim 1 or 2, wherein: One or more 2D design files have line properties associated with custom angle values, and other line properties are predefined for multiple common values.

15. The cutting system of claim 14, wherein: The plurality of common values ​​include values ​​selected from the group consisting of 0°, 15°, 22.5°, 30°, and 45°.

16. A method for cutting a substrate (450; 1100), the method comprising the steps of: (a) A cutting system having an adjustable tool assembly is provided, the adjustable tool assembly comprising a tool having a distal tool blade (1016; 1060) and a proximal tool shaft (308; 408) attached to a tool holder, the tool holder (i) being rotatable about a first axis perpendicular to the substrate (450; 1100) to define a cutting direction angle, and (ii) being configured to rotate the tool blade (1016; 1060) about a second axis perpendicular to the first axis to form a notch angle relative to the first axis degrees, wherein the notch angle is infinitely adjustable within an angular range, (iii) is adjustable in a Z direction perpendicular to the substrate (450; 1100), and (iv) optionally, is configured to rotate the tool blade (1016; 1060) about a third axis perpendicular to a plane defined by the tool blade (1016; 1060), wherein the rotation about the third axis adjusts the angle of attack of the tool blade (1016; 1060) relative to the substrate (450; 1100) to within a desired range; (b) causing relative movement between the tool assembly and the substrate (450; 1100), including automatically controlling the direction of the relative movement, the cutting direction angle, and the notch angle, wherein automatically controlling the notch angle includes automatically changing the notch angle from a first notch angle to a second notch angle using the adjustable tool assembly, The cutting system includes a computer processor, and the method further includes: the computer processor reads information from a design file, and controls the operation of the tool assembly and the relative movement between the tool assembly and the substrate (450; 1100) based on the information in the design file, It is characterized in that the design file is a 2D design file, and the method includes: the computer processor selects the cutting direction angle and the direction of the relative movement of the tool assembly based on the position of the line in the 2D design file, and selects the values ​​of the notch angle and the attack angle based on the line characteristics in the 2D design file.

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