Method and system for automatic cutting of a sheet in a roll of flexible material

Abstract

The invention relates to a method and a system for automatically cutting parts in a flexible material packed in a roll, comprising the successive steps of preparing an initial arrangement (S1), spreading a layer of flexible material on a cutting table (S2), starting the automatic cutting of parts in the spread material according to the initial arrangement (S5), during the cutting, preparing a list of parts to be kept (S6) as soon as a triggering event (Evt) is received, the arrangement of at least one part no longer being suitable for the cutting environment, or the list of parts of the initial arrangement requiring modification, and automatically preparing a new arrangement (S7) taking into account the positions of the parts to be kept, and calculating new positions for all or part of the other parts, regardless of their position in the initial arrangement.

Description

Technical Field

[0001] This invention relates to the general field of automatically cutting components in flexible materials packaged in rolls, and more particularly to the management of triggering events of components that occur during the cutting process and may affect the quality and efficiency of the cutting.

[0002] The invention is particularly applicable to the clothing and furniture industries. Background Technology

[0003] Generally, the automatic cutting of components in flexible materials is performed by a conveyor cutting machine operated by a control station.

[0004] The cutting process is as follows. The operator receives a pre-prepared list of cutting jobs to be performed at the control station. Each job contains all the information required for the cutting, namely: the arrangement of the parts to be cut and the material to be cut.

[0005] The material used (flexible material) is typically packaged in rolls and loaded onto the supply module of the cutting machine. This material is then transported sequentially through different modules of the cutting machine via conveyors: the cutting module, where the parts are cut; and the unloading module, where the operator collects the cut parts. When the cutting machine processes patterned fabrics, it also includes a module for acquiring material to scan upstream of the cutting module.

[0006] Once the material is delivered to the cutting module, the system knows the relative positions of the components thanks to a pre-prepared arrangement stored on the cutting surface. To accurately cut these components from the material, the operator must continue to position these arrangements on the material.

[0007] Preparing for component placement requires both optimizing material consumption and achieving high-quality cutting results. To this end, limitations can be imposed on cutting supports. For example, the available strip width can restrict the placement area of ​​the components. Similarly, the type of material used can limit the minimum proximity distance between components.

[0008] In addition to these constraints imposed by cutting supports, further constraints can be imposed by designers and manufacturers during the creation phase. For example, this could be satisfying the weave of a fabric with clearly defined rotation values, or imposing position-dependent connection constraints between components in patterned fabrics.

[0009] When the operator starts production at the pilot station of the cutting machine, the system automatically activates the supply module based on the material data included in the first cutting job in the manifest. On this supply module, the operator can load the roll corresponding to the material given to them. Depending on the machine selected, the operator can specify the material's orientation and facing surface. This operation will be performed either at the pilot station or on the supply module.

[0010] Once this step is completed, the material is transported to the cutting module, and possibly simultaneously via the acquisition module. The latter can digitize the spread material on the cutting table and provide the operator with the material's actual properties.

[0011] When the material is delivered to the cutting module, the operator uses the image provided by the acquisition module or the pointing tool embedded in the cutting head to position the arrangement in the correct place and begin cutting.

[0012] During production, discrepancies may arise between theoretical information (given in advance before cutting) and actual information (noticed by the operator or specific rolls during cutting), causing the layout preparation to become outdated. Failure to account for these discrepancies can impact the quality of the cutting results or the resulting efficiency. Therefore, several adjustments can be made to the layout during production.

[0013] Furthermore, during the cutting process of the arrangement, it is possible that the material roll ends up and the available material is no longer sufficient to complete the cutting of the arrangement that has already begun.

[0014] To overcome this problem, a known solution is to require the operator to show the end of the current volume in order to divide the arrangement into two parts, thereby avoiding the “change” area between volumes.

[0015] Existing technological solutions such as Figures 1A to 1C As shown. Figure 1A This indicates the arrangement of multiple components P1 to P10 during the cutting process. Components P1-P3 have already been cut in the current volume Rc (and have reached the unloading module), component P4 is in the process of being cut, and components P5-P10 have not yet been cut (or have not yet been partially cut, or even completely cut). Furthermore, in... Figure 1A As can be seen, components P5 and P6 are straddled at the end of the current roll Rc (components P1 to P4 on them are cut off), and components P7 to P10 are placed outside the end of the current roll.

[0016] Based on this information, the operator defined, for example Figure 1B The volume change region Z is shown. (As shown in the image) Figure 1C As shown, components P5 to P7 located in region Z will not be cut on the current roll Rc, but will be placed on the next roll Rs to be cut. More specifically, the arrangement of components P1 to P10 is divided into two, with components P5 to P10 being moved to the arrangement to be cut on the next roll Rs.

[0017] This solution in the prior art can limit the number of parts that should be rejected for volume changes. However, as Figure 1C As shown, the existing arrangement has to be divided into two parts, which would result in significant material loss.

[0018] This solution is also used to avoid defective regions in the material: the beginning of a defective region is assimilated to the end of the current roll, and the end of a defective region is assimilated to the beginning of the next roll; the space between two rolls is therefore considered a defective region.

[0019] In practice, if a defect is detected before cutting a part in the defective area, the operator may wish to avoid cutting parts that will be unusable later. Known solutions include, for the roll end problem, dividing the arrangement into two parts as described above to avoid the defective area. However, this solution suffers from the same drawback as mentioned above: significant material loss.

[0020] Furthermore, during the unloading process, the operator may notice defects in the component that render it unusable. In this case, he may "reject" it. Once the arrangement is completely cut and unloaded, all rejected components are assigned to a new arrangement for recutting.

[0021] This solution allows for the recutting of defective parts, thus enabling the production of all required components in one usable manner. However, the smaller the number of rejected parts, the greater the risk of material waste. Furthermore, waiting for a new layout to recut these rejected parts results in lost production time.

[0022] More generally, the arrangement prepared before production and given during the cutting process is usually sufficient. However, it often happens that the arrangement must be modified to take into account the problems mentioned above. Currently, solutions proposed to overcome these problems include adaptation to the existing initial arrangement: slight shifts in part position or rejection of parts for recutting in a new, additional arrangement.

[0023] The advantage of these adjustments is that they avoid quality problems. On the other hand, the modified layout results in significant material waste and additional production time. Summary of the Invention

[0024] The purpose of this invention is to provide a cutting process that does not have the above-mentioned disadvantages when a triggering event occurs during the cutting arrangement process.

[0025] According to the present invention, this objective is achieved by providing a method for automatically cutting components in a flexible material packaged in rolls, comprising the following sequential steps: a) Prepare an initial layout for the list of components to be cut in the flexible material; b) Lay at least one layer of flexible material on the cutting table; c) Based on the initial arrangement, automatically cut the components in the material spread on the cutting table; d) During the cutting of the initial arrangement, once a trigger event is received indicating that the arrangement of at least one component is no longer suitable for the cutting environment, or that the list of components in the initial arrangement needs to be modified, prepare a list of components to be retained; and e) Taking into account the position of the component to be retained, automatically prepare a new arrangement and calculate the new positions of all or some of the other components (referred to as the components to be repositioned), regardless of their positions in the initial arrangement.

[0026] The method according to the invention is significant because it proposes to automatically prepare a list of components to be held upon receiving a triggering event during the cutting arrangement, and then prepare a new arrangement different from the initial arrangement, which takes into account the positions of the components to be held and calculates the new positions of all or some of the other components to be repositioned.

[0027] Therefore, for example, in the event of a detected roll end or cutting defect, the method according to the invention proposes to recalculate the arrangement of all or part of the other components to be repositioned, in order to generate a new optimized arrangement with significant material gain. Here, "new arrangement" refers to the overall arrangement of the components to be repositioned, prepared without considering the component positions defined in the initial arrangement. In particular, this new arrangement is not merely a simple optimization of the initial arrangement.

[0028] Furthermore, the method according to the invention can yield significant yield gains because it can maintain minimal cutting time during the generation of new arrangements, thereby avoiding any production stoppages.

[0029] Preferably, step e) is followed by step f) which automatically cuts the component in the material spread on the cutting table according to the new arrangement.

[0030] The new arrangement prepared in step e) may include all or part of the components still to be cut in the initial arrangement. In this case, the new arrangement prepared in step e) may also include one or more components that are no longer suitable for the cutting environment.

[0031] Preferably, step d) includes determining the number of the remaining components to be cut based on an assessment of the cutting time and the time allocated to calculating the new arrangement. In this case, the time allocated to calculating the new arrangement is less than the assessment of the cutting time for the remaining components to be cut.

[0032] Preferably, the selection of the newly arranged component from all the components still to be cut in the initial arrangement is achieved by satisfying any constraint conditions of the component's arrangement.

[0033] The triggering event is selected from: the detection of the end of the roll (the material laid out on the cutting table and packaged on the roll), the detection of defects in the material laid out on the cutting table, and the detection of defects in the cut part that needs to be recut.

[0034] When the triggering event includes the detection of the end of a roll (material laid out on the cutting table and packaged on the roll), step e) includes establishing a first arrangement of the components at the end of the roll and a second arrangement of the remaining components on another roll of material.

[0035] When the triggering event includes the detection of defects in the material spread on the cutting table, step e) includes excluding the area in the spread material where defects exist in order to establish the new arrangement.

[0036] When the triggering event includes the detection of a defect in a cut component that needs to be recut, step e) includes adding the defective component to the new arrangement.

[0037] Preferably, the new arrangement in step e) is prepared to minimize yield loss. To this end, step e) is performed according to the initial arrangement without interrupting the cutting of the still-to-be-cut component.

[0038] Also preferably, the step e) of preparing the new arrangement is performed iteratively to obtain the highest possible efficiency.

[0039] Step c) includes the preceding step, which modifies the initial arrangement taking into account the actual characteristics of the material to generate the actual arrangement of the component on the spread material.

[0040] The present invention also relates to a system for automatically cutting components in a flexible material packaged in rolls, comprising: An apparatus for preparing an initial arrangement of a list of components to be cut from the flexible material; A cutting table capable of laying at least one layer of flexible material; A device for automatically cutting the component in the material spread on the cutting table according to the initial arrangement; During the cutting process of the initial arrangement, a triggering event occurs once the arrangement of at least one component is no longer suitable for the cutting environment, or the list of components in the initial arrangement needs to be modified; and The device automatically prepares a list of components to be held and a new arrangement, taking into account the position of the component to be held, and calculates the new positions of all or some of the other components (referred to as components to be repositioned), without considering their positions in the initial arrangement. Attached Figure Description

[0041]

【 Figure 1A-1C [Already described] Figure 1A-1CAn example of volume end management in the prior art is shown.

[0042]

Figure 2

[0043]

Figure 3

[0044]

Figures 4A-4B

[0045]

Figures 5A-5B

[0046]

Figures 6A-6B

[0047]

Figures 7A-7B

[0048]

Figures 8A-8C

[0049]

Figures 9A-9C

[0050] This invention relates to the use of, for example Figure 2 The cutting system shown automatically cuts multiple components from a flexible material packaged in rolls.

[0051] In the known manner, the cutting system 2 may consist of four modules through which the material passes (from upstream to downstream along the material's forward direction F): a supply module 4 located at one end of the cutting table 6, an acquisition module 8 (optional), a cutting module 10, and an unloading module 12 located at the other end of the cutting table.

[0052] The supply module 4 receives material packaged in rolls for cutting. The acquisition module 8 is an optional module for scanning the material spread out on the cutting table. The cutting module 10 includes a movable frame 10a with cutting tools for cutting the parts. The unloading module 12 allows the operator to unload the cut parts off the worktable.

[0053] The flexible material to be cut is driven from the supply module 4 to the unloading module 12 on the cutting table 2 by a conveyor. The cutting system 2 also includes a control station 14, which allows the operator to guide different modules according to the material to be cut and the cutting task to be performed.

[0054] In actual operation, the operator receives the information required for cutting from the computer workstation 15 on the console, namely (for each cutting job): the initial arrangement of the list of parts to be cut, and the material to be cut.

[0055] The flexible material used in the cutting process is represented by a fabric from which the parts must be cut. Each material is associated with a set of previously recorded technical characteristics (in particular, color, description of arbitrary patterns, strip width, etc.).

[0056] Figure 3 This is a flowchart of different steps in a method according to the invention for automatically cutting components in a roll-packaged flexible material, particularly, these different steps are performed by, for example... Figure 2 The cutting system shown is used to perform this operation.

[0057] The first step S1 of the method includes preparing an initial arrangement for a list of components to be cut in the flexible material.

[0058] The setup can be manual or automatic, but is most often prepared by a specialized operator (different from the person operating the cutting system) to fully optimize material consumption and obtain high-quality cutting results.

[0059] In known methods, the arrangement takes into account constraints imposed by the cutting support, such as strip width (which limits the arrangement area) and the type of material used (which limits the minimum proximity distance between components), as well as constraints imposed by the designer and / or manufacturer, such as satisfying the weave of the fabric, and in patterned fabrics, the connection between components and the pattern points.

[0060] In particular, when the material includes patterned fabrics, the initial arrangement is prepared by taking into account the constraints of the connections between components. For example, reference may be made to FR 2002947, filed by the applicant on March 26, 2020, which describes a method for preparing a component arrangement under constraints of component arrangement in a patterned fabric.

[0061] The next step S2 of the method according to the invention includes spreading a layer of material to be cut on the cutting table.

[0062] Generally, when the operator starts production at the control station, the cutting system automatically activates the supply module based on the material data contained in the first cutting job in the inventory. On this supply module, the operator will be able to load the roll corresponding to the material supplied to them.

[0063] This supply module is typically equipped with sensors and actuators to ensure tension-free, wrinkle-free, and well-aligned unwinding and fabric spreading. The module usually includes a fabric presence detector. This detector identifies the ends of the roll. Measurement of fabric tension also allows for the detection of the roll ends when the fabric ends are bonded to the central mandrel of the roll.

[0064] The material is then transported from the cutting table to the cutting module. Depending on the system configuration, the fabric can pass through an acquisition module that records new material information. This acquisition module can be a scanner that records and analyzes material images, a simple detector placed above the selvage of the fabric and detecting marks indicating defects on the fabric, or any other device that provides material information before cutting (step S3).

[0065] Step S3 may take into account any discrepancies that may exist between the theoretical information of the material (given in advance during the cutting operation) and the actual information observed by the operator or given in the roll during the cutting process. These discrepancies may be caused by printing defects, fabric spreading defects on the cutting table, variations in loom yarn density that may lead to irregular pattern repeating spacing, and / or fabric deformation.

[0066] Ignoring these differences would affect the quality of the cutting results. Simultaneously, the initial layout is planned to be automatically modified or adjusted (step S4) to conform to the actual fabric spreading on the cutting table. An example of modifying the initial layout is described in EP 0759,708.

[0067] Then, the next step S5 of the method according to the invention includes starting to cut the initial arrangement (possibly modified in step S4). This operation is performed at the cutting module level of the cutting system.

[0068] In this step, the material moves on the cutting table and is cut into different parts according to the initial arrangement, which may be modified.

[0069] When the cut parts reach the unloading module level of the cutting system, they are collected by the operator.

[0070] During or at the end of step S5, a triggering event Evt may occur. The different types of triggering events involved include: detection of the end of the roll (the material laid out on the cutting table is wrapped on the roll), detection of defects in the material laid out on the cutting table, and detection of defects in the cut part that needs to be recut.

[0071] The triggering event can occur automatically (e.g., a defect in the material spread on the cutting table that can be detected by the acquisition module of the cutting system) or it can be triggered manually by the operator.

[0072] In both cases, when such a triggering event occurs, a signal is sent to the operator, and information is sent to the control station for processing.

[0073] Upon receiving this information, a list of components to be retained is automatically prepared (step S6 of the method). The components in this list are those whose positions will not be modified in the new arrangement prepared in the next step S7. For example, components that have already been cut and components that do not need to be recut constitute part of the list of components to be retained.

[0074] In the next step S7, the automatic placement module automatically prepares a new placement.

[0075] This new arrangement is independent of the initial arrangement prepared in step S1. However, this new arrangement takes into account the position of the component to be held (generated by step S6) and calculates new positions for all or some of the other components (referred to as the components to be repositioned), regardless of their position in the initial arrangement. Furthermore, this new arrangement satisfies the constraints imposed on the initial arrangement.

[0076] Preparing a new arrangement is beneficial in order to minimize yield loss. In particular, it is advantageous to prepare without interrupting the cutting of components that are still to be cut according to the initial arrangement.

[0077] Different examples of preparations for new arrangements based on different possible triggering events will be described later.

[0078] Finally, the final step S8 of the method involves continuing cutting according to the new arrangement (at the cutting module level of the cutting system). When the cut parts reach the unloading module level of the cutting system, they are collected by the operator.

[0079] It should be noted that, depending on the new arrangement, the triggering event may occur in the cutting step S8. In this case, repeat steps S6 to S8.

[0080] about Figure 4A and 4BAn exemplary implementation of preparing a new arrangement under a triggering event will now be described, which includes detecting the end of a roll (of which material laid out on a cutting table is packaged).

[0081] In this example, the length of the current roll Rc (the material spread out on the cutting table and wrapped on the roll) is insufficient to cut all the parts in the initial arrangement. Figure 4A Therefore, the remaining components must be generated on the next volume Rs.

[0082] To generate the components for the next volume of Rs ( Figure 4B All steps prior to cutting must be performed (especially material loading, determining the cutting area layout, etc.). To complete these steps at the end of the current roll Rc normally and independently, a second cutting job will be created. The latter will have its own layout (containing all parts that must be cut on the next roll).

[0083] When dealing with the end of the roll, two new arrangements are necessary: The first new arrangement is used to optimize the efficiency of component Px at the end of the current volume Rc; The second new arrangement is used to optimize the efficiency of the component Py associated with the next volume Rs.

[0084] about Figure 5A and 5B An exemplary implementation of preparing a new arrangement under a triggering event, which includes the detection of defects in the material laid out on the cutting table, will now be described.

[0085] Figure 5A This illustrates the use of a cutting system (e.g.) Figure 2 (As shown) The arrangement of component P during the cutting process.

[0086] During cutting, the acquisition module 6 (or the operator) detects defects on the material spread on the cutting table at the defect area 16. This defect area 16 is located at the position of the part to be cut, Pz.

[0087] Before cutting components that will become unusable (including component Pz), the cutting method according to the invention directly prepares a new arrangement, specifically stipulating that no components may be placed on the defective area 16. For this purpose, the defective area 16 is assigned to an automatic placement module for exclusion from the new arrangement.

[0088] Figure 5B This illustrates one possible outcome of a new arrangement prepared under these circumstances.

[0089] Before preparing a new arrangement, create a list of components to be retained (i.e., components in the new arrangement will not have their positions modified). Figure 5BIn the example, these specific components Pc are located at the cutting module 10 level.

[0090] The new arrangement was prepared by taking into account the position of the component Pc to be held, and calculating new positions for all or part of the other components (components to be repositioned). The component Pz, which was previously located on defect area 16, forms a specific portion of these components to be repositioned.

[0091] In order to avoid the generation of components in defective areas, a new layout is also prepared in order to optimize the use of materials.

[0092] about Figure 6A and 6B An exemplary implementation of preparing a new arrangement under a triggering event, which includes the detection of defects in the cut component that needs to be recut, will now be described.

[0093] In this example, the defect was not detected during part cutting, but rather by the operator unloading the part at the unloading module 12 level of the cutting system. Figure 6A In the process, defective component Pv (18) was identified by the operator during unloading.

[0094] In this case, known solutions include recutting the defective component by preparing an additional arrangement that contains only the component, which is cut at the end of the current arrangement (causing significant material loss).

[0095] On the contrary, such as Figure 6B As shown, the method according to the invention proposes to establish a list of components to be retained, and then to establish a new arrangement, particularly including components P'v to be recut.

[0096] The new arrangement is prepared with the positions of the components to be retained in mind to optimize material usage. This new arrangement calculates new positions for all or part of the other components (the components to be repositioned). Specifically, defective components P'v that must be recut form part of one of these components to be repositioned.

[0097] Since the defective component was detected during component unloading, it is possible that the initial Qi arrangement had already been completely cut off when the defective component was detected.

[0098] exist Figure 7A and 7B In the specific case shown, if the current arrangement Qc (after the initial arrangement Qi) is prepared on the same material, then the defective component P'v can be integrated into the current arrangement Qc.

[0099] In other words, the new arrangement prepared according to the present invention includes not only the defective component P'v, but also all components belonging to the current arrangement Qc.

[0100] about Figures 8A to 8C The method for establishing the list of components to be retained (corresponding to step S6 of the method according to the invention) and the list of components to be repositioned (step S7 of the method according to the invention) when preparing a new arrangement will now be described.

[0101] Components to be retained are those whose positions will not be modified in the new arrangement. Components to be repositioned are those whose positions will be automatically recalculated in the new arrangement.

[0102] Figure 8A This is an example of the initial arrangement during the cutting process. The different modules of the cutting system are arranged from upstream to downstream in the material's forward direction F as follows: supply module 4, acquisition module 6, cutting module 10, and unloading module 12.

[0103] Among all the components in the initial arrangement, there is a distinction between components that have been cut with openings and components that are being cut with dots.

[0104] In this example, the triggering event Evt includes the detection of the end of roll Rc (the material laid out on the cutting table and wrapped on the roll).

[0105] Figure 8B This illustrates how, upon detecting a trigger event Evt (Volume End), the initially arranged components are assigned to different categories:

[0106] 1. Parts to be held (parts with openings): These are parts that have been cut or are being cut. Therefore, these parts need to be held in their initial position and are thus grouped into the "parts to be held" category.

[0107] 2. Parts to be repositioned (empty parts): These are parts that cannot maintain their initial position because they cannot be cut correctly (in this example, these are all parts that are not on the current roll Rc on the cutting table or that span the end of the current roll Rc). Therefore, these parts need to be repositioned and are thus grouped into the "Parts to be repositioned" group.

[0108] 3. Components to be judged (components in the dashed section): Other components in this arrangement.

[0109] Then, each component to be judged needs to be grouped into one of two groups (component to be held or component to be repositioned).

[0110] When selecting the classification of these components to be judged, it must be considered that, in order to improve efficiency, all of these components should be considered as "to be repositioned" (the more components to be repositioned, the more possible combinations the placement algorithm will have, thus making it more efficient).

[0111] However, it should also be considered that in order to continue production, cutting needs to continue, and all parts should be considered "to be held" (the more parts to be held, the greater the probability of receiving the arrangement results before the machine stops cutting).

[0112] Therefore, preferably, the present invention specifies that the number of components belonging to the "components to be held" group is determined based on the assessment of their cutting time and the time allocated to calculating the new arrangement.

[0113] In fact, by evaluating the cutting time for each component, it is possible to estimate the remaining cutting time, which is the sum of the cutting times for all holding components. If there are no components in the "to be held" group, or if they have all been cut off, the remaining cutting time is zero. In this case, cutting will stop to accept the new arrangement.

[0114] The preparation time for a new layout can be limited to the time specified by the software. Therefore, a maximum computation time can be imposed on the automatic layout module, and the cutting time can be kept relative to some parts corresponding to that maximum computation time (along with a possible fixed additional cost as a difference).

[0115] This search for components is preferably performed by prioritizing those closest to the unloading module 12. This arbitrary selection maintains process fluidity by providing the operator with the components to be unloaded.

[0116] The results obtained are as follows Figure 8C As shown, Figure 8B The components to be judged are divided into one of two groups (components to be held: components with openings; and components to be repositioned: empty components).

[0117] It should be noted that the selection of these components to be judged (one of two groups: components to be held or components to be repositioned) can also be based on some of the components to be judged having arrangement restrictions (the material to be cut includes patterned fabrics) or proximity restrictions.

[0118] In particular, when it comes to the arrangement of patterned materials, the limitations of the connections between the components and the classification of the components to be judged must be considered.

[0119] In fact, the concept of a master component and a child component arises when there are constraints on the connection between two components. The master component passes its positioning instructions to the child component, ensuring it is positioned correctly. Therefore, if the master component is not positioned, the child component cannot be positioned. On the other hand, this explains why a child component cannot be placed in the "to be repositioned" group if its master component has already been placed in the "to be held" group.

[0120] There is also the possibility that a sub-component can be a main component of another component, just as a main component can be a sub-component of another component.

[0121] In this scenario, when the main component is assigned to the "to be repositioned" group, all its sub-components will also be assigned to that group.

[0122] When the main component is assigned to the "to be held" group, all its sub-components can be placed in the "to be repositioned" group, taking into account the constraints imposed on it by the main component.

[0123] For components with access restrictions, the following distinctions apply:

[0124] 1. Proximity / alignment constraint (quality constraint), which forces two parts to maintain their relative arrangement to ensure, for example, perfect continuity of yarn.

[0125] These components form a fixed, indivisible block of components. This means that all of these components can be assigned to the "to be held" group on the current roll, or assigned to the "to be repositioned" group and placed on the next roll, while maintaining their relative positions.

[0126] 2. Limitations on the proximity of associated components to their main components: Ensure component cut (proximity-X): The "proximity-X" limits the distance between the main component and its "sub-components" so that they are in the same cut window when the latter is placed in front of its main component. Alternatively, to ensure product quality (color stability of the roll, its rinsing solution deteriorates with length), the distance between the main component and the associated component can be limited on all other axes: when the associated component is placed after the main component, proximity +X limits the distance between the main component and the associated component; when the associated component is placed above and below the main component respectively, proximity +Y / -Y limits the distance between the associated component and the main component.

[0127] In this scenario, these components also form a fixed, indivisible block, allowing them to be entirely assigned to the "to be held" group on the current roll, or entirely assigned to the "to be repositioned" group and placed on the next roll, while maintaining their relative positions. However, this constraint is not always met, especially when part of a group has been cut and must be held, while another part must be repositioned.

[0128] When the part to be judged is assigned to one of the two groups, production can be resumed (if it has been interrupted) or continued (if it has not been interrupted), while preparing for a new automatic arrangement (step S7 of the method).

[0129] In addition to the arrangement associated with each component or the proximity constraints imposed by the material, new information is required to determine the new arrangement.

[0130] As mentioned earlier, the preparation time for new arrangements is limited by the remaining cutting time. Furthermore, processing can be interrupted if a certain efficiency threshold is reached.

[0131] Therefore, the system can determine the preparation parameters for new automated deployment by providing the maximum computation time and target efficiency.

[0132] Furthermore, the dimensions of the newly arranged area will depend on the materials used in the new arrangement. These dimensions depend on the environment in which the new arrangement takes place, namely:

[0133] The width can be given based on the strip width measured on the machine or the characteristics of the material, and the limit can be given based on the strip width measured on the machine or the characteristics of the material.

[0134] 2. A constraint on the arrangement Xmax can be imposed. When the volume end is known, it is defined by detecting the volume end. When the volume end is unknown, this constraint is infinite.

[0135] 2. A placement constraint Xmin can be specified to avoid positioning parts in areas inaccessible to the cutting module as it continues cutting. In fact, as cutting continues, the cutting module and the automatic placement module share a constraint position that can be removed from the cutting area. This position will be a value available to the placement module. This Xmin must take into account the accessible space left by the part to be repositioned, as well as areas inaccessible to the cutting module or the held part.

[0136] For each component Pc(i) to be held, calculate the maximum value Max(i); for each component Pr(j) to be repositioned, calculate the minimum value Min(j). The limit Xmin is equal to the set of maximum values ​​in Max(i) that are less than the minimum values ​​(j). The cutting module must ensure that the arrangement position is not excluded from the cutting area.

[0137] Production can resume during the automatic preparation of the new arrangement, which allows for the continued cutting and unloading of the retained parts. However, to avoid bringing available material for the arrangement of parts into areas inaccessible to the cutting module, the conveyor advance must be limited to the same value as the authorized part arrangement position Xmin.

[0138] Production, thus restricted, can resume its progress: the repositioning of parts will always be limited to the area accessible by the cutting module, regardless of the amount of feeder advance.

[0139] Figures 9A to 9C Different steps of an exemplary implementation of the characteristics of a new arrangement according to the method of the present invention.

[0140] therefore, Figure 9A The area Z1 on the surface of the cutting table that may be used for the new arrangement is shown, as well as the components that belong to the "to be held" group and the components that belong to the "to be repositioned" group in the initial arrangement.

[0141] Figure 9B The information sent to the automatic layout module to prepare a new layout is shown, namely: layout constraints Xmax and Xmin, which define the constraints for preparing the new layout, the parts to be placed and held, and the list of parts to be repositioned and no longer placed.

[0142] at last, Figure 9C The location of the newly prepared arrangement of the repositioned components is shown.

[0143] Furthermore, as mentioned earlier, the arrangement on patterned materials increases the limitations on the connections between components. Additionally, when selecting the classification of components as "to be held" or "to be repositioned," sub-components can be separated from main components. Moreover, even if both sub-components and main components belong to the "to be repositioned" group, it cannot be guaranteed that the two components can be positioned on the same arrangement.

[0144] In the case where the main component is located in the first new arrangement and the sub-component is located in the second new arrangement, the processing is very similar to that specified in the applicant's patent application FR 2002947, filed on March 26, 2020. This is equivalent to converting the connection points of the sub-component into patterned points to ensure that the component can be processed independently of its main component.

[0145] In contrast to patent application FR 2002947, the final position of the main component may be uncertain during this conversion. To obtain acceptable results, the extrapolation of the actual position of the component will be a function of the actual spacing length. The frame (the actual theoretical frame) will be constructed based on the theoretical frame, but using the spacing length actually measured at the time of cutting (the average of the last two lines).

[0146] If a component is associated with two master components (components on each axis) at two different connection points, then the pattern points created are calculated from the intersection of the connection points at the extrapolated positions of the master components (projections on each axis).

[0147] Otherwise, when a sub-component is placed in the first new position and the main component is placed in the second new position, the extrapolated position of the main component is unknown (especially since the actual spacing of the new arrangement is unknown). The conversion from connection points to pattern points cannot be applied. Therefore, the component cannot be processed. To avoid this situation, the parameters of the automatic placement module allow that a component is positioned in the new arrangement only after all its main components have been positioned.

[0148] Now we will describe how to improve productivity.

[0149] The purpose of the new layout is to respond to issues requiring modifications to the initial layout with minimal impact on productivity. To this end, the computation time for the new layout is hidden by the cutting components retained in its initial layout. Therefore, this means that the time allocated to the new layout is already set.

[0150] In some cases, computation time can be short because the problem to be solved has a strong responsiveness, such as detecting defects shortly before a component is cut from an area of ​​unusable material. Therefore, fewer components can be assigned to the "to be held" group, resulting in shorter setup time.

[0151] In this scenario, the triggering event occurs far from the initial layout end, necessitating the replacement of many components. Considering the aforementioned layout time constraints, the layout result may be unsatisfactory. In this case, a second optimization stage can be applied. It will function similarly to the first stage (keeping the components to be cut hidden from computation time and replacing others). This time, more components will be retained, allowing the automatic layout module to prepare the second layout within a longer computation time. Components from the second result (better than those from the first result) can be integrated into the layout during the cutting process without interruption.

Claims

1. A method for automatically cutting components in a flexible material packaged in a roll, comprising the following sequential steps: a) Prepare an initial arrangement for the list of components to be cut in the flexible material (S1); b) Lay at least one layer of flexible material on the cutting table (S2); c) Automatic cutting of the components in the material spread on the cutting table according to the initial arrangement (S5); d) During the automatic cutting of the initial arrangement, once a trigger event (Evt) is received indicating that the arrangement of at least one of the components is no longer suitable for the cutting environment, or that the list of components in the initial arrangement needs to be modified, a list of components to be held is prepared (S6); and e) Taking into account the position of the component to be held, automatically prepare a new arrangement (S7) and calculate the new position of all or part of the components to be repositioned, regardless of their position in the initial arrangement.

2. The method according to claim 1, wherein, Step e) is followed by step f) which automatically cuts the component in the material spread on the cutting table according to the new arrangement (S8).

3. The method according to claim 1, wherein, The new arrangement prepared in step e) includes all or part of the components of the initial arrangement that are still to be cut.

4. The method according to claim 3, wherein, The new arrangement prepared in step e) also includes one or more components that are no longer suitable for the cutting environment.

5. The method according to claim 3, wherein, Step d) includes determining the number of the remaining components to be cut based on an assessment of the cutting time and the time allocated to calculating the new arrangement.

6. The method according to claim 5, wherein, The time allocated to calculating the new arrangement is less than the estimated cutting time for the components still to be cut.

7. The method according to claim 3, wherein, The selection of a new component from all the components still to be cut in the initial arrangement is performed by satisfying any constraints on the arrangement of the component.

8. The method according to claim 1, wherein, The triggering event is selected from: The end of the roll is inspected, and the material spread on the cutting table is packaged onto the roll; Detection of defects in the material spread on the cutting table, and Detection of defects in parts that need to be recut.

9. The method according to claim 8, wherein, When the triggering event includes the detection of the end of the roll and the material spread on the cutting table is packaged on the roll, step e) includes establishing a first arrangement of the components on the end of the roll and a second arrangement of the remaining components on another roll of material.

10. The method according to claim 8, wherein, When the triggering event includes the detection of defects in the material spread on the cutting table, step e) includes excluding areas in the spread material where defects exist in order to establish the new arrangement.

11. The method according to claim 8, wherein, When the triggering event includes the detection of a defect in a cut part that needs to be recut, step e) includes adding the defective part to the new arrangement.

12. The method according to claim 1, wherein, Prepare the new arrangement described in step e) to minimize yield loss.

13. The method according to claim 12, wherein, According to the initial arrangement, step e) is performed without interrupting the cutting of the components that are still to be cut and held.

14. The method according to claim 1, wherein, Iteratively execute step e) to prepare the new arrangement to achieve the highest possible efficiency.

15. The method according to claim 1, wherein, Step c) includes the preceding step, which modifies the initial arrangement taking into account the actual characteristics of the material to generate the actual arrangement of the component on the spread material.

16. A system for automatically cutting components in a roll-packaged flexible material, comprising: An apparatus for preparing an initial arrangement of a list of components to be cut in the flexible material; A cutting table capable of laying at least one layer of flexible material; A device for automatically cutting the components in the material spread on the cutting table according to the initial arrangement; During the automatic cutting of the initial arrangement, a triggering event is initiated once it is received that the arrangement of at least one component is no longer suitable for the cutting environment, or that the list of components in the initial arrangement needs to be modified; as well as A device that automatically prepares a list and new arrangement of the components to be held, taking into account their positions, and calculates the new positions of all or some of the components to be repositioned, without considering their positions in the initial arrangement.

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