A flexible order breaking method and system for teak wood based on production orders

Abstract

The application discloses a flexible order breaking method and system for teak wood based on production orders, and relates to the technical field of teak furniture production. The method comprises the following steps: grouping orders according to completion time; extracting board parameters, including quantity, grade, size, stress position / direction and texture direction; preferentially matching excess materials, performing geometric matching and stress texture matching judgment, and executing multi-order excess material collaborative optimization joint nesting; and if the matching fails, performing degraded matching. The system comprises order grouping, parameter extraction, primary matching, and primary matching modules, including excess material priority, geometric matching, condition one judgment, multi-order collaborative optimization unit, degraded matching and the like. The application improves teak excess material utilization, ensures that the selected material meets stress and texture requirements, and improves order completion rate and product quality.

Description

Technical Field

[0001] This invention relates to the field of furniture manufacturing technology, specifically a method and system for flexibly splitting teak board orders based on production orders. Background Technology

[0002] In the production of teak furniture, orders typically include requirements for various specifications and grades of teak planks. Traditional order splitting methods rely on manual experience, selecting whole sheets of planks from the warehouse for cutting or selecting multiple pre-cut planks based on order requirements. This approach has several problems: first, it's difficult to consider the natural properties of the planks, such as grade, grain direction, and stress characteristics, leading to improper material selection that could cause strength issues or aesthetic defects; second, the utilization rate of leftover materials is low, with a large amount of high-value teak leftover material being wasted; and third, when multiple orders are running concurrently, frequent conflicts in plank allocation occur, requiring repeated adjustments. Existing order splitting systems for panel furniture cannot be directly applied to teak scenarios because they do not handle the heterogeneity of solid wood (grade, grain, defects, etc.). Therefore, there is an urgent need for a method and system that can comprehensively consider the multiple attributes of teak planks and achieve flexible order splitting. Summary of the Invention

[0003] To address the shortcomings of existing technologies, the purpose of this invention is to provide a method and system for flexibly splitting teak board orders based on production orders, which can solve the problems described in the background art.

[0004] The technical solution to achieve the objective of this invention is: a method for flexibly splitting teak lumber orders based on production orders, comprising the following steps: Step S1: Obtain multiple production orders and their respective completion times, and divide the multiple production orders into at least one production order group according to the completion times; wherein, each production order group contains at least two production orders, and the time difference between the earliest completion time and the latest completion time within the same production order group is less than or equal to a preset time threshold. Step S2: Traverse each production order and extract the teak board parameters required for the production order according to the product design requirements of the production order; the teak board parameters include at least: target quantity, target grade, target size, target stress location, target stress direction, and grain direction; Step S3: Iterate through the currently available teak lumber inventory in the warehouse and match each production order with teak lumber that meets the teak lumber parameters; if a match fails, mark the production order as a production order to be split. Step S4: For each production order group, if all production orders in the group are successfully matched, the splitting of the production order group is confirmed to be completed; if there is at least one production order to be split, the production order to be split is added to the split queue, and the remaining production order groups are processed until all production orders to be split are obtained. Step S5: Sort the production orders to be split according to their completion time, and prioritize the production orders with the earliest completion time for downgraded matching and splitting; if they still cannot be matched after downgraded matching, mark the production order as a production order that cannot be split and transfer it to the manual processing flow. Step S6: Iterate through all production orders to be split, output a list of all successfully matched teak boards and their corresponding production order numbers, and complete the order splitting.

[0005] Furthermore, step S3 specifically includes: Step S3-1: For each target grade, calculate the total quantity of teak planks required for that grade; Step S3-2: Prioritize finding teak boards that meet the grade and satisfy condition one from the surplus inventory in the warehouse; wherein, the surplus inventory refers to non-whole teak boards remaining after the previous cutting, and each board in the surplus inventory is recorded with the original grade, actual size, defect information and grain direction. Step S3-3: Perform a geometric matching judgment on each piece of sheet in the surplus material inventory: determine whether the surplus material can be cut into a blank part that meets the target size through one or more cuts; Step S3-4: If there is leftover material that satisfies the geometric matching condition, then further determine whether the leftover material satisfies condition one: Condition 1: The stress location and direction of the teak board match the grain direction; The matching means that, based on mechanical analysis, when a force is applied at the stress position along the force direction, the original grain direction of the teak board will not be damaged, thus preventing a decrease in strength or cracking. Step S3-5: If both the geometric matching condition and condition one are met, the leftover material is selected first, the cutting plan is recorded, and the inventory status of the leftover material is updated. Step S3-6: After completing the matching of leftover materials for a single order, perform multi-order leftover material collaborative optimization for multiple production orders that have not yet been matched within the same production order group: merge the blank part requirements of multiple production orders that are of the same level, have compatible texture direction and are smaller than the preset threshold, in order to try to perform joint layout on the same piece of leftover material; Step S3-7: If there are no teak boards that meet the conditions in the surplus inventory, then iterate through all available teak boards of this grade in the whole board inventory and determine whether each teak board meets condition one; if it does, then determine the teak board as the candidate board corresponding to this grade and update the whole board inventory occupancy status. Step S3-8: If none of the boards in this grade meet condition one, then mark the production order as a production order to be split.

[0006] Furthermore, in step S3-3, the specific implementation process of the geometric matching judgment includes the following steps: a) If the scrap is rectangular, determine whether the length, width, and thickness of the scrap are all greater than or equal to the length, width, and thickness of the target dimension plus the preset machining allowance. b) If the scrap is not rectangular, calculate the minimum bounding rectangle of the scrap and determine whether the minimum bounding rectangle satisfies the condition in a). If it does, further determine whether the blank part of the target size can be completely within the actual outline of the scrap, and the minimum distance between the edge of the blank part and the edge of the scrap outline is not less than the safe cutting distance. c) If there are defects in the leftover material, the defective area must be avoided during geometric matching. That is, the placement of the target blank part must not overlap with the defective area, and the distance from the edge of the defective area must not be less than the preset safety margin.

[0007] Furthermore, the joint sorting includes: a) Collect a list of raw component requirements for all unmatched orders within the production order group, and group them by grade and texture direction; b) For each group of blank parts, use a two-dimensional rectangular nesting algorithm or an irregular contour-based nesting algorithm to search for surplus materials in the surplus material inventory that can accommodate multiple blank parts and satisfy condition one and geometric matching judgment. c) If a suitable surplus material is found, the surplus material is allocated to the multiple production orders involved at once, and a multi-order joint cutting plan is generated, while the surplus material inventory is updated; if no suitable material is found, the process reverts to single-order matching mode.

[0008] Furthermore, step S5 specifically includes: Step S5-1: Determine whether the production order to be dismantled is allowed to use teak boards of a lower grade than the target grade; Step S5-2: If allowed, try to match teak boards that are one level, two levels, ... up to the lowest level of the target level in turn, and repeat the above steps for each downgraded level until a teak board that satisfies geometric matching and condition one is found. Step S5-3: During the downgrade matching process, if the sheet material used is from the surplus material inventory and the original grade of the surplus material is higher than the grade currently being matched, then the surplus material is allowed to be used in a downgraded manner; if the original grade of the surplus material is lower than the grade currently being matched, then it is not allowed to be used. Step S5-4: If no teak lumber that meets the conditions is found after traversing all grades below the target grade, the production order is marked as an order that cannot be split and is transferred to the manual processing flow.

[0009] Furthermore, the teak board parameters also include matching identifiers; during the matching process, while determining whether the teak board meets condition one, it is also determined whether the teak board belongs to the same log sawing batch as the boards required by other production orders in the same group. If so, it is matched first; when optimizing the collaborative use of leftover materials from multiple orders, if the blank parts of multiple orders have the same matching identifiers, they are arranged in adjacent areas of the same leftover materials during joint layout to ensure the continuity of texture.

[0010] Furthermore, the mechanical analysis in condition one includes pre-establishing a force-texture mapping table through finite element simulation or an empirical database, and querying the mapping table for rapid determination during matching.

[0011] Furthermore, before matching, the actual defect information of each available teak board is obtained, including end crack length, knot location, and warping. When the target grade is A, boards containing defects exceeding a preset threshold are excluded. This rule also applies to boards in the surplus inventory. When optimizing surplus materials from multiple orders, defect areas must be avoided independently for each blank component during joint layout.

[0012] Furthermore, in step S1, the preset time threshold is set according to the drying equilibrium cycle of the teak board, and the value range is 3 to 7 days.

[0013] A flexible teak lumber order splitting system based on production orders includes: Order grouping module: used to obtain multiple production orders and their respective completion times, and divide the multiple production orders into at least one production order group according to the completion time; wherein, each production order group contains at least two production orders, and the time difference between the earliest completion time and the latest completion time within the same production order group is less than or equal to a preset time threshold; Parameter extraction module: used to traverse each production order and extract the teak board parameters required for the production order according to the product design requirements of the production order; the teak board parameters include at least: target quantity, target grade, target size, target stress location, target stress direction, and grain direction; Primary matching module: used to traverse the currently available teak lumber inventory in the warehouse and match each production order with teak lumber that matches the teak lumber parameters; if the matching fails, the production order is marked as a production order to be split. Intra-group verification module: For each production order group, if all production orders in the group are successfully matched, the splitting of the production order group is confirmed to be completed; if there is at least one production order to be split, the production order to be split is added to the split queue, and the remaining production order groups are processed until all production orders to be split are obtained. Downgrade matching module: Sort the production orders to be split according to their completion time, and prioritize downgrade matching for the production orders to be split with the earliest completion time; if a match still cannot be made after downgrade matching, the production order is marked as a production order that cannot be split and is transferred to the manual processing flow. Output module: Used to traverse all production orders to be split and output a list of all successfully matched teak boards and their corresponding production order numbers.

[0014] Furthermore, the primary matching module further includes: Grade Quantity Statistics Unit: Used to calculate the total quantity of teak planks required for each target grade; Leftover material priority matching unit: used to prioritize finding teak boards that meet the grade and satisfy geometric matching and condition one from the leftover material inventory in the warehouse; wherein, the leftover material inventory refers to non-whole teak boards remaining after the previous cutting, and each board in the leftover material inventory is recorded with original grade, actual size, defect information and grain direction. Condition 1 Judgment Unit: Used to determine whether each teak board meets Condition 1: Condition 1: The stress location and direction of the teak board match the grain direction; The term "matching" means that, based on mechanical analysis, when a force is applied at the stress location along the force direction, the original grain direction of the teak board will not be damaged. Candidate determination unit: used to determine the teak board as the candidate board corresponding to the grade when condition one is met, and update the inventory status; for leftover materials, it is also necessary to record the cutting plan and update the leftover material inventory. Pending Dismantling Mark Unit: Used to mark the production order as a pending dismantling production order when none of the boards at this level meet condition one.

[0015] Furthermore, the primary matching module also includes a geometric matching unit, used to perform geometric matching judgment on each piece of sheet metal in the surplus material inventory, determining whether the surplus material can be cut into a blank part that meets the target size through one or more cuts; the geometric matching judgment includes: If the leftover material is rectangular, determine whether the length, width, and thickness of the leftover material are all greater than or equal to the length, width, and thickness of the target size plus the preset processing allowance. If the scrap is not rectangular, calculate the minimum bounding rectangle of the scrap and make a judgment to further verify whether the blank part can fall completely within the actual outline of the scrap and meet the safe cutting distance. If there are defects in the leftover material, the defective area must be avoided during geometric matching to ensure that the blank part does not overlap with the defective area and to maintain a safety margin.

[0016] Furthermore, the primary matching module also includes a multi-order collaborative optimization unit, used to perform multi-order surplus material collaborative optimization for multiple production orders within the same production order group that have not yet been matched after completing the surplus material matching for a single order: merging the requirements for blank parts of the same grade, compatible texture direction, and small size from multiple production orders, and attempting to perform joint layout on the same piece of surplus material; the joint layout includes: Collect a list of blank component requirements for all unmatched orders within the production order group, and group them by grade and texture direction; For each group of blank parts, a two-dimensional rectangular nesting algorithm or a nesting algorithm based on irregular contours is used to search for surplus materials in the surplus material inventory that can accommodate multiple blank parts and satisfy their respective conditions and geometric matching rules. If a suitable surplus material is found, it is allocated to multiple production orders at once, and a multi-order joint cutting plan is generated, while the surplus material inventory is updated.

[0017] Furthermore, the degradation matching module is specifically used for: Determine whether the production order to be dismantled is permitted to use teak boards of a lower grade than the target grade; If allowed, try to match teak boards that are one level, two levels, ... down to the lowest level of the target level in turn, and repeat the function of the above module for each downgraded level until a teak board that meets the conditions is found. During the downgrade matching process, if the material used is a sheet from the surplus inventory and the original grade of the surplus material is higher than the grade currently being matched, then the surplus material is allowed to be used in a downgraded manner; if the original grade of the surplus material is lower than the grade currently being matched, then it is not allowed to be used. If the target level is not found after iterating through all levels below it, the production order is marked as an order that cannot be split and is transferred to the manual processing flow.

[0018] Furthermore, the parameter extraction module is also used to extract the same set pairing identifier from the parameters of the teak board; the geometric matching unit and the condition-1 judgment unit are also used to determine whether the teak board belongs to the same log sawing batch as the boards required by other production orders in the same group. If so, it is matched first; when the multi-order collaborative optimization unit is jointly sorting, if the blank parts of multiple orders have the same same set pairing identifier, it is given priority to arrange them in the adjacent area of ​​the same leftover material to ensure the continuity of texture.

[0019] Furthermore, the condition-one judgment unit has a built-in force-texture mapping database, which is constructed through finite element simulation or historical experimental data to quickly determine the matching between the force location, force direction and texture direction.

[0020] Furthermore, it also includes an inventory defect perception module, which is used to collect or input the actual defect information of each available teak board in real time, and transmit the defect information to the primary matching module to exclude boards containing defects exceeding a preset threshold during matching; the multi-order collaborative optimization unit independently avoids defect areas for each blank component during joint layout.

[0021] Furthermore, the preset time threshold in the order grouping module ranges from 3 to 7 days and can be dynamically adjusted according to the drying balance cycle of teak boards.

[0022] The present invention has the following beneficial technical effects: I. Improve the utilization rate of teak scraps and reduce raw material costs This invention improves the overall utilization rate of sheet metal by prioritizing the matching of surplus materials, using geometric matching algorithms (covering rectangular, non-rectangular, and defect avoidance), and collaborative optimization of surplus materials from multiple orders (joint layout). Combined with rules for downgrading the use of surplus materials, raw material costs are reduced.

[0023] II. Accurately ensure product quality and eliminate potential risks associated with material selection. By using stress-texture matching (condition 1), the material texture direction of the board is ensured to be compatible with the stress conditions, preventing cracking failure caused by horizontal grain load. Dual constraints of grade and defect automatically exclude defective boards from Grade A panels, and matching labels ensure consistent texture and controllable color difference for the same product.

[0024] III. Improve order splitting efficiency and order delivery capability Full-process automation further reduces the time required for single order splitting, improves processing capacity, thereby increasing order splitting efficiency and shortening order delivery cycles. Order grouping reduces resource contention, and degraded matching improves order completion rates. Attached Figure Description

[0025] Figure 1 This is a flowchart illustrating a preferred embodiment of the method of the present invention; Figure 2 This is a flowchart illustrating the specific process of step S3; Figure 3 This is a flowchart illustrating the specific process of step S5; Figure 4 This is a schematic diagram of the system framework of the present invention. Detailed Implementation

[0026] The present invention will be further described below with reference to the accompanying drawings and specific embodiments: like Figures 1-3 As shown, a method for flexibly splitting teak lumber orders based on production orders is described, the method comprising the following steps: Step S1: Obtain multiple production orders and their respective completion times, and divide the multiple production orders into at least one production order group according to the completion times; wherein, each production order group contains at least two production orders, and the time difference between the earliest completion time and the latest completion time within the same production order group is less than or equal to a preset time threshold.

[0027] It is understandable that teak lumber undergoes dimensional changes during storage in a warehouse due to drying equilibrium. If the order completion time span is too large, the lumber used in earlier orders may have different moisture content than that in later orders, leading to deformation or color differences in the final product. By grouping orders with similar completion times (time difference ≤ preset threshold, e.g., 3-7 days), it ensures that the lumber used in orders within the same group is in a similar moisture content stabilization period, thereby guaranteeing product consistency and quality stability. Furthermore, grouping facilitates subsequent collaborative optimization across multiple orders, improving the utilization rate of surplus materials. The time threshold can be dynamically adjusted according to the drying equilibrium cycle of teak lumber to adapt to different seasons and inventory conditions, enabling flexible order splitting.

[0028] For example, retrieve all unsplit production orders in the current production plan. Each order includes information such as product model, quantity, and delivery date. In this embodiment, there are 5 production orders with completion dates (i.e., required completion dates): Order A (2026-07-05), Order B (2026-07-06), Order C (2026-07-08), Order D (2026-07-15), and Order E (2026-07-18). The preset time threshold is set to 3 days.

[0029] Orders are grouped into production order groups based on their completion time: orders with completion times differing by no more than 3 days are grouped together. Specifically: Orders A (07-05) and B (07-06) are 1 day to 3 days apart and can be grouped together. Orders B (07-06) and C (07-08) are 1 day to 3 days apart and can also be grouped together. Therefore, orders A, B, and C are grouped together. Similarly, orders D and E can be grouped into another group.

[0030] For simplicity, this embodiment groups orders A, B, and C into the first group (with time differences of 1 day and 2 days respectively), and orders D and E into the second group (with a time difference of 3 days). The earliest and latest completion time differences within each group are all within a preset time threshold.

[0031] Step S2: Traverse each production order and extract the teak board parameters required for the production order according to the product design requirements of the production order; the teak board parameters include at least: target quantity, target grade, target size, target stress location, target stress direction, and grain direction.

[0032] Understandably, to extract the teak lumber parameters, one could iterate through each production order and extract the parameters based on the product design BOM. Taking order A as an example, which requires the production of a teak dining table, the following lumber components are needed after disassembly: Desktop panel: 1 piece, Grade A, size 1800mm×900mm×25mm, the stress position is the center of the desktop (load-bearing), the stress direction is perpendicular to the desktop (downward), and the texture direction must be parallel to the grain (i.e., the texture is along the length direction). Table legs: 4 pieces, grade B, size 750mm×80mm×80mm, the stress point is the top (support), the stress direction is along the length (axial compression), and the grain direction must be parallel to the grain. Cross brace: 2 pieces, grade C, size 800mm×60mm×40mm, stress position at both ends (connection), stress direction along the length (tension), texture direction is not limited.

[0033] Similarly, the parameters for orders B, C, D, and E are extracted respectively. In this embodiment, it is assumed that all orders require a total of 5 pieces of Grade A board, 12 pieces of Grade B board, and 8 pieces of Grade C board.

[0034] Teak, as a natural heterogeneous material, directly impacts product strength and aesthetics through its grade, grain, and stress characteristics. Traditional order splitting methods focus solely on size and quantity, neglecting these crucial attributes and leading to inappropriate material selection. This step extracts multi-dimensional parameters to lay the foundation for subsequent precise matching. For example, the tabletop requires Grade A, straight grain, and central load-bearing capacity, while the table legs require Grade B, straight grain, and axial compression. Structured parameters allow computers to automatically identify and match, avoiding the arbitrariness of human experience. Only by clearly defining the requirements can targeted inventory matching be performed; this forms the data foundation of the entire order splitting method.

[0035] Step S3: Traverse the currently available teak lumber inventory in the warehouse and match teak lumber that meets the teak lumber parameters for each production order.

[0036] This step reduces manual intervention through automated matching. The matching process follows a strategy of "prioritizing surplus materials, coordinating multiple orders, and supplementing with whole boards," maximizing the use of high-value teak surplus materials and reducing costs. If matching fails, the order is marked for further processing and downgraded, avoiding forced matching that could lead to quality issues. This approach allows for the separation of failed orders for more flexible downgrade processing, rather than a blanket rejection, enhancing the flexibility of order splitting.

[0037] It is understandable that step S3 specifically includes: Step S3-1: For each target grade, calculate the total quantity of teak planks required for that grade.

[0038] Step S3-2: Prioritize finding teak boards that meet the grade and condition one from the surplus inventory in the warehouse; wherein, the surplus inventory refers to non-whole teak boards remaining after the previous cutting, and each board in the surplus inventory is recorded with the original grade, actual size (including length, width, thickness and irregular outline), defect information and grain direction.

[0039] Step S3-3: For each piece of sheet metal in the surplus inventory, perform a geometric matching judgment: determine whether the surplus material can be cut into a blank part that meets the target size through one or more cuts. The geometric matching judgment includes: a) If the scrap is rectangular, determine whether the length, width, and thickness of the scrap are all greater than or equal to the length, width, and thickness of the target dimension plus the preset machining allowance. b) If the scrap is non-rectangular (such as trapezoidal, L-shaped, or arc-shaped edge), calculate the minimum bounding rectangle of the scrap and determine whether the minimum bounding rectangle satisfies the condition in a). If it does, further determine whether the blank part of the target size can be completely within the actual outline of the scrap, and the minimum distance between the edge of the blank part and the edge of the scrap outline is not less than the safe cutting distance. c) If the remaining material has defects (such as end cracks or knots), the defect area must be avoided during geometric matching. That is, the placement position of the target blank part must not overlap with the defect area, and the distance from the edge of the defect area must not be less than the preset safety margin.

[0040] Step S3-4: If there is a leftover material that meets the geometric matching condition, then further determine whether the leftover material meets condition one: the stress position and stress direction of the teak board match the grain direction; where “matching” means that, based on mechanical analysis, when a force is applied at the stress position along the stress direction, the original grain direction of the teak board will not be destroyed, resulting in a decrease in strength or cracking.

[0041] Step S3-5: If both the geometric matching condition and condition one are met, the leftover material is selected first, and the cutting scheme (including the position of the blank part on the leftover material and the cutting path) is recorded. The inventory status of the leftover material is updated (the occupied area is removed, and a new leftover material record is generated if there is leftover material).

[0042] Step S3-6: After completing the matching of surplus materials for a single order, for multiple production orders within the same production order group that have not yet been matched, perform multi-order surplus material collaborative optimization: merge the requirements of blank parts of the same grade, compatible texture direction, and small size from multiple production orders, and attempt to perform joint layout on the same piece of surplus material; the joint layout includes: a) Collect a list of raw component requirements for all unmatched orders within the production order group, and group them by grade and texture direction; b) For each group of blank parts, use a two-dimensional rectangular nesting algorithm or a nesting algorithm based on irregular contours to search for surplus materials in the surplus material inventory that can accommodate multiple blank parts and satisfy their respective conditions and geometric matching rules. c) If a suitable surplus material is found, the surplus material is allocated to the multiple production orders involved at once, and a multi-order joint cutting plan is generated. At the same time, the surplus material inventory is updated (a new surplus material record is generated if there is surplus material remaining); if no suitable surplus material is found, the process reverts to the single order matching mode.

[0043] Step S3-7: If there are no teak boards that meet the conditions in the remaining inventory (including single order matching and multi-order collaborative optimization), then iterate through all available teak boards of this grade from the total board inventory and determine whether each teak board meets condition one; if it does, then determine the teak board as the candidate board corresponding to this grade and update the total board inventory occupancy status. Step S3-8: If all boards (including scraps and whole boards) under this grade do not meet condition one, then mark the production order as a production order to be split.

[0044] Understandably, teak scraps are valuable, and prioritizing their use significantly reduces raw material costs. Furthermore, scraps have typically been stored for a period, resulting in more stable moisture content, which is beneficial for product quality. The shapes of scraps are often irregular (trapezoidal, L-shaped, etc.), making it crucial to determine whether they can be cut into the desired rectangular blank. This step uses the minimum bounding rectangle and actual contour containment checks to ensure the blank can be completely removed from the scrap, avoiding the discovery of dimensional inadequacies after cutting. Simultaneously, defect avoidance rules prevent the use of areas with cracks or knots, ensuring component strength. Geometric matching is a prerequisite for physical feasibility; without this step, scrap matching is meaningless. This rule maximizes scrap utilization; for example, an L-shaped scrap might be perfectly cut into a rectangular component, which traditionally would be discarded manually.

[0045] Teak is an anisotropic material, with its compressive strength along the grain being much higher than that across the grain. Using cross-grained boards for load-bearing components will easily lead to cracking during use. This step uses mechanical analysis (which can be achieved using finite element simulation or an empirical database) to ensure that the selected material meets the stress requirements, fundamentally eliminating potential quality problems. For example, table legs bear axial pressure and should ideally be made of wood with the grain aligned with the grain; if cross-grained boards are used, they are very likely to break within a year.

[0046] Matching leftover materials from a single order often only utilizes a portion of the material, with the remainder potentially being discarded due to its small size. By merging small components from multiple orders into a single layout, multiple components can be cut from the same piece of leftover material, significantly improving material utilization. For example, two small panels (600×400 and 500×300) can be placed side-by-side on a 1200×800 piece of leftover material, increasing utilization from 50% to 95%. Orders within the same order group have similar completion times, so merging layouts does not affect their individual production schedules, and the combined cutting can be completed in the same process, improving production efficiency.

[0047] Step S4: For each production order group, if all production orders in the group are successfully matched with boards that meet their respective teak board parameters, then the splitting of the production order group is confirmed to be completed; if at least one production order in the group is marked as a production order to be split, then the production order to be split is added to the split queue, and the remaining production order groups are processed until all production order groups are processed and all production orders to be split are obtained.

[0048] Step S5: Sort the production orders to be split according to their completion time, and prioritize the earliest completed production order for downgrading and splitting. Specifically, this includes: Step S5-1: Determine whether the production order to be dismantled is allowed to use teak boards of a lower grade than the target grade.

[0049] Step S5-2: If allowed, try to match teak boards that are one level, two levels, ... down to the lowest level of the target level in sequence, and repeat the judgment process of steps S3-2 to S3-8 for each downgraded level (i.e., prioritize matching from the surplus inventory, try multi-order collaborative optimization, and then consider the whole board inventory) until a teak board that meets the geometric matching and condition one is found.

[0050] Step S5-3: During the downgrade matching process, if the board material in the surplus material inventory is used and the original grade of the surplus material is higher than the grade currently being matched, then the surplus material is allowed to be used in a downgraded manner, that is, it is treated as a board material of the current grade for matching; if the original grade of the surplus material is lower than the grade currently being matched, then it is not allowed to be used, and it is necessary to continue to look for surplus material or whole board material of a higher original grade.

[0051] Step S5-4: If no teak lumber that meets the conditions is found after traversing all grades below the target grade, the production order is marked as an order that cannot be split and is transferred to the manual processing flow.

[0052] Step S6: Iterate through all production orders to be split, output a list of all successfully matched teak boards and their corresponding production order numbers, and complete the order splitting.

[0053] When the target grade inventory is insufficient, it is permissible to use a lower-grade board material (e.g., using grade B for grade A panels), but the load-bearing performance must not be affected (condition one). This avoids order delays due to material shortages and improves production flexibility. Simultaneously, when downgrading and using surplus materials, higher-grade surplus materials are allowed to be downgraded (e.g., grade A surplus materials used as grade B), but lower-grade surplus materials are not allowed to be used as higher-grade materials (e.g., grade C used as grade B), ensuring a minimum quality standard. Downgrading is a result of balancing quality and cost, and safety is ensured through condition one. Orders with the earliest completion time are prioritized, adhering to the principle of prioritizing urgent orders.

[0054] It is understood that the teak board parameters also include matching identifiers; in steps S3-4 and S3-7, while determining whether condition one is met, it is also determined whether the teak board belongs to the same log sawing batch as the boards required by other production orders in the same group. If so, it is matched first; in the multi-order surplus material collaborative optimization step S3-6, if the blank parts of multiple orders have the same matching identifier, they are arranged in the adjacent area of ​​the same surplus material during joint layout to ensure the continuity of texture.

[0055] During the matching process, it is determined whether the teak boards belong to the same batch of logs sawn for other production orders in the same group. If so, they are matched first. In multi-order collaborative optimization, if multiple rough parts have the same matching identifier, they are prioritized for placement in adjacent areas of the same scrap material to ensure grain continuity. The purpose of this approach is that high-end teak furniture requires consistent grain and color within the same set of products (such as the headboard panels of a bed set). The matching identifier ensures that boards from the same batch of logs are assigned to the same set of products, avoiding color differences. Boards sawn from the same log have similar grain, and the grain continuity of boards at adjacent sawing positions is strong.

[0056] For example, in steps S3-4, the mechanical analysis includes pre-establishing a force-texture mapping table through finite element simulation or an empirical database, and querying the mapping table for quick determination during matching.

[0057] Understandably, mechanical analysis involves a large amount of computation, making it unsuitable for online real-time judgment. By pre-establishing mapping tables (e.g., "compression along the grain → allowed", "compression across the grain → not allowed"), the judgment time can be reduced from seconds to milliseconds, meeting the real-time requirements of production.

[0058] For example, step S3 further includes: before matching, obtaining the actual defect information of each available teak board, the defect information including end crack length, knot location, and warping; when the target grade is A, excluding boards containing defects exceeding a preset threshold; the same rule applies to boards in the surplus material inventory; in the multi-order surplus material collaborative optimization steps S3-6, when jointly sampling, each blank component needs to independently avoid the defect area.

[0059] Understandably, the natural defects in teak lumber directly affect its performance. Grade A panels require a flawless surface; any knots or cracks necessitate downgrading. By identifying defects, we prevent the use of defective panels in high-requirement components, thus ensuring product quality.

[0060] For example, in step S1, the preset time threshold is set according to the drying balance cycle of the teak board, and the value range is 3 to 7 days.

[0061] It is understandable that teak will slowly release moisture in a dry environment, with minimal changes in moisture content within 3-7 days. During this period, using boards from the same batch for the same order can ensure dimensional stability. Drying speeds vary depending on the season and region, and this preset time threshold can be dynamically adjusted to adapt to actual production environments.

[0062] like Figure 4 As shown, the present invention also provides a flexible teak lumber order splitting system based on production orders, comprising: Order grouping module: used to obtain multiple production orders and their respective completion times, and divide the multiple production orders into at least one production order group according to the completion time; wherein, each production order group contains at least two production orders, and the time difference between the earliest completion time and the latest completion time within the same production order group is less than or equal to a preset time threshold.

[0063] Parameter extraction module: used to traverse each production order and extract the teak board parameters required for the production order according to the product design requirements of the production order; the teak board parameters include at least: target quantity, target grade, target size, target stress location, target stress direction, and grain direction.

[0064] The primary matching module iterates through the currently available teak lumber inventory in the warehouse and matches teak lumber that matches the parameters of each production order. This module further includes: Grade Quantity Statistics Unit: Used to calculate the total quantity of teak planks required for each target grade.

[0065] Leftover material priority matching unit: used to prioritize finding teak boards that meet the grade and satisfy geometric matching and condition one from the leftover material inventory in the warehouse; wherein, the leftover material inventory refers to non-whole teak boards remaining after the previous cutting, and each board in the leftover material inventory is recorded with original grade, actual size (including length, width, thickness and irregular outline), defect information and grain direction.

[0066] Geometric matching unit: Used to perform geometric matching judgment on each piece of sheet metal in the surplus material inventory, determining whether the surplus material can be cut into a blank part that meets the target size through one or more cuts. The geometric matching judgment includes: If the leftover material is rectangular, then determine whether the length, width, and thickness of the leftover material are all greater than or equal to the length, width, and thickness of the target size plus the preset machining allowance.

[0067] If the scrap is not rectangular, calculate the minimum bounding rectangle of the scrap and make a judgment to further verify whether the blank part can fall completely within the actual outline of the scrap and meet the safe cutting distance.

[0068] If there are defects in the leftover material, the defective area must be avoided during geometric matching to ensure that the blank part does not overlap with the defective area and to maintain a safety margin.

[0069] Condition 1 Judgment Unit: Used to determine whether each teak board meets Condition 1: the stress position and direction of the teak board match the grain direction; wherein, “matching” means that, based on mechanical analysis, when a force is applied at the stress position along the stress direction, the original grain direction of the teak board will not be destroyed.

[0070] Multi-order collaborative optimization unit: After completing the matching of surplus materials for a single order, this unit performs multi-order surplus material collaborative optimization for multiple production orders within the same production order group that have not yet been matched. It merges the requirements for blank parts of the same grade, compatible texture direction, and small size from multiple production orders, and attempts to perform joint layout on the same piece of surplus material. The joint layout includes: Collect a list of blank component requirements for all unmatched orders within the production order group, and group them by grade and texture direction.

[0071] For each group of blank parts, a two-dimensional rectangular nesting algorithm or a nesting algorithm based on irregular contours is used to search for surplus materials in the surplus material inventory that can accommodate multiple blank parts and satisfy their respective conditions and geometric matching rules.

[0072] If a suitable surplus material is found, it is allocated to multiple production orders at once, and a multi-order joint cutting plan is generated, while the surplus material inventory is updated.

[0073] Candidate determination unit: When condition one is met, the teak board is determined as the candidate board corresponding to this grade, and the inventory status is updated; for leftover materials, the cutting plan also needs to be recorded and the leftover material inventory is updated (if there are leftover materials, a new leftover material record is generated).

[0074] Pending Dismantling Marking Unit: Used to mark a production order as a pending dismantling production order when all boards (including scrap and whole boards) at this level do not meet condition one.

[0075] Intra-group verification module: For each production order group, if all production orders in the group are successfully matched, the splitting of the production order group is confirmed to be completed; if there is at least one production order to be split, the production order to be split is added to the split queue, and the remaining production order groups are processed until all production orders to be split are obtained.

[0076] The downgrade matching module is used to sort the production orders to be split according to their completion time, prioritizing the earliest completed production order for downgrade matching and splitting. Specifically, this module is used for: Determine whether the production order to be dismantled is permitted to use teak boards of a lower grade than the target grade.

[0077] If allowed, try to match teak boards that are one level lower, two levels lower, and so on down to the lowest level. Repeat the process of prioritizing leftover material matching, geometric matching, multi-order collaborative optimization, and condition one judgment for each downgraded level until a teak board that meets the conditions is found.

[0078] During the downgrade matching process, if the material used is a sheet from the surplus inventory and its original grade is higher than the grade currently being matched, then the surplus material is allowed to be used in a downgraded manner; if the original grade of the surplus material is lower than the grade currently being matched, then it is not allowed to be used.

[0079] If the target level is not found after iterating through all levels below it, the production order is marked as an order that cannot be split and is transferred to the manual processing flow.

[0080] Output module: Used to traverse all production orders to be split and output a list of all successfully matched teak boards and their corresponding production order numbers.

[0081] For example, the parameter extraction module is also used to extract the same set pairing identifier from the teak board parameters; the geometric matching unit and the condition-1 judgment unit are also used to determine whether the teak board belongs to the same log sawing batch as the boards required by other production orders in the same group. If so, it is matched first; when the multi-order collaborative optimization unit is jointly sorting, if the blank parts of multiple orders have the same same set pairing identifier, it is arranged in the adjacent area of ​​the same leftover material to ensure the continuity of texture.

[0082] For example, the condition-one judgment unit has a built-in force-texture mapping database, which is constructed through finite element simulation or historical experimental data, and is used to quickly determine the matching between the force position, force direction and texture direction.

[0083] For example, it also includes an inventory defect perception module, which is used to collect or input the actual defect information of each available teak board (including surplus inventory and whole board inventory) in real time, and transmit the defect information to the primary matching module to exclude boards containing defects exceeding a preset threshold during matching; the multi-order collaborative optimization unit avoids defect areas independently for each blank component during joint layout.

[0084] For example, the preset time threshold in the order grouping module ranges from 3 to 7 days and can be dynamically adjusted according to the drying balance cycle of teak boards.

[0085] The embodiments disclosed in this specification are merely illustrative of one aspect of the invention, and the scope of protection of the invention is not limited to these embodiments. Any other functionally equivalent embodiments fall within the scope of protection of the invention. Those skilled in the art can make various other corresponding changes and modifications based on the technical solutions and concepts described above, and all such changes and modifications should fall within the scope of protection of the claims of this invention.

Claims

1. A method for flexibly splitting teak lumber orders based on production orders, characterized in that, Includes the following steps: Step S1: Obtain multiple production orders and their respective completion times, and divide the multiple production orders into at least one production order group according to the completion times; wherein, each production order group contains at least two production orders, and the time difference between the earliest completion time and the latest completion time within the same production order group is less than or equal to a preset time threshold. Step S2: Traverse each production order and extract the teak board parameters required for the production order according to the product design requirements of the production order; the teak board parameters include at least: target quantity, target grade, target size, target stress location, target stress direction, and grain direction; Step S3: Iterate through the currently available teak lumber inventory in the warehouse and match each production order with teak lumber that meets the teak lumber parameters; if a match fails, mark the production order as a production order to be split. Step S4: For each production order group, if all production orders in the group are successfully matched, the splitting of the production order group is confirmed to be completed; if there is at least one production order to be split, the production order to be split is added to the split queue, and the remaining production order groups are processed until all production orders to be split are obtained. Step S5: Sort the production orders to be split according to their completion time, and prioritize the production orders with the earliest completion time for downgraded matching and splitting; if they still cannot be matched after downgraded matching, mark the production order as a production order that cannot be split and transfer it to the manual processing flow. Step S6: Iterate through all production orders to be split, output a list of all successfully matched teak boards and their corresponding production order numbers, and complete the order splitting.

2. The method for flexibly splitting teak lumber orders based on production orders according to claim 1, characterized in that, Step S3 specifically includes: Step S3-1: For each target grade, calculate the total quantity of teak planks required for that grade; Step S3-2: Prioritize finding teak boards that meet the grade and satisfy condition one from the surplus inventory in the warehouse; wherein, the surplus inventory refers to non-whole teak boards remaining after the previous cutting, and each board in the surplus inventory is recorded with the original grade, actual size, defect information and grain direction. Step S3-3: Perform a geometric matching judgment on each piece of sheet in the surplus material inventory: determine whether the surplus material can be cut into a blank part that meets the target size through one or more cuts; Step S3-4: If there is leftover material that satisfies the geometric matching condition, then further determine whether the leftover material satisfies condition one: Condition 1: The stress location and direction of the teak board match the grain direction; The matching means that, based on mechanical analysis, when a force is applied at the stress position along the force direction, the original grain direction of the teak board will not be damaged, thus preventing a decrease in strength or cracking. Step S3-5: If both the geometric matching condition and condition one are met, the leftover material is selected first, the cutting plan is recorded, and the inventory status of the leftover material is updated. Step S3-6: After completing the matching of leftover materials for a single order, perform multi-order leftover material collaborative optimization for multiple production orders that have not yet been matched within the same production order group: merge the blank part requirements of multiple production orders that are of the same level, have compatible texture direction and are smaller than the preset threshold, in order to try to perform joint layout on the same piece of leftover material; Step S3-7: If there are no teak boards that meet the conditions in the surplus inventory, then iterate through all available teak boards of this grade in the whole board inventory and determine whether each teak board meets condition one; if it does, then determine the teak board as the candidate board corresponding to this grade and update the whole board inventory occupancy status. Step S3-8: If none of the boards in this grade meet condition one, then mark the production order as a production order to be dismantled.

3. The method for flexibly splitting teak lumber orders based on production orders according to claim 2, characterized in that, In step S3-3, the specific implementation process of the geometric matching judgment includes the following steps: a) If the scrap is rectangular, determine whether the length, width, and thickness of the scrap are all greater than or equal to the length, width, and thickness of the target dimension plus the preset processing allowance. b) If the scrap is not rectangular, calculate the minimum bounding rectangle of the scrap and determine whether the minimum bounding rectangle satisfies the condition in a). If it does, further determine whether the blank part of the target size can be completely within the actual outline of the scrap, and the minimum distance between the edge of the blank part and the edge of the scrap outline is not less than the safe cutting distance. c) If there are defects in the leftover material, the defective area must be avoided during geometric matching. That is, the placement of the target blank part must not overlap with the defective area, and the distance from the edge of the defective area must not be less than the preset safety margin.

4. The method for flexibly splitting teak lumber orders based on production orders according to claim 3, characterized in that, The joint sorting includes: a) Collect a list of raw component requirements for all unmatched orders within the production order group, and group them by grade and texture direction; b) For each group of blank parts, use a two-dimensional rectangular nesting algorithm or an irregular contour-based nesting algorithm to search for surplus materials in the surplus material inventory that can accommodate multiple blank parts and satisfy condition one and geometric matching judgment. c) If a suitable surplus material is found, the surplus material is allocated to the multiple production orders involved at once, and a multi-order joint cutting plan is generated, while the surplus material inventory is updated; if no suitable material is found, the process reverts to single-order matching mode.

5. The method for flexibly splitting teak lumber orders based on production orders according to claim 4, characterized in that, Step S5 specifically includes: Step S5-1: Determine whether the production order to be dismantled is allowed to use teak boards of a lower grade than the target grade; Step S5-2: If allowed, try to match teak boards that are one level, two levels, ... up to the lowest level of the target level in sequence, and repeat the steps of any one of claims 2 to 4 for each downgraded level until a teak board that satisfies geometric matching and condition one is found. Step S5-3: During the downgrade matching process, if the sheet material used is from the surplus material inventory and the original grade of the surplus material is higher than the grade currently being matched, then the surplus material is allowed to be used in a downgraded manner; if the original grade of the surplus material is lower than the grade currently being matched, then it is not allowed to be used. Step S5-4: If no teak lumber that meets the conditions is found after traversing all grades below the target grade, the production order is marked as an order that cannot be split and is transferred to the manual processing flow.

6. A flexible order splitting system for teak lumber based on production orders, characterized in that, include: Order grouping module: used to obtain multiple production orders and their respective completion times, and divide the multiple production orders into at least one production order group according to the completion time; wherein, each production order group contains at least two production orders, and the time difference between the earliest completion time and the latest completion time within the same production order group is less than or equal to a preset time threshold; Parameter extraction module: used to traverse each production order and extract the teak board parameters required for the production order according to the product design requirements of the production order; the teak board parameters include at least: target quantity, target grade, target size, target stress location, target stress direction, and grain direction; Primary matching module: used to traverse the currently available teak lumber inventory in the warehouse and match each production order with teak lumber that matches the teak lumber parameters; if the matching fails, the production order is marked as a production order to be split. Intra-group verification module: For each production order group, if all production orders in the group are successfully matched, the splitting of the production order group is confirmed to be completed; if there is at least one production order to be split, the production order to be split is added to the split queue, and the remaining production order groups are processed until all production orders to be split are obtained. Downgrade matching module: Sort the production orders to be split according to their completion time, and prioritize downgrade matching for the production orders to be split with the earliest completion time; if a match still cannot be made after downgrade matching, the production order is marked as a production order that cannot be split and is transferred to the manual processing flow. Output module: Used to traverse all production orders to be split and output a list of all successfully matched teak boards and their corresponding production order numbers.

7. The flexible teak lumber order splitting system based on production orders according to claim 6, characterized in that, The primary matching module includes: Grade Quantity Statistics Unit: Used to calculate the total quantity of teak planks required for each target grade; Leftover material priority matching unit: used to prioritize finding teak boards that meet the grade and satisfy geometric matching and condition one from the leftover material inventory in the warehouse; wherein, the leftover material inventory refers to non-whole teak boards remaining after the previous cutting, and each board in the leftover material inventory is recorded with original grade, actual size, defect information and grain direction. Condition 1 Judgment Unit: Used to determine whether each teak board meets Condition 1: Condition 1: The stress location and direction of the teak board match the grain direction; The term "matching" means that, based on mechanical analysis, when a force is applied at the stress location along the force direction, the original grain direction of the teak board will not be damaged. Candidate determination unit: used to determine the teak board as the candidate board corresponding to the grade when condition one is met, and update the inventory status; for leftover materials, it is also necessary to record the cutting plan and update the leftover material inventory. Pending Dismantling Mark Unit: Used to mark the production order as a pending dismantling production order when none of the boards at this level meet condition one.

8. The flexible teak lumber order splitting system based on production orders according to claim 7, characterized in that, The primary matching module also includes a geometric matching unit, which is used to perform geometric matching judgment on each piece of board in the surplus material inventory to determine whether the surplus material can be cut into a blank part that meets the target size through one or more cuts. The geometric matching judgment includes: If the leftover material is rectangular, determine whether the length, width, and thickness of the leftover material are all greater than or equal to the length, width, and thickness of the target size plus the preset processing allowance. If the scrap is not rectangular, calculate the minimum bounding rectangle of the scrap and make a judgment to further verify whether the blank part can fall completely within the actual outline of the scrap and meet the safe cutting distance. If there are defects in the leftover material, the defective area must be avoided during geometric matching to ensure that the blank part does not overlap with the defective area and to maintain a safety margin.

9. The flexible teak lumber order splitting system based on production orders according to claim 8, characterized in that, The primary matching module also includes a multi-order collaborative optimization unit, used to perform multi-order surplus material collaborative optimization for multiple production orders within the same production order group that have not yet been matched after completing the surplus material matching for a single order: merging the requirements for blank parts of the same grade, compatible texture direction, and small size from multiple production orders, and attempting to perform joint layout on the same piece of surplus material; the joint layout includes: Collect a list of blank component requirements for all unmatched orders within the production order group, and group them by grade and texture direction; For each group of blank parts, a two-dimensional rectangular nesting algorithm or a nesting algorithm based on irregular contours is used to search for surplus materials in the surplus material inventory that can accommodate multiple blank parts and satisfy their respective conditions and geometric matching rules. If a suitable surplus material is found, it is allocated to multiple production orders at once, and a multi-order joint cutting plan is generated, while the surplus material inventory is updated.

10. The flexible teak lumber order splitting system based on production orders according to claim 9, characterized in that, The degradation matching module is specifically used for: Determine whether the production order to be dismantled is permitted to use teak boards of a lower grade than the target grade; If permitted, then attempt to match teak boards that are one level, two levels, ... up to the lowest level of the target level, and repeat the function of the module described in any one of claims 7 to 9 for each downgraded level until a teak board that meets the conditions is found. During the downgrade matching process, if the material used is a sheet from the surplus inventory and the original grade of the surplus material is higher than the grade currently being matched, then the surplus material is allowed to be used in a downgraded manner; if the original grade of the surplus material is lower than the grade currently being matched, then it is not allowed to be used. If the target level is not found after iterating through all levels below it, the production order is marked as an order that cannot be split and is transferred to the manual processing flow.

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