Material Processing Systems

Abstract

The automated material processing system includes a frame having a longitudinal axis, a gantry movable along the longitudinal axis of the frame, and a first belt extending along the longitudinal axis and moving around a cavity having a cavity opening within the gantry. A second belt supported by the gantry extends across the frame in a frame transverse direction perpendicular to the longitudinal axis and covers at least a portion of the cavity opening. A material processing system for processing material extends across at least a portion of the first belt and a portion of the second belt, and a vacuum system movable with the gantry is operably connected to a manifold adjacent to both sides of the cavity opening.

Description

[Technical Field]

[0001] The present invention relates to the field of automated material joining systems, and more particularly to automated systems that include both joining and cutting of materials. Cross-reference to related patent applications

[0002] This application claims the benefit of U.S. Patent Application No. 63 / 429,771, entitled Material Joining and Cutting System. Summary of the Invention [Means for solving the problem]

[0003] In some embodiments, the technology described herein relates to an automated material processing system including a frame having a longitudinal axis, a gantry movable along the longitudinal axis of the frame, a first belt extending along the longitudinal axis and moving around a cavity having a cavity opening in the gantry, a second belt supported by the gantry and extending across the frame in a frame transverse direction perpendicular to the longitudinal axis and covering at least a portion of the cavity opening, a material handling system for processing material extending across at least a portion of the first belt and a portion of the second belt, and a vacuum system movable with the gantry and operably connected to a manifold adjacent either side of the cavity opening.

[0004] In some aspects, the technology described herein relates to an automated system for joining and cutting flexible materials, the automated system including: a frame having a longitudinal axis; a gantry movable along the longitudinal axis; a belt system extending along the longitudinal axis and moving through a cavity in the gantry; a joining system supported by the gantry and movable along a frame transverse axis perpendicular to the longitudinal axis, for joining at least two materials; a cutting system supported by the gantry and movable along the frame transverse axis, for cutting the materials together in two or more directions within a plane defined by the longitudinal axis and the frame transverse axis; and a vacuum system movable with the gantry and operably connected to manifolds on either side of the cavity opening.

[0005] In some aspects, the technology described herein relates to an automated system for joining and cutting flexible materials, the automated system including a frame having a longitudinal axis, a gantry movable along the longitudinal axis, a vacuum system having a duct movable with the gantry and along a transverse axis of the frame perpendicular to the longitudinal axis of the gantry, a belt system extending along the longitudinal axis and moving through a cavity in the gantry, and a material handling system movably supported by and along the gantry configured to process material supported by the belt system. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 is an isometric view of an automated material joining system.

[0007] [Figure 2] FIG. 2 is a partial side view of the system of FIG. 1.

[0008] [Figure 3] FIG. 10 is a side perspective view of an interface system within the gantry.

[0009] [Figure 4] FIG. 1 is an isometric view of the gantry.

[0010] [Figure 5A] FIG. 2 is a cross-sectional side view of the gantry.

[0011] [Figure 5B] FIG. 2 is a cross-sectional side view of a gantry in one embodiment.

[0012] [Figure 5C] FIG. 10 is a schematic diagram of the cross belt path within the gantry cavity.

[0013] [Figure 6] FIG.

[0014] [Figure 7] FIG. 2 is a perspective top view of a manifold and a guide plate.

[0015] [Figure 8] FIG.

[0016] [Figure 9] FIG. 1 is a side perspective view of a joint system.

[0017] [Figure 10] FIG. 2 is a bottom perspective view of the vacuum system.

[0018] [Figure 11] FIG. 3 is a partial side view of the system of FIG. 2 with the gantry in a second position.

[0019] [Figure 12] 1 is a diagram of the materials being loaded into the system.

[0020] [Figure 13] 1 is a diagram of the material after joining and cutting.

[0021] [Figure 14] FIG. 1 is a schematic diagram of a creasing module.

[0022] [Figure 15] FIG. 1 is a schematic diagram of a grommet insertion module.

[0023] [Figure 16] FIG. 1 is a schematic diagram of a metal snap insertion module.

[0024] [Figure 17] FIG. 1 is a schematic diagram of a CNC routing module.

[0025] [Figure 18] FIG. 2 is a schematic diagram of a blade cutting module.

[0026] [Figure 19] FIG. 1 is a schematic diagram of an embossing module.

[0027] [Figure 20] FIG. 2 is a schematic diagram of a printing module.

[0028] [Figure 21] FIG. 1 is a schematic diagram of an ultrasonic bonding module.

[0029] [Figure 22] FIG. 1 is a schematic diagram of a laser dump device with a sensor.

[0030] [Figure 23] FIG. 1 is a schematic diagram of a laser feedback control system.

[0031] [Figure 24] FIG. 2 is an isometric view of a gantry in one embodiment.

[0032] [Figure 25] FIG. 1 is an isometric view of a vacuum cassette.

[0033] [Figure 26]FIG. 10 is a cross-sectional view of opposing vacuum cassettes forming a gantry cavity.

[0034] [Figure 27] FIG. 1 is an isometric view of a vacuum cassette in a portion of the gantry. DETAILED DESCRIPTION OF THE INVENTION

[0035] 1 and 2, an automated material joining and cutting system 110 (system 110) for joining materials 112 is shown. The system 110 includes a frame 114 supporting a gantry 116 that is movable along a longitudinal axis 118 of the frame 114. A belt system 120 includes a first longitudinal belt system 122. In one embodiment, the belt system 120 further includes a horizontal belt 126 system within the gantry 116 that extends perpendicular to the longitudinal axis 118 and the first longitudinal belt system 122. In one embodiment, the longitudinal belt system 122 includes a plurality of individual belts 124 that are separated from one another and extend parallel to one another. As described below, the individual belts 124 are selectively movable relative to the frame 114 and the gantry 116. In one embodiment, system 110 has the same features as those described in pending PCT application PCT / EP2022 / 064663 entitled Automated Suturing System (the "'663 Application"), which is incorporated herein in its entirety. The '663 Application is attached hereto as Appendix A and is made a part hereof.

[0036] In one embodiment, system 110 includes a joining system 128 movably supported by gantry 116 for joining material 112. In one embodiment, joining system 128 includes a suturing system 130 for joining material 112 with stitches. In one embodiment, the vision system may be supported by an arch member 127 that is stationary relative to frame 114. In one embodiment, arch member 127 moves with gantry 116.

[0037] In one embodiment, system 110 includes a cutting system 134 that cuts material 112. In one embodiment, joining system 128 and cutting system 134 are both simultaneously secured to gantry 116, allowing system 110 to both join material 112 and cut material 112 while it is on the same system, without having to exchange joining system 128 for cutting system 134. In one embodiment, the joining head of joining system 128 and the cutting head of cutting system 134 are mounted adjacent to one another on gantry 116 and are automatically moved into operating positions by a controller.

[0038] 1-3 , the frame 114 includes a chassis including longitudinal members 136 extending parallel to a longitudinal axis 118 and cross members 138 extending perpendicular to the longitudinal members 136 and parallel to each other. A pair of longitudinal gantry support members 140 supports the gantry 116 for movement along the longitudinal axis 118. The gantry includes cross members 142 that support the joining system 128 and the cutting system 134 for movement across the frame perpendicular to the longitudinal axis 118. In one embodiment, the gantry 116 is moved longitudinally along the longitudinal gantry support members 140 by a motor 144 that moves the gantry 116 between a first longitudinal end 146 and a second longitudinal end 148. Systems for moving the gantry on the frame are known in the art and may include a single or dual lead screws and a stepper motor that may be controlled by a controller. Similarly, the joining system 128 and the cutting system 134 are moved along the cross member 142 in a direction perpendicular to the longitudinal axis 118 by motors controlled by the controller.

[0039] 1 and 4, the first longitudinal belt system 122 includes individual belts 124 that form a belt path. In one embodiment, the belt system 122 includes a single belt 124 that extends substantially along the entire width of the frame 114 (along the Y-axis). The belt path is defined by the gantry 116 and a first set of proximal crossbars 150a, 150b adjacent the first longitudinal end 146 and a second set of distal crossbars 152a, 152b adjacent the second longitudinal end 148. The gantry 116 includes a first bar 154, a second bar 156, a third bar 158, and a fourth bar 160. Each of the bars 150a, 150b, 152a, 152b, 154, 156, 158, and 160 extends in a transverse system direction perpendicular to the longitudinal axis 118, along the Y-axis as shown in FIG. 1. It should be noted that the term "along the Y-axis" refers to an axis coaxial with and parallel to the Y-axis in the XY plane. Belt 124 extends over crossbar 150a to gantry 116, then extends over first bar 154 along or parallel to longitudinal axis 118, then extends downward and rearward toward and around second bar 156. Belt 124 then extends forward toward and around third bar 158, then extends rearward and upward toward and around fourth bar 160. Belt 124 then extends toward and over upper distal crossbar 152a, then extends rearward toward and around lower distal crossbar 152b. Belt 124 then extends forward toward and beyond lower proximal crossbar 150b. As used herein, the term upper refers to the positive Z-axis and the term lower refers to the negative Z-axis. Similarly, the term rearward refers to the negative X-direction and the term forward refers to the positive X-direction. Angular support brackets 151 and 153 extend from lower support bars 150b and 152b, respectively. Brackets 151, 153 support manifold 168. With reference to FIG. 2, the positive X-direction extends from the loading side of system 110 toward the unloading side of system 110.Stated another way, the material to be processed is generally loaded at the first longitudinal end 146 and unloaded at the second longitudinal end 148 .

[0040] In one embodiment, each of the bars 154, 156, 158, and 160 rotates along its entire longitudinal axis on a bearing. One of the bars 154, 156, 158, and 160 is a motor-driven bar that drives the belt 124 around the belt path. In one embodiment, two or more bars are driven bars that synchronously drive the belt 124 around the belt path so that each belt 124 moves uniformly in the same direction. In one embodiment, individual rollers are provided for each bar of each belt such that the individual rollers rotate around one or more bars 150-160 independently of each other. In one embodiment, one or more of the bars 150-160 and / or the individual rollers on the bars do not rotate; rather, the belt 124 rotates around the bar without the bar or individual rollers rotating around the longitudinal axis of the bar. For example, the bars 154 and 158 can have smooth edges. Note that in one embodiment, the roller 154 is small (to reduce belt width) and has a 10 mm radius. In contrast, in one embodiment, roller 158 is larger than roller 154, ranging from 50 mm to 100 mm, and generates more traction when motor driven. The motor drive can also be located at the far end of the frame driving the end rollers.

[0041] Belt 124 forms a cavity 162 between rollers 154, 156, 158, and 160. The longitudinal distance between rollers 154 and 158 is less than the distance between rollers 156 and 160. In one embodiment, cavity 162 has a generally frustum prism shape with a narrow opening 170 and a wider base 172. Stated another way, the opening of cavity 162 is defined by the space between bars 154 and 158 between a first side 164 of gantry 116 and a second side 166 of gantry 116. It should be noted that cavity 162 moves relative to frame 114 as gantry 116 moves across the system.

[0042] 5, 6, and 7, the manifold 168 defines an opening 174 adjacent the narrow opening 170 of the cavity 162. The opening 174 has a first longitudinal end and a second longitudinal end extending in the transverse direction, spaced apart from and parallel to the first longitudinal end. The manifold 168 has a proximal region 180 and a second distal region 182. The proximal region 180 and the second distal region 182 of the manifold 168 have a plurality of openings 176 extending therethrough, generally aligned with each of the belts 124. In one embodiment, the proximal region 180 and the second distal region 182 are closely adjacent the opening 174 along the longitudinal axis. In one embodiment, the belts 124 are spaced 5 mm apart along the Y axis. The manifold 168 includes a first set of belt openings 184 adjacent the proximal region 180 and a second set of belt openings 186 adjacent the second distal region 182. Each belt 124 extends through one of the first belt openings 184 and one of the second belt openings 186. In one embodiment, the manifold 168 does not have openings through which the belts 124 pass; rather, the belts are guided via a ledge. In one embodiment, the horizontal belt 126 has a first longitudinal end closely adjacent to the portion of the belt 124 extending downward into the gantry cavity region and a second longitudinal end closely adjacent to the portion of the belt 124 extending upward from the gantry cavity region. In one embodiment, the distance between the longitudinal ends of the horizontal belt 126 and the portion of the belt 124 proximate the gantry 116 is 5 mm or less.

[0043] 2 and 5C , horizontal belt 126 extends in the cross-system direction around first roller 188, second roller 190, third roller 192, and fourth roller 194. One of rollers 188, 190, 192, and 194 is a drive roller, and the others are driven rollers. In one embodiment, more of rollers 188, 190, 192, and 194 are drive rollers. In one embodiment, none of rollers 188, 190, 192, and 194 are drive rollers; rather, belt 126 is fixed to a plate 198 that is automatically driven by a motor. Horizontal belt 126 includes at least one opening 196 that allows a joining member, such as a needle, to pass therethrough. In one embodiment, horizontal belt 126 includes two or more openings that allow a separate cutting tool, including a laser, knife, or other cutting tool described herein or known in the art, to pass therethrough.

[0044] The horizontal belt 126 has an outer surface extending outward and an opposite second surface. As described above, in one embodiment, the plate 198 is fixed to the horizontal belt 126 and adjacent the second surface. The plate 198 is rigid and moves across the system with the horizontal belt 126. In one embodiment, the plate 198 is connected to the horizontal belt 126 by a screw actuator or other known drive mechanism to move the horizontal belt 126. In one embodiment, the plate 198 and the horizontal belt 126 can be moved independently and automatically aligned during processes that require alignment of the openings in the horizontal belt 126 and the openings in the plate 198.

[0045] 1, 2, and 7, the gantry 116 includes an upper member 200 and a lower housing 202. The joining system 128 includes an upper member 204 movably supported on the upper member 200 of the gantry 116 and a lower member 206 movably supported on the lower housing 202. In one embodiment, the joining system 128 is a suturing system 130, with the upper member 204 including a needle mechanism and the lower member 206 including a bobbin. The needles 208 of the suturing system 130 extend through openings in the horizontal belt 126 and the plate 198. In one embodiment, the upper and lower members of the gantry 116 move along the longitudinal axis 118 (X-axis) and the transverse system axis (Y-axis) with a high degree of precision, such as + / −0.1 mm, so that the needles and hooks connect the threads and form the stitches.

[0046] The gantry 116 also supports the cutting system 134 having an upper portion 210 and a lower portion 212, where the upper portion 210 is movably supported on the upper member 200 of the gantry 116 and the lower portion 212 is movably supported on the lower housing 202. In one embodiment, the horizontal belt 126 includes a second opening between the upper portion 210 and the lower portion 212 of the cutting system 134 through which the cutting member passes. In one embodiment, the cutting system 134 is a laser cutting system in which a laser is generated in the upper portion 210 and a base member in the lower portion 212 dissipates the laser energy and removes fumes after cutting the material. In one embodiment, the cutting system 134 includes a laser system capable of cutting from both the bottom and top surfaces of the material 112. In this embodiment, both the upper and lower modules include both a laser and a base member.

[0047] 5A , the vacuum system 214 includes a vacuum pump supported by the gantry 116 and operably connected to the first duct 216 and the second duct 218. In one embodiment, the vacuum system 214 is secured to the exterior of the gantry 116 outside the cavity 162. The first duct 216 extends from a position below the cavity 162 to a position adjacent a lower surface 220 of the proximal region 180 of the manifold 168. The second duct 218 extends from a position below the cavity 162 to a position adjacent a lower surface 222 of the second distal region 182 of the manifold 168. The first duct 216 and the second duct 218 include openings that face openings through the proximal region 180 and the second distal region 182. A vacuum system 214 applies a vacuum to the material 112 being joined and cut adjacent the opening 170 and provides a force to the material 112 to maintain its position as the gantry 116 moves vertically within the frame 114. The belt 124 slides on the top surface of the vacuum box despite friction between the underside of the belt 124 and the surface of the vacuum box, also known as the print belt. The belt 124 has low friction on its underside and high friction on its top surface to better grip the material 112.

[0048] In one embodiment, the vacuum system 214 provides sufficient vacuum to allow the material 112 to be held in a fixed position relative to the frame 114 as the gantry 116 moves along the longitudinal axis 118 .

[0049] 8 , in one embodiment, the manifold 168 includes a belt bending plate 224 configured to guide the belt 124 into the gantry 116 toward the bars 154 and 160. The belt bending plate 224 includes a first opening 226 having a radius R1 and a path 228 that guides the belt 124 toward and away from the bar 154 at an angle 230 greater than or less than 90 degrees. In one embodiment, the angle 230 is less than 45 degrees. The belt 124 extends around the first bar 154 such that the belt 124 is directed toward the second bar 156. Similarly, the belt bending plate 224 includes a second opening 232 that extends toward and away from the bar 160 and includes a second guide path 234 having a similar but opposite geometry to the path 228.

[0050] In one embodiment, the system 110 includes an internal cavity vacuum system including a vacuum pump disposed outside the gantry 116, supported on or outside the frame 114, and operably connected to a hose or duct within the gantry 116 to remove gases associated with the laser cutting and / or material removed during the cutting process. In one embodiment, the system 110 includes an air pump (not shown) disposed outside the gantry 116, supported on or outside the frame 114, and operably connected to a hose or duct within the gantry 116 to provide positive air pressure within the gantry 116, which escapes through the horizontal belt 126 and forms a cushion of air in the portion of the material 112 directly above the horizontal belt 126. In one embodiment, the operation of the internal cavity vacuum system and the air pump is controlled by a controller to operate only when necessary. In other words, the internal cavity vacuum system can operate automatically only when the cutting system 134 is available. Similarly, the air pump can operate automatically only when the gantry 116 is moving along the longitudinal axis 118. Similarly, the vacuum system 214 can operate automatically only when the gantry 116 is moving along the longitudinal axis 118. The controller can operate all three air devices (the one vacuum system 214, the inner cavity vacuum system, and the air pump) automatically turning each system on and off based on the movement of the gantry 116 along the longitudinal axis 118 and / or the operation of the cutting system 134.

[0051] In one embodiment, the air pump operates to provide positive air pressure to lift a portion of the material 112 from the base of the frame 114 along substantially the entire operating width of the frame 114, along which the material 112 extends. In one embodiment, the air pressure provided is sufficient to minimize friction between the horizontal belt 126 and the material 112 as the gantry 116 moves along the longitudinal axis 118 to avoid buckling or any breakage or unintended movement of the material being processed. In this manner, positional control of the material being processed is maintained. In one embodiment, the area to which the air pump applies air pressure is limited to the area where the material 112 is present. In one embodiment, a sensor detects the position of the material 112 adjacent to the horizontal belt 126 and limits air flow to the area of ​​the horizontal belt 126 where the material 112 is present. In one embodiment, a cavity vacuum system provides vacuum in the vicinity where the cutting system 134 operates. Stated another way, the cavity vacuum system includes hoses that travel along the gantry 116 with the cutting system 134 so that, as a portion of the material 112 is removed, the cavity vacuum system focuses on removing air and material adjacent to the portion of the material 112 being removed. In one embodiment, a single vacuum pump is provided to remove gas and / or material removed from the material 112 during the cutting operation and to provide vacuum to the material 112 via a manifold 168 outside the cavity area. Automatic control valves and / or dampers operably connected to the vacuum pump provide vacuum where needed, as described herein. In one embodiment, the single vacuum pump is located on the gantry 116 and moves with the gantry. In one embodiment, the single vacuum pump is operably connected to both the cavity vacuum system and the vacuum system 214 via hoses and / or ducts and is located outside the gantry. In this embodiment, a hose management system known in the art maintains a portion of the hoses outside the gantry within the frame 114 to allow for free movement of the gantry 116.

[0052] 7, the belt 124 includes a plurality of openings 242 that allow air to enter therethrough in response to the vacuum 214. In one embodiment, the pattern of the plurality of openings 242 through the belt 124 is sufficient to allow a vacuum to be applied to the underside of the material being processed adjacent the cavity opening 174. In one embodiment, the applied vacuum is sufficient to hold two or more stacked materials together, provided that at least a first material adjacent the belt 124 is porous.

[0053] In one embodiment, the horizontal belt 126 does not extend entirely above the lower housing 202 and the lower portion 206 of the joining system 128 and the lower portion 212 of the suturing system 130, respectively. Referring to FIG. 5C , the horizontal belt 126 deflection system includes a first upper bar 243, a first lower bar 244, a second lower bar 246, and a second upper bar 248. Bars 243, 244, 246, and 248 may rotate and / or include roller bearings. A portion of the horizontal belt 126A (see FIG. 5A , where 126 is shown in dashed lines when a horizontal belt deflection system is used) extends below the lower housing 202 and the lower portion 206 as the suturing system joining system 128 and cutting system 134 move along the gantry 126 along a system transverse axis perpendicular to the longitudinal axis 118. In one embodiment, a portion of the horizontal belt 126A extends below the gantry but above the lower portion of the belt 124. The system transverse axis and the longitudinal axis 118 lie in a plane generally perpendicular to gravity when the system 110 is in its orientation of use. Stated another way, the longitudinal axis 118 is along the X-axis as shown in FIGS. 1 and 2, and the system transverse axis is along the Y-axis as shown in FIGS. 1 and 2. Referring to FIG. 5C, in one embodiment, the lower housing 202 and lower portion 206 are elevated from a base member 250 that moves along the system transverse axis or a line parallel to the system transverse axis. In one embodiment, the stitching system joining system 128 and the cutting system 134 move together, and in one embodiment, the stitching system 128 and the cutting system 134 can move along or parallel to the system transverse axis independently of each other. Referring to FIGS. 5B and 5C, the horizontal belt 126 forms a second cavity within the cavity 162. In one embodiment, the system 110 includes two or more gantries 116 that operate independently of each other, each including a material processing module. In one embodiment, each of the multiple gantries includes a different module. For example, one gantry includes a cutting module and another gantry includes a suturing module. Similarly, one or more of the multiple gantries may include two or more suturing modules.In one embodiment, at least one of the gantries includes two or more cutting modules. In one embodiment, one gantry includes a suturing unit that performs a cross stitch and a second gantry includes a suturing unit that performs a lock stitch. In one embodiment, one gantry includes two suturing units that perform different stitch types.

[0054] In one embodiment, the belt 126 is replaced by a telescoping plate or the like that telescopes as the gantry housing holding the material processing modules, such as the joining and cutting modules, moves back and forth between the longitudinal sides of the frame 114. This ensures that the area directly above the cavity opening is free of any belt material. In one embodiment, the second belt in the claims provided below is replaced by a telescoping plate.

[0055] In one embodiment, the belt 124 has several features. In one embodiment, the friction of one side of the belt that contacts the material 112 has a higher coefficient of friction than the other side of the belt that does not contact the material 112. The belt 124 includes a plurality of perforated holes that allow vacuum airflow to secure the material 112, thereby preventing the material 112 from shifting during joining and / or cutting operations, such as stitching. In one embodiment, the belt 1249s needs to be thin and flexible to move in and out of the gantry as described herein. In one embodiment, the belt 124 is thin and / or flexible enough to bend over small rollers that cause the belt to turn 110-120 degrees downward into the cavity 162. In one embodiment, the belt 124 has minimal stretch along its longitudinal axis and is durable enough to last one or two years with heavy use. In one embodiment, commercially available Habasit FAB-2E material is used; however, many other brands and types can be selected. In one embodiment, the belt 124 includes parallel grooves on the back surface to aid in belt tracking. The belt grooves align with grooves on one of the rollers or rounded paths as shown in FIG. 8 to ensure tracking. In one embodiment, each belt 124 can vary in width perpendicular to the longitudinal axis of the belt from 25 mm to 100 mm. However, the width of each belt 124 can be less than 25 mm or greater than 100 mm. In one embodiment, the width of each belt is 25 mm. In one embodiment, each belt has two rows of holes. In one embodiment, each hole has a diameter of 4 mm. In one embodiment, each longitudinal row of holes is offset from one another such that the holes are offset from one another along or parallel to the system transverse axis, or Y-axis.

[0056] In one embodiment, the horizontal belt 126 is a single belt. In one embodiment, the horizontal belt 126 is non-perforated and has no holes except for holes that allow the joining and cutting members to extend therethrough. In one embodiment, the horizontal belt 126 includes perforations to provide air cushions that help slightly lift the material 112 over the active area (where the belt moves under the fabric 112) so that friction between the horizontal belt 126 and the material 112 does not push the material 112 laterally in the cross-system direction (along the Y-axis). In one embodiment, the horizontal belt 126 has an upper surface that faces / contacts the material 112 with a low coefficient of friction. The horizontal belt 126 has high tensile strength that allows it to move the lower housing 202 and the lower part 206 along the cross-system axis. In one embodiment, the horizontal belt 126 is driven by a motor, and the connection between the horizontal belt 126 and the lower housings 202 and 206 moves the lower housing 202 and the lower part 206, including the base member 238. One of rollers 188, 190, 192, and 194 is a drive roller that moves horizontal belt 126 along the path of horizontal belt 126. In one embodiment, base member 238 is driven by a motor independently of horizontal belt 126. In one embodiment, base member 238 is driven by a motor and operably connected to horizontal belt 126 to move horizontal belt 126 when base member 238 is moved along or parallel to the system cross axis.

[0057] 4, the gantry 116 includes a housing having formed thereon a plurality of rib members 236 that guide each of the belts 124. The rib members 236 extend from a base member 238 toward a top member 240 adjacent the cavity opening.

[0058] Referring to FIG. 2 , material 112 may be supplied to system 110 by a first supply roll 252 supplying the first material and a second supply roll 254 supplying the second material. A take-up roll 256 is configured to take up the spliced ​​first and second materials. In one mode of operation, material 112 is disposed on top of belt 124 through gantry 116 along longitudinal axis 118 between an entrance side of system 110 and an exit side of system 110 in an area where gantry 116 can operate to splice and cut material 112. Gantry 116 is automatically moved along longitudinal axis 118 as splicing system 128 and cutting system 134 are moved along a transverse axis of system 110 to splice and cut material 112 in a predetermined pattern. In this first mode, material 112 remains stationary during operation of splicing system 128 and cutting system 134. Once the material 112 is spliced ​​and cut, the processed material is moved toward an outlet by take-up roll 256. In one embodiment, belt 124 is moved in an outlet direction such that the processed material 112 is moved from the inlet side toward the outlet side. In an embodiment in which only a portion of the material 112 is spliced ​​and cut, take-up roll 256 can be replaced with a tray or another conveyor for moving the spliced ​​and cut product for packaging or further processing.

[0059] In one embodiment, the system 110 includes a vision registration system for registering a joining path along which the material 112 will be joined and a cutting path along which the material 112 will be cut to the printed image. In one embodiment, the vision system can acquire an image of the material 112 with the printed image facing downwards so that the printed textile material can be joined (stitched) and cut in registration with the printed image. In one embodiment, a first camera is mounted above the material being processed on the gantry and is movable with the gantry. In one embodiment, a second camera is fixed relative to the system 110 and does not move relative to the frame.

[0060] In a second mode of operation, material 112 that is not part of a roll is placed (manually or by a robotic loader) on belt 124 between the upper member of gantry 116 and horizontal belt 126. In this mode, material 112 remains stationary relative to frame 114 as gantry 116 is moved along longitudinal axis 118 and joining system 128 and cutting system 134 are moved along or parallel to the system transverse axis to join and cut material 112. The processed material 112 can then be manually removed (by hand or by a robotic loader) from system 110, or belt 124 is moved such that the processed material is moved in a direction toward the exit side of system 110.

[0061] In a third mode of operation, the material 112 is separated from the roll and placed on the system as described above for the second mode of operation. In this third mode, the belt 124 moves toward and away from the exit side, and the gantry 116 also moves along the longitudinal axis 118, thereby moving the material toward and away from the exit side. The splicing system 128 and cutting system 134 move along or parallel to the gantry 116 in the system transverse axis as described herein. Two or more layers of rolls or two or more sheets can be stacked on top of each other to be sewn together and cut. In one embodiment, the system 110 is used for quilting, which has an inner foam layer between two outer fabric layers. In one embodiment, the system 110 is also used for embroidery.

[0062] 2 and 11, in a first mode, belt 124 is fixed relative to bars 150a, 150b, 152a, and 152b. However, the portion of belt 124 between bars 150a and 152a moves along a belt path through gantry 116. Referring to FIG. 2, point A on belt 124 in a first position moves through gantry 116 as gantry 116 is moved from the exit side toward the entrance side. The vacuum generated by vacuum system 214 helps to maintain material 112 in a stationary position relative to frame 114 as gantry 116 moves along longitudinal axis 118.

[0063] In one embodiment, the system 110 includes processing both ends of a flexible or rigid material simultaneously on a flatbed formed by the belt 124. In this embodiment, a second gantry 116 may be used that includes additional processing modules used separately or in conjunction with the joining system 128 and / or cutting system 134. The second gantry system may also include a second joining system 128 and a second cutting system 134. It is also contemplated that the second system 110 may be used in series with the first system 110. For example, when processing material to make an automobile airbag, the first system 110 may have a special vent on one side, which the second system 110 may join to another material. Also, straps and fittings or other tabs may be added (using a robot) during the first system operation and then sewn to layer #2 during the second system operation.

[0064] Creasing Tool: Referring to FIG. 14 , the creasing module 258 includes an upper member 260 supported by the gantry 116 and a lower member 262 supported by the base member 250. The creasing module 258 can be used to creasing folding carton and corrugated board materials and utilizes male and female hard tool dies to produce high-quality creases (pleats). The upper and lower members 260, 262 of the creasing module form the male and female portions of the creasing machine and are operated by the gantry 116 to simultaneously move two opposing creasing wheels together, with the male creasing wheel in an upper tool position and the female creasing wheel in a lower position (in a moving cavity). It should be noted that the creasing module 258 includes independent vertical movement of the male and female creasing wheels to engage and disengage the wheels from the material 112 to be creasing. In one embodiment, both wheels operate synchronously in the same direction (tangentially) in the X and Y directions. In one embodiment, the male wheel is placed inside the cavity and the female wheel is placed on the creasing material attached to the outside of the cavity.

[0065] Referring to FIG. 15 , grommet insertion module 264 is used alone or in conjunction with joining system 128 and / or cutting system 134 to insert one or more grommets into material 112. Grommets are used in connection with sewn products, such as banners, flags, tarps, sails, bags, curtains, and shower curtains, to prevent tearing, add strength, or for aesthetic value. A grommet typically consists of two circular parts that are pressed together from opposite sides into a pre-cut hole. Using system 110, a grommet supply tool supported on upper portion 265a of gantry 116 automatically inserts the upper grommet part. A corresponding lower tool 265b (in a moving cavity) supplies the lower grommet part and then presses the two parts together to secure them. By adding automated grommet insertion, system 110 can sew, cut, and add grommets, thereby enabling fully automated production of a wide range of sewn products. A grommet is a ring or edge strip inserted into a hole through a thin material, typically a sheet of fabric, sheet metal, or carbon fiber, wood, or honeycomb composite. Grommets generally have flared or collared sides to hold them in place and are often made of metal, plastic, or rubber. Grommets may be used to prevent tearing or abrasion of the penetrated material, to protect from abrasion of insulation on wires, cables, or lines routed through the penetration, to cover sharp edges of the penetration, or all of the above. Small grommets, sometimes called eyelets, are used, for example, to thread strings on shoes, tarpaulins, and sails.

[0066] A description of a known automated grommet machine can be found at https: / / plastgrommet.com / us / grommet-presses / automatic / multipress.php. An automated system is integrated into system 110 by separating the upper portion of the automated grommet machine from the lower portion, placing the upper portion in a module supported on top of gantry 116, and placing the lower portion in a lower module supported on base member 250 below material 112. The use of the automated grommet module enables fully automated production of banners, curtains, and tarpaulins, including roll-off, stitching, cutting, and grommeting, all in one system. Banners, curtains, and tarpaulins can also be sewn, cut, and grommeted into non-rectangular shapes at no additional cost. Grommets can also be inserted anywhere on the surface of material 112, not just at the edges. New and creative products can be manufactured using system 110 when the sewn product does not need to be rectangular and grommets can be attached in the center (or anywhere) for pole or wire support, such as for makeshift tents, temporary awnings, etc.

[0067] Referring to FIG. 16 , the metal snap and button insertion module 266 is used alone or in conjunction with the joining system 128 and / or the cutting system 134. Snaps and buttons are used for temporary connections between pieces of fabric, as opposed to grommets, which allow fabrics to be attached for other applications, such as boat covers, grill covers, bags, tents, and luggage. As with grommets, there are two pieces with snaps. However, there is this double attachment of the two fabrics to be connected, one male and one female, which "snap" together to hold them together. In metal button applications, the buttons are not sewn on, but rather attached by a bottom pin that is inserted through the fabric into the button head. By adding automated button and snap insertion, the system 110 can sew, cut, and add snaps / buttons, thereby enabling fully automated production of a wide range of sewn products.

[0068] Referring to FIG. 17 , in one embodiment, the cutting system 134 includes a routing tool 268 for cutting the material 112. The router module includes an upper portion supported by the upper portion of the gantry 116 and a lower portion supported by the lower portion of the gantry 116, such as the base 250. When using smaller diameter routing bits or drills (ranging from 0.1 mm to 5 mm in diameter), these tools are prone to breakage when moving in the X or Y directions on the flatbed table. Therefore, the speed at which the tool moves must be significantly reduced. Also, the rotational speed of the bit or drill must be reduced to avoid vibrations that degrade the edge quality of the processed material. By supporting the bit 270 or drill at its top and bottom on small bearings 272 within the moving cavity, the bit or drill can run at higher X and Y speeds and higher rotational speeds, or a thinner bit can be used, which is advantageous in many situations (less dust, less material waste, finer routing capabilities, and faster speeds). It also allows for thicker materials to be processed in a single routing pass rather than multiple subsequent passes. This allows the router bit to be held by both the upper and lower modules.

[0069] Referring to Figures 18A-18D, the cutting system 134 includes an elongated oscillating blade 274 supported at one end by an upper module 276 mounted on the top of the gantry 116 and at the other end by a lower module 278 within the cavity 162. The oscillating blade module is used to cut multi-layered fabrics (up to 100 layers or more) up to 10-20 cm thick, or when cutting harder, thicker materials, the blade is prone to deflection, causing inaccurate cuts or breakage. However, an oscillating blade system can be used with multi-layered fabrics less than 10 cm thick or greater than 20 cm thick. Cutting speed, number of fabric layers, and material thickness are reduced with the oscillating blade system. In some cases, the flatbed motion control software must also dynamically adjust (slow) the cutting motion (rotation, lift, lower, oscillate) to compensate for blade deflection and avoid breakage. Using system 110, the oscillating blade can be lowered into the moving cavity 162, where it is supported by both the upper blade holder and the lower cavity. This allows for faster cutting of thicker stacks / layers of fabric or thicker / harder materials. It also allows for automatic sharpening of the blade while it is partially in the cavity. In one embodiment, the oscillating blade and holder within the cavity are controlled tangentially, whereby the holder pivots as the blade pivots.

[0070] Referring to FIG. 18B, the cutting system 134 is a wire cutting module 280 that uses a thin metal wire or cable 282 to mechanically cut materials such as foam, nonwovens, wood, glass, stone, ferrite, metal, and crystal. Industrial wire saws are typically electrically powered. Wire saws are classified as continuous (or endless, or loop) or oscillating (or reciprocating). The wire itself is sometimes called a "blade." In some applications, the wire travels at high speeds of up to 200 km / h.

[0071] The cutting system 134 can include a heated wire module that uses a heated wire element to cut the material 112. The heated wire module includes an upper portion supported by the upper portion of the gantry 116 and a lower module supported by the lower portion of the gantry 116, such as the base member 250 within the cavity 162.

[0072] Each of the modules described herein can be used alone or in combination with one or more of the other modules described herein in system 110. It is also contemplated that system 110 may include one or more additional gantries that are automatically controlled to perform operations on different regions of material 112 simultaneously.

[0073] The system 110 supports the material 112 without requiring separate frame members or separately securing the longitudinal edges of the material 112. In one embodiment, the system 110 operates to join, cut, and / or perform other functions identified herein on the material 112 without securing the longitudinal edges of the material 112. In one embodiment, the system 110 operates to join, cut, and / or perform other functions on the material 112 without securing any edges of the material 112 to the frame 114.

[0074] 19, in one embodiment, the upper and lower modules include embossing wheels 286 that emboss a pattern into material 112. With reference to FIG. 20, in one embodiment, the upper and / or lower modules can include printing modules that apply a printed image to one or both sides of material 112.

[0075] Referring to FIG. 21 , in one embodiment, the joining system 128 includes an ultrasonic welding system 132 that ultrasonically bonds the materials 112. The upper module includes an ultrasonic horn 290, as known in the art. The horn vibrates ultrasonically and acts to bond the plastic material 112, which is positioned between the horn and an anvil in the lower module. In one embodiment, one or both of the horn and the anvil 292 are rotating members. In one embodiment, the axis of the rotating member pivots in the direction of movement of the gantry relative to the frame 114. Ultrasonic welding is an industrial process that applies high-frequency ultrasonic vibrations locally to workpieces held together under pressure to form a solid-state bond. Ultrasonic welding is commonly used to join plastics and metals, particularly dissimilar materials. With ultrasonic welding, no connecting bolts, nails, solder materials, or adhesives are required to join the materials. The advantages of ultrasonic welding are that it is much faster than traditional adhesives or solvents and forms an airtight joint without puncturing the materials, as occurs with stitching. Ultrasonic welding can be used with both hard and soft plastics and metals. Two types of machines are used for ultrasonic welding: 1) a first machine with a fixed sonotrode and a rotating wheel for high-speed, precise welding (especially curved lines); and 2) a second machine with a rotating sonotrode and a rotating wheel for high-speed welding (straight seams). The system 110 provides a fully automated welding process for a variety of materials, with two tools capable of applying pressure from both sides of the workpiece while moving synchronously in the X and Y directions. This allows for welding of non-linear contours. After welding, the piece can be cut while the material is held in place by a vacuum hold-down. In one embodiment, the ultrasonic horn uses a rotating wheel at the top and a metal support plate (anvil) at the bottom (or alternatively, a separate wheel to reduce resistance during movement). In one embodiment, if the horn and anvil are wheels, they move synchronously in the same direction (tangentially) in the X and Y directions.

[0076] In one embodiment, the joining system 128 includes a laser welding system that uses laser energy to join the material 112. Laser welding systems can use various types of lasers, including CO2 lasers or diode lasers, which are often used to cut fabrics. Cutting fabrics with a laser offers many advantages over using blade cutting tools. Laser systems do not apply mechanical force (friction) to the fabric because the laser uses a beam of light to vaporize the cutting path. This eliminates the risk of fabric movement during cutting. Lasers also provide finer cutting capabilities for cutting details at higher cutting speeds. Lasers have the ability to cut multiple layers of material 112. Lasers can seal the free edges of the material, thereby reducing fraying when cutting fabrics, including polyester.

[0077] Fumes can be exhausted through a single small hole in the moving cavity (next to the needle hole). In a typical laser cutter, the entire surface area, typically the same size as the flatbed table itself, typically contains a vacuum extraction function. As described herein, the vacuum in the cavity 162 effectively exhausts the fumes associated with the laser cutting process. In other words, within the moving cavity 162, there is a mechanical laser diffusion surface that also contains a vacuum extraction function. By reducing the vacuum area from several square meters of the entire frame to a single hole just a few millimeters in diameter, much higher vacuum flow rates and efficiency are possible. This also saves energy compared to using a full-size machine to vacuum extract. Full-size extraction fumes are typically exhausted outdoors, requiring new air entering the building to be heated or cooled by the HVAC (heating, cooling, and air conditioning) system. A typical 20-horsepower blower pushes a large amount of air outdoors, requiring a lot of new, fresh air to enter. This is especially expensive to operate during the air conditioning season. In one embodiment, the laser beam is in the range of 0.05 mm to 0.1 mm. In one embodiment, the holes through the horizontal belt 126 are larger than the laser beam. In one embodiment, the size of the holes in the horizontal belt 126 through which the laser beam passes is 1 mm to 2 mm.

[0078] System 110 is capable of double-sided processing by using an upper and lower portion located on either side of material 112. This is achieved by moving openings through which the upper and lower portions interact with each other and with material 112. The openings are provided by the belt path of belt 124, which moves a portion of belt 124 around cavity 162 and through the bottom of gantry 116.

[0079] Laser Feedback System

[0080] 22 and 23, cutting system 134 is a laser cutting system in which a laser is generated in upper portion 210 and a base member located in cavity 162 or lower portion 212 dissipates the laser energy and removes fumes after the material is cut. In one embodiment, an automatic laser calibration system 300 automatically adjusts the laser energy to adjust the power of the laser during movement of the laser head over the particular substrate on which the laser is acting. Laser calibration system 300 includes a laser beam dump device 302 that includes an optical sensor 304 that detects laser light as a function of the laser energy delivered by the laser beam of laser nozzle 306 in upper portion 210. In one embodiment, optical sensor 304 includes a phototransistor, such as one with a frequency of 180 kHz available from Vishay Semiconductor Opto Division under part number BPW85B. Due to the speed at which measurements can be made, automatic laser calibration system 300 can adjust the laser intensity in real time to account for material thickness, material color, material seams, or other material variations as the material is processed by system 110.

[0081] In one embodiment, a laser beam dump device 302 is located within the lower portion 212 of the cutting system 134. The laser beam dump device 302 is secured to the gantry 116 and cross member 142, allowing the laser beam dump device 302 to move along the longitudinal axis 118 and in a transverse table direction perpendicular to a direction parallel to the longitudinal axis 118. The laser beam dump device 302 includes a housing 308 defining a chamber 310 including a highly reflective surface 312 disposed therein. Laser beam dump devices 302 are well known in the art. U.S. Pat. No. 10,345,561 describes a laser beam dump device and is incorporated herein by reference to describe the general operation of the laser beam dump device 302. The highly reflective surface 312 may be in the shape of a cone or an angled plane that reflects laser energy entering the chamber 310 toward an inner surface 314 of the housing 308.

[0082] In one embodiment, laser light sensor 304 is positioned at or adjacent to surface 314 to detect the amount of light energy received from highly reflective surface 312. The amount of light energy detected by light sensor 304 is a function of the light energy emitted from laser nozzle 306 after the laser beam cuts the material being cut by the laser. A signal from the light sensor is provided to controller 326, which acts to increase or decrease the laser energy emitted from laser nozzle 306 to a predetermined intensity.

[0083] In one embodiment, a user calibrates the laser energy during the setup phase based on the type of material being cut and the speed at which the laser nozzle moves over the material being cut. For example, the amount of laser energy of the laser beam irradiated onto the material being cut is a predetermined constant value for a particular speed at which the laser nozzle moves over the material. In one embodiment, the speed at which the laser module moves relative to the material can vary depending on the type of cut being made. For example, linear movement of the nozzle head can be at a first speed measured in inches per minute, while arcuate or non-linear movement of the nozzle head can be at a second speed different from the first speed. In one embodiment, the second speed is slower than the first speed. In one embodiment, the actual amount of energy emitted by the laser beam changes during the cutting operation.

[0084] In one embodiment, the optical sensor 304 can detect the percentage of energy emitted from the laser beam. For example, once the laser energy is set to obtain proper cutting of a particular type of material at a predetermined speed, the amount of optical energy detected by the optical sensor 304 is determined. As a non-limiting example, after the laser beam cuts the material, the amount of laser energy that enters the laser beam dump device 302, reflects off the highly reflective surface 312, and can be detected by the optical sensor 304 is 10% of the laser beam's energy. This desired optical detection value, referred to herein as the calibration value, is stored during actual cutting of material during a production run. If the amount of energy detected by the laser beam dump device 302 during a production run falls below the 10% calibration value, the controller signals the laser device to increase the laser intensity until the laser optical sensor 304 registers the proper optical detection value. Similarly, if the amount of energy detected by the light sensor 304 is greater than a calibrated value of 10%, the controller signals the laser beam to reduce the level of energy until the energy detected by the light sensor 304 is within a predetermined value of the desired light detection value. In one embodiment, if the calibrated value exceeds an upper limit, the controller instructs the actuator or motor control device 500 to increase the gantry speed. Similarly, in one embodiment, if the calibrated value is below a lower limit, the controller instructs the controller to decrease the gantry speed. In one embodiment, if the calibrated value is outside the lower or upper limits, the controller instructs both to change the gantry speed and to change the laser energy.

[0085] Referring to FIG. 15 , the laser beam dump device 302 includes a cooling loop 316 that circulates a coolant adjacent to the highly reflective surface 312 to prevent thermal damage to the highly reflective surface 312. In one embodiment, an air pump 318 introduces air into the chamber 310 of the housing 308 through at least one opening 320. The air pumped into the chamber 310 is removed through the second exit opening 324 by a vacuum 322 applied to the second exit opening 324. In one embodiment, the vacuum applied to the chamber 308 may be connected to the vacuum system 214 or to a separate vacuum. The amount of air introduced into and removed from the housing 308 per unit time can be varied depending on the amount of particulates formed within the housing 308 to ensure that the optical sensor 304 accurately measures the light energy reflected from the highly reflective surface 312. In one embodiment, there is no air pump 318, but ambient air enters the at least one opening 320 as a result of the vacuum pressure applied through the second exit opening 324.

[0086] In one embodiment, an external air filter is installed within the vacuum system 214 to remove unpleasant odors and contaminants from the fumes exhausted from the system. Because the fume extraction is directly below the cutting location, the opening 301 is a 1-5 mm diameter hole; in one embodiment, the opening 301 is a 2 mm diameter hole. This reduction helps minimize material from being drawn into the opening. This results in several orders of magnitude greater concentration of the extraction area, significantly reducing the size of the vacuum pump required and the energy required to drive it. Smaller filter systems can also be applied. The amount of air removed is expected to be reduced by a factor of 10 to 100 compared to current technology, which requires vacuuming a flat surface (the entire system size). In other words, because of the moving vacuum chamber 322 operably connected to the housing 308, the size of the opening 301 can be smaller because any fumes within the laser beam dump device 302 are exhausted through the second exit opening 324 and do not need to be exhausted by a vacuum chamber located on the top surface of the material adjacent to the laser nozzle 306. Additionally, the use of the laser beam dump device 302 in the cavity 404 eliminates belts made of metal or other materials that do not burn in the presence of laser energy. Metal belts reflect the laser energy, resulting in burnt or brown residue on portions of the material being processed. Non-metallic belt materials minimize this condition. Additionally, the laser beam dump device 302, which moves with and along the gantry as described herein, eliminates the effect of laser energy bouncing. In one embodiment, a vacuum is applied to the top of the laser module and another vacuum is applied to the bottom of the laser module, and both move with and along the gantry in a transverse frame direction along the longitudinal axis 118. The transverse frame direction is perpendicular to the longitudinal axis 118 and not perpendicular to the material being processed (not the Z-axis direction).

[0087] It is also possible to significantly increase the airflow velocity, which further eliminates the risk of fumes escaping the system and creating a foul odor in the room and to the operators.

[0088] The laser nozzle 306 and laser beam dump device 302 move with the gantry in a longitudinal direction parallel to or along the longitudinal axis 118 and along the longitudinal axis of the gantry, which is perpendicular to the longitudinal axis 118 of the frame.

[0089] The particular material being cut will have threads or areas that require different levels of laser energy to cut. Referring to Figure 23, the feedback system includes a controller that can instantly change the energy level of the laser beam to ensure proper cutting of all of the different areas of the material being cut by the laser.

[0090] 1 and 24-27, in one embodiment, the cross-member 142 of the gantry 116, which defines the cavity 162, is formed by a first cross-member plate 350, a second cross-member plate 352, and a base plate 354 extending perpendicularly between the first cross-member plate 350 and the second cross-member plate 352. The first cross-member plate 350 and the second cross-member plate 352 have inner surfaces facing each other and outer surfaces facing opposite the inner surfaces. The first cross-member plate 350 and the second cross-member plate 352 are generally disposed in a plane perpendicular to the longitudinal axis 118 (the YZ plane). In this embodiment, the first cross-member plate 350 and the second cross-member plate 352 replace the bars 150a, 150b, 152a, and 152b in the embodiment shown in FIG. 4 and described above. 25, vacuum system 214 includes a plurality of vacuum cassettes 356 that replace brackets 151, 153 and crossbars and rollers 155, 156, 158, and 160 of the embodiments described hereinabove. A pair of vacuum cassettes 356 is provided for each belt 124. The vacuum cassette 356 located closer to the proximal region 180 of system 110 is identified by the reference numeral 356a, and the vacuum cassette located closer to the second distal region 182 is identified by the reference numeral 356b.

[0091] Each vacuum cassette 356 includes a first upper roller 358, a second upper roller 360, and a lower roller 362. For purposes of illustration, vacuum cassettes 356 and features identified within vacuum cassettes 356 are identified with the suffix a for vacuum cassettes 356 closer to proximal region 180 and the suffix b for vacuum cassettes 356 closer to second distal region 182. The belt 124 extends over and around the first upper roller 358a of the second vacuum cassette 356a, extends toward and around the second upper roller 360 of the vacuum cassette 356a, then extends toward and around the first lower roller 362a of the vacuum cassette 356a, then extends under the base plate 354 toward and around the lower roller 362b of the vacuum cassette 356b, then extends toward and around the second upper roller 360b of the vacuum cassette 356b, then extends toward and around the first upper roller 358b of the vacuum cassette 356b, and then extends toward the second distal region 182. Each vacuum cassette 356 has a first region 364 in fluid communication with one of the first duct 216 and the second duct 218, and a second region 366 that is not in fluid communication with either the first duct 216 or the second duct 218. The first region 364 of each vacuum cassette 356 is in fluid communication with the adjacent vacuum cassette 356. The second region 366 supports a second upper roller 360 and a lower roller 362.

[0092] Each vacuum cassette 356 includes a top plate 368 and a plurality of openings 370 extending therethrough, the plurality of openings 370 being in fluid communication with a vacuum passageway 372 that is in fluid communication with the first region 364. The vacuum passageway 372 is defined by the area between the top plate 368, the bottom plate 374, and the first region 364. The belt 124 includes a first surface 376 that contacts the material to be processed and a second, opposing surface 378. An upper surface 380 of the top plate 368 is in contact with the second, opposing surface 378 of the belt 124. It should be noted that the top plate 368 of the vacuum cassette 356 forms a manifold through which a vacuum is applied through the plurality of openings 242 in the belt 124 to the underside of the material to be treated or processed.

[0093] 26 and 27, the first cross-member plate 350 and the second cross-member plate 352 include tabs 382 and 384, respectively. The vacuum cassette 356a includes a notch 386 that receives the tab 382 of the first cross-member plate 350 to position the vacuum cassette 356 relative to the first cross-member plate 350 in the installed position. Similarly, the vacuum cassette 356b includes a notch 386 that receives the tab 384 of the second cross-member plate 352 to position the vacuum cassette 356b relative to the second cross-member plate 352 in the installed position.

[0094] Vacuum cassette 356a extends through bosses 388 in second region 366 and is secured to first cross-member plate 350 by fasteners that are threadedly received into threaded holes in first cross-member plate 350. Similarly, vacuum cassette 356b extends through bosses 388 in second region 366 and is secured to second cross-member plate 352 by fasteners that are threadedly received into threaded holes in cross-member plate 352. Referring to FIG. 25 , first upper roller 358 is secured to vacuum cassette 356 by end adjustment plate 390. A pair of fasteners 392 secures end adjustment plate 390 to side plate 394 to allow adjustment of first upper roller 358 relative to vacuum cassette 356. In one embodiment, a second pair of fasteners secures a second end adjustment plate to a second side plate 395 to allow further adjustment of first upper roller 358. In one embodiment, the fasteners 392 extend through both the first side panel 394 and the second side panel 395 .

[0095] By design, a gap 396 is provided between the leading edge of the end adjustment plate 390 and the side plate 394 so that the first upper roller 358 can move in a plane perpendicular to the direction of gravity (the X-Y plane) along or parallel to the longitudinal axis when the vacuum cassette 356 and system 110 are in the installed position. Adjusting the first upper roller 358 allows a user to adjust the movement of the belt 124 around the cavity 398. In one embodiment, the first upper roller 358 has a rounded surface with a diameter greater than the diameter of the center of the first upper roller 358 adjacent the side plates 394, 395. In one embodiment, each side plate 394, 395 includes an opening 400 to the first region 364 that allows fluid communication between the first regions 364 of adjacent vacuum cassettes 356. The leading vacuum cassette 356 is connected to one of the first duct 216 and the first duct 217 so that each first region 364 of each vacuum cassette 356 is connected to the vacuum system. A bottom plate 374 opposite the top plate 368 includes an opening that fluidly connects one of the first duct 216 and the first duct 217 to the first region 364. The first duct 216 and the second duct 218 move with the gantry 116 when the gantry 116 moves longitudinally along the longitudinal axis 118 of the system 110, and move in a direction perpendicular to the longitudinal axis 118 when the base member 250 moves along the longitudinal axis of the gantry 116. Flexible hoses 402 connected to the first ducts 216 and the first ducts 217 are connected to a vacuum source external to the system 110. In one embodiment, the first duct 216 and the first duct 217 are connected to the first regions 364 of the respective vacuum cassettes 356a and 356b at a first side of the frame. The first side of the frame is the side of the frame identified by an operator facing the frame with the first longitudinal end 146 on the left and the second longitudinal end 148 on the right. The second side of the frame is the side opposite the first side of the frame in the positive Y direction. In one embodiment, the first duct 216 and the first duct 217 are also operably connected to the first regions 364 of the cassette pair closest to the second side of the frame. In this manner, a vacuum is applied to the first regions 364 on both sides of the row of multiple cassettes 356a and 356b.

[0096] Referring to FIG. 26 , the cavity 404 is substantially rectangular, as opposed to the triangular shape of the cavity 162 described herein above. The cavity 404 has a longitudinal opening 406 that allows processing equipment to extend from above the material to be processed into the area within the cavity 404. In one embodiment, the width 408 of the longitudinal opening 406 along a direction parallel to the longitudinal axis of the system 110 is between 20 mm and 40 mm. In one embodiment, the width 410 of the cavity 404 below the lower plate 374 and the base plate 354 along a direction parallel to the longitudinal axis 118 of the system 110 is between 200 mm and 400 mm. Stated another way, the width 408 is less than 50% of the width 410. In one embodiment, the longitudinal opening 406 is 30 mm and the width 410 is 200 mm. In one embodiment, the height of cavity 404 from base plate 354 to bottom plate 374 of vacuum cassette 356 is less than width 410. In one embodiment, vacuum cassette 356 can be designed to have an opening that is greater or less than 40 mm depending on the tool used.

[0097] 25 and 26, front member 412 includes a ledge 414 that supports and guides the periphery of horizontal belt 126. In other words, first periphery 127a is supported on ledge 414a of vacuum cassette 356a, and second periphery 127b is supported on ledge 414b of vacuum cassette 356b.

[0098] 24 and 25, vacuum is applied through first region 364 and not to cavity 398. Also, in one embodiment, vacuum is applied only to the portion of belt 124 directly above top plate 368 of vacuum cassette 356. Stated another way, with reference to FIGS. 1 and 24, system 110 is vacuum-free between ends 146 and 148 of system 110 along longitudinal axis 118, except for the region above top plate 368 of vacuum cassette 356 immediately adjacent longitudinal opening 406 of cavity 404.

[0099] It should be noted that all other aspects of the system 110 described herein above operate similarly to the vacuum cassette 356 and vacuum cavity 404 as well as the cavity 162 shown in FIGS. 1-11 . It should be noted that the cavity 162 has a generally triangular shape, with the base of the triangle having a width parallel to the longitudinal axis 118 that is larger than the cavity opening. The cavity 404 has a generally rectangular shape with a width parallel to the longitudinal axis 118 that is substantially the same from the base plate toward the region proximate the cavity opening. It should be noted that the path of the belt 124 through the vacuum cassette 356a includes a portion extending from the first roller toward the second roller in a direction generally opposite the direction of the belt path from the first longitudinal end 146 toward the first roller. In one embodiment, the vacuum cassette 356 has two rollers to provide a triangular cavity shape with a base larger than the cavity opening. In one embodiment, the vacuum cassette 356 has four or more rollers. The term material as used herein may refer to a single material or two or more laminated materials.

[0100] The term material processing system as used herein includes any of the cutting (including but not limited to laser, vibrating blade, routing, wire), joining (including but not limited to stitching, ultrasonic welding), creasing, grommet insertion, metal snap insertion, routing, embossing, and printing modules and systems described herein. The term surface processing system as used herein includes any of the aforementioned modules that operate on the surface of a material.

[0101] The vacuum system described herein provides a hold-down force on the material being processed adjacent the cavity opening. Note that in FIG. 26 , a vacuum path 372 is identified by an arrow extending from the plurality of openings 370 through the first region 364. Note that the vacuum operates to move air in opposite directions to the arrows shown in FIG. 26 . Stated another way, the applied vacuum moves air through the material being processed, through the plurality of openings 370, through the first region 364, and into one of the first duct 216 and the second duct 218.

[0102] The following is a list of non-limiting exemplary embodiments disclosed herein.

[0103] Exemplary Embodiment 1. An automated material processing system including: a frame having a longitudinal axis; a gantry movable along the longitudinal axis of the frame; a first belt extending along the longitudinal axis and moving around a cavity having a cavity opening in the gantry; a second belt supported by the gantry and extending across the frame in a frame transverse direction perpendicular to the longitudinal axis and covering at least a portion of the cavity opening; a material handling system extending across at least a portion of the first belt and a portion of the second belt for processing material; and a vacuum system movable with the gantry and operably connected to a manifold adjacent either side of the cavity opening.

[0104] Exemplary Embodiment 2. The automated material processing system of Exemplary Embodiment 1, wherein the material processing system includes a first portion outside the cavity and a second portion within the cavity.

[0105] Exemplary Embodiment 3. The automated material processing system of Exemplary Embodiments 1-2, wherein the cavity has a rectangular shape with a pair of sidewalls, a base that supports a portion of the material processing system, and a cavity opening.

[0106] Exemplary Embodiment 4. The automated material processing system of any one of Exemplary Embodiments 1-3, wherein the cavity opening adjacent the support surface that supports the material to be processed has a cavity opening width that is smaller than a cavity width between the cavity opening and the cavity base member.

[0107] Exemplary Embodiment 5. The automated material processing system of any one of Exemplary Embodiments 1-4, wherein the second belt has a belt path that extends substantially the entire length of the gantry in a direction perpendicular to the longitudinal axis of the frame, and the second belt extends above the cavity, around a first pair of rollers on a first side of the frame, under the portion of the first belt that extends below and around the cavity, and around a second pair of rollers on a second side of the frame.

[0108] Exemplary Embodiment 6. The automated material processing system of any one of Exemplary Embodiments 1-5, wherein the first belt has a belt path around the frame and the cavity, the belt path extending from a first end of the frame on a first longitudinal side of the cavity opening, around a first roller adjacent the first longitudinal side of the cavity opening, over a second roller closer to the first end of the frame than the first roller, over a third roller farther from the first roller than the second roller, below the cavity, over a fourth roller located farther from the first end of the frame than the third roller, over a fifth roller closer to the cavity opening than the fourth roller, and over a sixth roller adjacent a second longitudinal side of the cavity opening.

[0109] Exemplary Embodiment 7. The automated material processing system of any one of Exemplary Embodiments 1-6, wherein the first belt has a first surface having a first coefficient of friction that supports the material to be processed and a second opposing surface having a second coefficient of friction that is less than the first coefficient of friction.

[0110] Exemplary Embodiment 8. The automated material processing system of Exemplary Embodiment 7, wherein the second belt has a first surface facing the material to be processed that has a coefficient of friction that is less than the first coefficient of friction of the first side of the first belt.

[0111] Exemplary Embodiment 9. The automated material processing system of any one of Exemplary Embodiments 1-8, wherein the manifolds adjacent either side of the cavity opening have a plurality of openings facing the material to be processed, the manifolds provide a vacuum force that draws the material to be processed toward the manifolds, and the manifolds extend a predetermined distance away from the cavity openings.

[0112] Exemplary Embodiment 10. The automated material processing system of Exemplary Embodiment 9, wherein the cavity is not a vacuum.

[0113] Exemplary Embodiment 11. The automated material processing system of any one of Exemplary Embodiments 1-10, wherein the vacuum system includes a plurality of vacuum cassette pairs operably connected to the vacuum source.

[0114] Exemplary Embodiment 12. The automated material processing system of Exemplary Embodiment 11, wherein each vacuum cassette includes a first region in fluid communication with the vacuum source and a second region including at least two rollers.

[0115] Exemplary Embodiment 13. The automated material processing system of Exemplary Embodiment 12, wherein each vacuum cassette includes a top plate having a plurality of openings in fluid communication with the first region.

[0116] Exemplary Embodiment 14. The automated material processing system of any one of Exemplary Embodiments 1-13, wherein the vacuum system includes a plurality of vacuum cassette pairs, one vacuum cassette of each vacuum cassette pair including a first roller, a second roller, and a third roller, and the other vacuum cassette of each vacuum cassette pair including a fourth roller, a fifth roller, and a sixth roller.

[0117] Exemplary Embodiment 15. The automated material processing system of Exemplary Embodiment 13, wherein each cassette includes a notch that receives one longitudinal edge of the second belt adjacent a lower surface of the second belt, and wherein an upper surface of the second belt that faces the material to be processed is parallel to a top plate of the vacuum cassette.

[0118] Exemplary Embodiment 16. The automated material processing system of any one of Exemplary Embodiments 2-15, wherein the material processing system is a laser system including a laser nozzle disposed in the first portion and a laser dump device disposed in a second portion within the cavity.

[0119] Exemplary Embodiment 17. The automated materials processing system of Exemplary Embodiment 16, wherein the laser dump device includes an optical sensor that detects laser scattered from a reflective surface.

[0120] Exemplary Embodiment 18. The automated material processing system of Exemplary Embodiment 17, including a controller that receives a signal from the optical sensor and provides instructions to the laser nozzle to adjust laser energy emitted from the laser nozzle in response to the signal from the optical sensor.

[0121] Exemplary Embodiment 19. The automated material processing system of Exemplary Embodiment 18, wherein the controller directs a first actuator that drives the gantry along the longitudinal axis of the frame and a second actuator that moves the material processing system along the longitudinal axis of the gantry.

[0122] Exemplary Embodiment 20. The automated material processing system of any one of Exemplary Embodiments 1-19, wherein the material processing system includes a joining system supported by the gantry and movable along a frame transverse axis perpendicular to the longitudinal axis to join at least two materials.

[0123] Exemplary Embodiment 21. The automated material processing system of any one of Exemplary Embodiments 1-20, wherein the material processing system includes a cutting system supported by the gantry and movable along the frame transverse axis to jointly cut the material in two or more directions within a plane defined by the longitudinal axis and the frame transverse axis.

[0124] Exemplary Embodiment 22. The automated material processing system of any one of Exemplary Embodiments 2-20, wherein the material processing system includes a creasing module including a first module disposed outside the cavity and a second lower member disposed within the cavity, the first member and the second member being on opposite sides of the material to be creasing.

[0125] Exemplary Embodiment 23. The automated material processing system of any one of Exemplary Embodiments 2-20, wherein the material processing system includes a grommet insertion module including a first member disposed outside the cavity and a second lower member disposed within the cavity, the first member and the second member being on opposite sides of the material into which the grommet is to be inserted.

[0126] Exemplary Embodiment 24. The automated material processing system of any one of Exemplary Embodiments 2-20, wherein the material processing system includes a button insertion module including a first member disposed outside the cavity and a second lower member disposed within the cavity, the first member and the second member being on opposite sides of the material to which the button is attached.

[0127] Exemplary Embodiment 25. The automated material processing system of any one of Exemplary Embodiments 2-20, wherein the material processing system includes a routing tool module including a first member disposed outside the cavity that holds a first end of the router bit, and a second lower member disposed within the cavity having a member that guides a portion of the router bit within the cavity.

[0128] Exemplary Embodiment 26. The automated material processing system of any one of Exemplary Embodiments 2-20, wherein the material processing system includes an oscillating blade module including a first member disposed outside the cavity that drives a first end of the oscillating blade, and a second lower member disposed within the cavity having a member that guides a portion of the oscillating blade within the cavity.

[0129] Exemplary Embodiment 27. An automated system for joining and cutting flexible materials, the automated system including: a frame having a longitudinal axis; a gantry movable along the longitudinal axis; a belt system extending along the longitudinal axis and moving through a cavity in the gantry; a joining system supported by the gantry and movable along a frame transverse axis perpendicular to the longitudinal axis, for joining at least two materials together; a cutting system supported by the gantry and movable along the frame transverse axis, for cutting the materials together in two or more directions in a plane defined by the longitudinal axis and the frame transverse axis; and a vacuum system movable with the gantry and operably connected to manifolds on either side of the cavity opening.

[0130] Exemplary embodiment 28. An automated system for joining and cutting flexible materials, the automated system including: a frame having a longitudinal axis; a gantry movable along the longitudinal axis; a vacuum system having a duct movable with the gantry and along a frame transverse axis perpendicular to the longitudinal axis of the gantry; a belt system extending along the longitudinal axis and moving through a cavity in the gantry; and a material handling system movably supported by and along the gantry, configured to process material supported by the belt system.

[0131] While the present disclosure has been described with reference to exemplary embodiments, those skilled in the art will recognize that changes can be made in form and detail without departing from the spirit and scope of the defined subject matter. For example, while different exemplary embodiments have been described as including one or more features providing one or more advantages, it is contemplated that the described features may be interchangeable with one another or alternatively combined with one another in the described exemplary embodiments or other alternative embodiments. Because the technology of the present disclosure is relatively complex, not all variations in the technology are foreseeable. The present disclosure as described is clearly intended to be as broad as possible. For example, unless otherwise specified, a definition reciting a single specific element also encompasses a plurality of such specific elements.

Claims

1. 1. An automated material processing system comprising: a frame having a longitudinal axis; a gantry movable along a longitudinal axis of the frame; a first belt extending along the longitudinal axis and moving around a cavity having a cavity opening in the gantry; a second belt supported by the gantry and extending across the frame in a transverse frame direction perpendicular to the longitudinal axis and covering at least a portion of the cavity opening; a material processing system extending across at least a portion of the first belt and a portion of the second belt for processing a material; a vacuum system movable with the gantry and operably connected to manifolds adjacent either side of the cavity opening; Automated material processing systems including:

2. The automated material processing system of claim 1 , wherein the material handling system includes a first portion outside the cavity and a second portion within the cavity.

3. The automated material processing system of claim 1 , wherein the cavity has a rectangular shape having a pair of side walls, a base that supports a portion of the material processing system, and a cavity opening.

4. 10. The automated material processing system of claim 1, wherein the cavity opening adjacent the support surface supporting the material to be processed has a cavity opening width that is less than the cavity width between the cavity opening and the cavity base member.

5. 2. The automated material processing system of claim 1, wherein the second belt has a belt path that extends substantially the entire length of the gantry in a direction perpendicular to a longitudinal axis of the frame, and the second belt extends over the cavity, around a first pair of rollers on a first side of the frame, under the cavity and under a portion of the first belt that extends around the cavity, and around a second pair of rollers on a second side of the frame.

6. 2. The automated material processing system of claim 1, wherein the first belt has a belt path around the frame and cavity, the belt path extending from a first end of the frame on a first longitudinal side of the cavity opening, around a first roller adjacent the first longitudinal side of the cavity opening, over a second roller closer to the first end of the frame than the first roller, over a third roller farther from the first roller than the second roller, below the cavity, over a fourth roller located farther from the first end of the frame than the third roller, over a fifth roller closer to the cavity opening than the fourth roller, and over a sixth roller adjacent the second longitudinal side of the cavity opening.

7. 10. The automated material processing system of claim 1, wherein the first belt has a first surface having a first coefficient of friction for supporting a material to be processed and a second opposing surface having a second coefficient of friction less than the first coefficient of friction.

8. 8. The automated material processing system of claim 7, wherein the second belt has a first surface facing the material to be processed that has a coefficient of friction that is less than the first coefficient of friction of the first side of the first belt.

9. 2. The automated material processing system of claim 1, wherein the manifold adjacent to each side of the cavity opening has a plurality of openings facing the material to be processed, the manifold provides a vacuum force that draws the material to be processed toward the manifold, and the manifold extends a predetermined distance away from the cavity opening.

10. The automated materials processing system of claim 9 , wherein the cavity is free of a vacuum.

11. The automated materials processing system of claim 1 , wherein the vacuum system includes a plurality of vacuum cassette pairs operably connected to a vacuum source.

12. The automated material processing system of claim 11 , wherein each vacuum cassette includes a first region in fluid communication with the vacuum source and a second region including at least two rollers.

13. The automated material processing system of claim 12 , wherein each vacuum cassette includes a top plate having a plurality of openings in fluid communication with the first region.

14. 7. The automated material processing system of claim 6, wherein the vacuum system includes a plurality of vacuum cassette pairs, one vacuum cassette of each vacuum cassette pair including the first roller, the second roller, and the third roller, and the other vacuum cassette of each vacuum cassette pair including the fourth roller, the fifth roller, and the sixth roller.

15. 14. The automated material processing system of claim 13, wherein each cassette includes a notch that receives one longitudinal edge of the second belt adjacent the lower surface of the second belt, and an upper surface of the second belt that faces the material to be processed is parallel to a top plate of the vacuum cassette.

16. 3. The automated material processing system of claim 2, wherein the material processing system is a laser system including a laser nozzle disposed in the first portion and a laser dump device disposed in the second portion within the cavity.

17. 17. The automated materials processing system of claim 16, wherein the laser dump device includes an optical sensor that detects laser scattered from a reflective surface.

18. 20. The automated materials processing system of claim 17, further comprising a controller that receives a signal from the optical sensor and provides instructions to the laser nozzle to adjust laser energy emitted from the laser nozzle in response to the signal from the optical sensor.

19. 20. The automated material processing system of claim 18, wherein the controller directs a first actuator that drives the gantry along a longitudinal axis of the frame and a second actuator that moves the material handling system along a longitudinal axis of the gantry.

20. 10. The automated material processing system of claim 1, wherein said material handling system includes a joining system supported by said gantry and movable along a frame transverse axis perpendicular to said longitudinal axis to join at least two materials.

21. 10. The automated material processing system of claim 1, wherein the material handling system includes a cutting system supported by the gantry and movable along the frame transverse axis to jointly cut material in two or more directions within a plane defined by the longitudinal axis and the frame transverse axis.

22. 3. The automated material processing system of claim 2, wherein the material processing system includes a creasing module including a first module positioned outside the cavity and a second lower member positioned within the cavity, the first member and the second member being on opposite sides of the material to be creasing.

23. 3. The automated material processing system of claim 2, wherein the material processing system includes a grommet insertion module including a first member positioned outside the cavity and a second lower member positioned within the cavity, the first member and the second member being on opposite sides of a material into which a grommet is inserted.

24. 3. The automated material processing system of claim 2, wherein the material processing system includes a button insertion module including a first member positioned outside the cavity and a second lower member positioned within the cavity, the first member and the second member being on opposite sides of a material to which a button is attached.

25. 3. The automated material processing system of claim 2, wherein the material processing system includes a routing tool module including a first member positioned outside the cavity that holds a first end of a router bit, and a second lower member positioned within the cavity having a member that guides a portion of the router bit within the cavity.

26. 3. The automated material processing system of claim 2, wherein the material processing system includes an oscillating blade module including a first member disposed outside the cavity that drives a first end of an oscillating blade, and a second lower member disposed within the cavity having a member that guides a portion of the oscillating blade within the cavity.

27. 1. An automated system for joining and cutting flexible materials, comprising: a frame having a longitudinal axis; a gantry movable along said longitudinal axis; a belt system extending along the longitudinal axis and moving through a cavity in the gantry; a joining system supported by the gantry and movable along a frame transverse axis perpendicular to the longitudinal axis, for joining at least two materials; a cutting system supported by the gantry and movable along the frame transverse axis to cut material together in two or more directions within a plane defined by the longitudinal axis and the frame transverse axis; a vacuum system movable with the gantry and operably connected to manifolds on either side of the cavity opening; Automated systems including:

28. 1. An automated system for joining and cutting flexible materials, comprising: a frame having a longitudinal axis; a gantry movable along said longitudinal axis; a vacuum system having a duct movable along a frame transverse axis perpendicular to the longitudinal axis of the gantry; a belt system extending along the longitudinal axis and moving through a cavity in the gantry; a material handling system movably supported by and along the gantry configured to process material supported by the belt system; Automated systems including:

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