Adjustable Knife Assembly for Variable Notch Angle Cutting
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Solution Overview
Problem
Commercial cutting systems lack flexibility in cutting angles and require manual adjustments, limiting their ability to produce a range of angles efficiently during the cutting process of thicker materials like corrugated cardboard or plastic honeycomb boards.
Innovation Solution
A knife assembly with a rotatable knife holder and blade that allows for infinitely adjustable cut direction and notch angles, along with a control system that can automatically change these angles based on design file information, enabling precise and efficient cutting of various angles without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If commercial cutting systems use fixed-angle V-notch knife assemblies, then cutting at specific predetermined angles (e.g., 15°, 22.5°, 30°, 45°) is achievable, but flexibility for cutting at arbitrary angles is lost and manual changing of adapters is required
Solution Approach 1:
The knife assembly incorporates dynamic adjustment mechanisms that allow the cutting angle to be changed continuously during operation. The system uses motorized actuators to rotate the knife blade to any desired angle within the working range, transforming the static fixed-angle system into a dynamic adjustable one, thereby achieving arbitrary cutting angles without manual adapter changes
Solution Approach 2:
The invention changes the key parameter of cutting angle from discrete fixed values to continuous variable values. By implementing a motorized rotation mechanism with precision control, the system can adjust the knife blade angle to any value within the specified range (e.g., -60° to +60°), enabling flexible cutting at arbitrary angles while maintaining device simplicity through electronic control
2Adaptability or versatility
If manual changing of knife adapters is performed to achieve different cutting angles, then multiple angles can be obtained, but production time is lost and operator intervention is required
Solution Approach 1:
The knife assembly implements self-service functionality through automated angle adjustment. The system uses sensors to detect the required cutting angle from design files and automatically positions the knife blade to the correct angle using motorized actuators, eliminating the need for manual operator intervention and adapter changes, thereby maintaining high production speed while achieving diverse cutting angles
Solution Approach 2:
The invention replaces the manual mechanical adapter-changing process with an automated motorized rotation system. Instead of physically swapping adapters, the system uses electric motors with precision control to rotate the knife blade to any required angle, substituting manual mechanical operations with automated electromechanical control, thus eliminating production time loss
3Manufacturing precision
If fixed-angle knives are used for thicker materials requiring folding, then V-shaped slots can be produced at predetermined angles, but the ability to create arbitrary fold angles (e.g., non-standard corner angles) is limited
Solution Approach 1:
The knife assembly uses dynamic angle adjustment mechanisms with precision control systems that allow the cutting angle to be changed continuously during operation. Motorized actuators rotate the knife blade to any desired angle within the working range, transforming the static fixed-angle system into a dynamic one, thereby achieving both accurate cuts and arbitrary fold angles for thicker materials
Solution Approach 2:
The invention changes the cutting angle parameter from discrete fixed values to continuous variable values through motorized rotation. The system can adjust the knife blade angle to any value within the specified range (e.g., -60° to +60°), enabling precise cutting at arbitrary angles to create non-standard fold angles while maintaining manufacturing precision through controlled motion
4Ease of manufacture
If multiple predetermined angle options are provided, then common cutting angles can be achieved, but the system cannot accommodate custom or arbitrary angle requirements
Solution Approach 1:
The invention transforms the angle parameter from a discrete set of predetermined values to a continuous variable that can be adjusted to any value within the working range. The motorized rotation system with precision control enables the knife blade to be positioned at any desired angle, providing both ease of operation through automated control and complete freedom in angle selection for custom requirements
Data Source
AI summary
A knife assembly for cutting a substrate during relative motion between the knife and the substrate, the assembly including a knife having a distal knife blade and a proximal knife shaft attached to a holder rotatable about a first axis perpendicular to the substrate to define a cut direction angle. The holder is also configured to rotate the knife blade about a second axis perpendicular to the first axis to form a notch angle relative to the first axis. The notch angle is preferably automatically infinitely adjustable within a range of angles. The holder may also, optionally, be configured to rotate the knife blade about a third axis perpendicular to a plane defined by the knife blade to adjust an angle of attack of the knife blade relative to the substrate.