Method and system for the automatic cutting of garment parts with faults on a patterned cloth
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Solution Overview
Problem
Existing automated cutting systems for patterned fabrics face challenges with misalignment between the fabric template and actual fabric placement, leading to defects and the need for manual recutting of defective pieces, which disrupts the process and results in fabric waste and imprecise pattern alignment.
Innovation Solution
An automated method for recutting defective pieces by assigning them to a new placement that preserves their placement constraints, optimizing material usage and ensuring precise pattern alignment through an algorithm that adapts the placement to the actual fabric characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual inspection and cutting methods are used, then flexibility in handling complex patterns is maintained, but productivity is low and labor costs are high
Solution Approach 1:
The system performs automatic defect detection and cutting location identification without manual intervention. The camera captures images, the processor analyzes them to locate defects, and the cutting device automatically positions and cuts defective portions, enabling the system to serve itself through automated workflows
Solution Approach 2:
Manual inspection and cutting operations are replaced by an automated system combining optical imaging (camera), computational analysis (processor), and automated cutting mechanisms. This substitution of mechanical/manual operations with automated systems resolves the contradiction by大幅提升 productivity while managing complexity through integration
2Productivity
If automatic cutting systems are implemented, then productivity increases, but adaptability to complex patterns and defect locations decreases
Solution Approach 1:
The system dynamically adjusts to different fabric patterns and defect locations through real-time image capture and processing. The cutting device can reposition itself based on dynamically identified defect locations, allowing the system to adapt to varying patterns while maintaining automated high-speed operation
Solution Approach 2:
The system uses visual feedback from camera images to automatically locate defects and determine cutting positions. This feedback loop enables the system to adapt to different patterns and defect locations without manual intervention, maintaining both productivity and adaptability
3Manufacturing precision
If conventional cutting methods are used, then equipment simplicity is maintained, but cutting precision and quality control are insufficient
Solution Approach 1:
The system performs preliminary defect detection and cutting location identification before the actual cutting operation. By pre-locating defects through image analysis and pre-positioning the cutting device, the system ensures precise cutting while maintaining relatively simple equipment through sequential operation steps
Data Source
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AI summary
The invention relates to a method and system for automatic cutting of defective portions in a patterned fabric repeating at a certain interval, comprising the steps of developing a theoretical layout of portions to be cut on a theoretical representation of the fabric whilst respecting layout constraints, spreading out at least one layer of fabric on a cutting table, checking at least one portion of the spread-out fabric to ascertain actual characteristics, modifying the theoretical layout in order to generate an actual layout taking into account the actual characteristics of the fabric, identifying in the actual layout of defective portions that will have defects once cut in the fabric and that will need to be cut again, and automatically allocating each defective portion to a new theoretical layout by adjusting the layout constraints associated with the defective portions depending on the actual layout.