Method and system for automatic cutting of defective portions in a patterned fabric
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Solution Overview
Problem
In the automatic cutting of patterned fabrics, the non-coincidence between the fabric model used for layout and the actual fabric spread out on the cutting table leads to defects, requiring manual re-cutting of defective parts, which interrupts the process, wastes material, and compromises pattern continuity.
Innovation Solution
A method for automatic cutting of defective parts in patterned fabrics, where the defective parts are identified and automatically re-allocated to a new theoretical layout, adjusting their layout constraints to match the actual fabric features, allowing for precise re-cutting without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual re-cutting of defective parts is performed, then defective parts can be corrected, but the automatic cutting process is interrupted and productivity decreases
Solution Approach 1:
The system automatically detects defective parts and re-allocates them to new layouts without human intervention. The computer workstation autonomously identifies parts that do not match the fabric pattern, calculates new positions, and generates updated cutting instructions, enabling the system to correct its own errors and maintain continuous operation.
Solution Approach 2:
The system incorporates a feedback mechanism where the actual fabric pattern is scanned and compared with the theoretical layout. Defective parts are identified through this comparison, and the system responds by automatically recalculating positions and generating corrected cutting instructions, creating a closed-loop control system that maintains quality without interrupting productivity.
2Reliability
If manual re-cutting is performed, then defective parts are corrected, but material waste increases due to re-positioning
Solution Approach 1:
The system dynamically adjusts the layout by re-positioning only the defective parts to new locations on the fabric, rather than discarding entire sections. The computer workstation calculates optimal new positions that maintain pattern continuity while maximizing fabric utilization, allowing flexible adaptation without excessive material waste.
Solution Approach 2:
Instead of discarding defective parts or entire fabric sections, the system recovers them by re-allocating to new positions in the layout. The automatic re-positioning process salvages usable fabric areas that would otherwise be wasted, maintaining pattern integrity while minimizing material loss.
3Manufacturing precision
If the theoretical layout is modified to match actual fabric, then pattern continuity is ensured, but the complexity of the cutting system increases
Solution Approach 1:
The system replaces manual mechanical layout adjustment with an automated computer-based system. The workstation scans the fabric pattern, automatically compares it with the theoretical layout, identifies discrepancies, and calculates corrected positions using software algorithms, eliminating the need for manual measurement and adjustment while achieving high precision.
Solution Approach 2:
The system creates a digital copy of the actual fabric pattern through scanning, then compares this copy with the theoretical layout. This allows precise identification of defective parts and automatic calculation of corrections without physically manipulating the fabric, simplifying the process while maintaining high accuracy.
4Productivity
If automatic re-cutting is implemented, then productivity is maintained, but the system complexity increases
Solution Approach 1:
The computer workstation performs multiple functions: it generates the initial theoretical layout, scans the actual fabric pattern, identifies defective parts, calculates new positions, and generates updated cutting instructions. This multi-functional approach consolidates what could be separate complex systems into a single integrated platform, maintaining productivity while managing complexity.
Solution Approach 2:
The system introduces a computer workstation as an intermediary between the fabric and the cutting machine. This intermediary handles the complex tasks of pattern recognition, defect detection, and layout recalculation, allowing the cutting machine itself to remain relatively simple while maintaining automatic operation and high productivity.
Data Source
AI summary
A method and system for automatic cutting of defective parts in a fabric with a pattern repeating at a certain pitch, includes the steps of producing a theoretical layout of parts 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 features, modifying the theoretical layout in order to generate an actual layout taking into account the actual features of the fabric, identifying in the actual layout, defective parts which will contain defects once cut in the fabric and which will need to be cut again, and automatically allocating each defective part to a new theoretical layout by adjusting the layout constraints associated with the defective parts according to the actual layout.