Counter-Die Cutter Milling with Feedback-Based Die Matching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing counter-die cutters are inefficient due to the inhomogeneity of wooden supports, leading to inaccuracies and deformations, resulting in suboptimal coupling of creasing rules with creasing channels, which increases material costs and reduces production throughput.
Innovation Solution
A method that involves acquiring digital drawings of both die and counter-die cutters, detecting the position and orientation of comparison holes on the finished die cutter, modifying the digital drawing of the counter-die cutter to match the real die cutter, and using a milling machine with an adapting unit to produce a counter-die cutter that accurately couples with the die cutter, avoiding the need for redesign and minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manual insertion of cutting rules into wooden support is used, then ease of manufacture is improved, but manufacturing precision deteriorates due to wood inhomogeneity and manual variability
Solution Approach 1:
The patent replaces manual mechanical insertion with automated laser cutting technology. The laser cutting system precisely cuts seats in the wooden support according to digital designs, eliminating manual variability and wood inhomogeneity issues while maintaining ease of manufacture through automation.
Solution Approach 2:
The patent uses digital drawings as precise copies of the desired die cutter configuration. These digital designs serve as templates that guide the laser cutting process, ensuring that the physical die cutter accurately replicates the intended design without manual errors.
2Productivity
If counter-die cutter is made by traditional milling based on digital drawing, then manufacturing time is reduced, but manufacturing precision deteriorates due to inaccuracies in the digital drawing from manual processes
Solution Approach 1:
The patent implements a feedback loop where the actual die cutter (with inserted rules) is measured and scanned to create an updated digital drawing. This measured data feeds back into the counter-die cutter design, ensuring that the milling process creates accurately positioned creasing channels that match the actual die cutter configuration.
Solution Approach 2:
The patent performs preliminary laser cutting of the wooden support and manual insertion of rules before creating the final digital drawing for counter-die cutter milling. This preliminary action allows the system to work with the actual finished die cutter configuration rather than relying solely on theoretical designs.
3Manufacturing precision
If redesign of counter-die cutter is performed to correct coupling inaccuracies, then manufacturing precision is improved, but loss of time increases due to additional manufacturing cycles
Solution Approach 1:
The patent uses feedback from measuring and scanning the actual die cutter to create an accurate digital representation. This feedback eliminates the need for redesign by incorporating the actual configuration into the counter-die cutter manufacturing process from the start.
Solution Approach 2:
The patent performs the measurement and digital drawing update as a preliminary step before milling the counter-die cutter. By having the accurate digital drawing ready in advance, the system avoids time-consuming redesign and remanufacturing cycles.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method of making a counter-die cutter (2) for a die cutting machine comprising a die cutter (1) and a respective counter-die cutter (2), is described, comprising the steps of: a. acquiring a digital drawing of a die cutter (1) to be made, such die cutter (1) being provided with comparing means; b. acquiring a digital drawing of a respective counter-die cutter (2) to be made; c. providing a wooden support (3) of the die cutter (1); d. making a plurality of comparing means on the support (3) of the die cutter (1); e. making the die cutter (1); f. detecting the position and/or orientation of the comparing means of the finished die cutter (1); g. comparing the detected position and/or orientation with corresponding position and/or orientation of the comparing means being in the digital drawing of the die cutter (1); h. modifying the digital drawing of the counter-die cutter (2) on the basis of the detected differences to adapt the digital drawing to the finished die cutter (1); i. making the counter-die cutter (2) on the basis of the modified digital drawing. An adapting unit (11) for a milling machine (12) adapted to make counter-die cutters (2) and a milling machine (12) comprising this unit are further described.