Integrated Crease Rule Cutting for Continuous Bending Lines
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Solution Overview
Problem
The existing process of re-configuring bending systems to switch between cutting and crease rules is cumbersome, requiring re-programming and manual handling of heavy rolls, which disrupts service and is inefficient.
Innovation Solution
A cutting system integrated with a controller, cutting stations, and sorters that generate and sort crease rules according to shape diagrams, allowing for simultaneous processing and insertion into pattern boards without needing to re-configure the bender.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the bending system is re-configured to switch between cutting and crease rules, then the system can handle different rule types, but the re-programming and manual handling of heavy rolls disrupts service and reduces productivity
Solution Approach 1:
The system is divided into separate functional modules: a bending system for cutting rules and a cutting system for crease rules. Each system operates independently with its own rule roll, eliminating the need to re-configure a single system. The bending system processes cutting rules while the cutting system processes crease rules simultaneously, maintaining continuous productivity.
Solution Approach 2:
A controller acts as an intermediary that receives shape diagrams and automatically determines the number and measurements of both cutting and crease rules needed. The controller coordinates both systems, sending appropriate shape diagrams to each system based on the pattern requirements, eliminating manual re-programming and switching operations.
2Adaptability or versatility
If manual handling of heavy rolls is performed to switch between cutting and crease rules, then rule type switching is possible, but manual handling increases time consumption and reduces operational speed
Solution Approach 1:
The system uses separate rolls mounted on different systems (bending system for cutting rules, cutting system for crease rules). This segmentation eliminates the need to physically handle and switch heavy rolls manually. Each system maintains its own roll and operates continuously without interruption.
Solution Approach 2:
The controller automatically manages the entire rule generation process. It determines rule requirements from shape diagrams, sends appropriate diagrams to the bending and cutting systems, and coordinates their operations. This automation eliminates manual intervention in roll handling and system re-configuration.
3Adaptability or versatility
If the bender is re-programmed to generate crease rules instead of cutting rules, then the system can produce different rule types, but re-programming increases device complexity and operational difficulty
Solution Approach 1:
The system separates cutting rule generation (bending system) from crease rule generation (cutting system). Each system is dedicated to a specific rule type and requires no re-programming for rule type switching. The controller manages the division of labor between the two systems based on pattern requirements.
Solution Approach 2:
The controller serves multiple functions: it generates shape diagrams, determines rule requirements, coordinates the bending system for cutting rules, and manages the cutting system for crease rules. This centralized control simplifies the overall system architecture by providing a universal control interface for both rule types.
Data Source
AI summary
A system for generating rules inserted into at least one pattern board including: a controller configured to generate at least one shape diagram, the controller also configured to determine number and measurement of crease rules to be generated based on the at least one shape diagram; a cutting station configured to receive and cut a first crease rule into the number and measurement of the crease rules; and a sorter configured to receive the crease rules from the cutting station and sort the crease rules according to the measurement of the crease rules, wherein the sorted crease rules are inserted into each of the at least one pattern board along with a cutting rule shaped by each of at least one bender.