Cut Data Generation for Large Pattern Segmentation

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Solution Overview

Problem

Conventional cutting apparatuses are limited in cutting large patterns as they can only handle workpieces of a specific size, restricting the generation of cut data for patterns exceeding the size that can be held by the special-purpose mat.

Innovation Solution

A cut data generating apparatus that identifies large patterns, divides them into smaller patterns, and generates cut data to allow these patterns to be cut from multiple workpieces, with the option to add margins for joining, enabling the cutting of large patterns beyond the size limitations of a single workpiece.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the cutting apparatus uses a special-purpose mat with adhesive layer to hold the workpiece, then the workpiece can be securely held and cut, but the size of the pattern that can be cut is limited to the size of the workpiece that can be held by the mat

Engineering Contradiction:

Improveworkpiece holding stabilityVSAvoidcuttable pattern size

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The large pattern is divided into multiple divided patterns that can each fit on separate workpieces. The cut data generating apparatus automatically segments the original large pattern into smaller divided patterns, allowing each to be held and cut on individual workpieces with the special-purpose mat, thereby resolving the contradiction between mat holding capability and desired pattern size.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple divided patterns are arranged and nested on a single workpiece when possible, optimizing the use of the special-purpose mat area. The apparatus determines whether divided patterns can be arranged on one workpiece along with another divided pattern, effectively nesting multiple pattern segments within the limited mat area to reduce the number of workpieces needed.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If the original pattern is divided into multiple smaller patterns, then large patterns exceeding workpiece size can be cut, but additional processing steps and margin additions are required

Engineering Contradiction:

Improvecuttable pattern size rangeVSAvoidcut data generation process

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The cut data generating apparatus performs preliminary actions by automatically dividing the large pattern and calculating optimal arrangements on workpieces before the actual cutting process. Margins are pre-added to divided patterns during the data generation phase, so that when workpieces are joined later, the cuts align perfectly without requiring manual adjustment or complex positioning during assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The apparatus determines autonomously whether divided patterns can be arranged on one workpiece with another divided pattern, and automatically generates the cut data with appropriate margins and positioning information. This self-service capability eliminates the need for manual intervention in the complex processes of pattern division, arrangement optimization, and margin calculation.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If multiple workpieces are used to cut large patterns, then patterns exceeding single workpiece size can be processed, but the number of workpieces increases material usage and joining complexity

Engineering Contradiction:

Improvelarge pattern cutting capabilityVSAvoidworkpiece material consumption

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The apparatus optimizes the arrangement of divided patterns by nesting multiple patterns onto single workpieces whenever possible. This maximizes the utilization of each workpiece area, reducing the total number of workpieces required and thereby minimizing material consumption and waste from unused portions of workpieces.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The system recovers value from workpiece areas that would otherwise be wasted by carefully planning the arrangement and cutting paths to maximize material utilization. The cut data is generated to minimize scrap material, and margins are optimized to allow efficient joining while minimizing excess material that would need to be discarded after assembly.

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentUS10195758B2Cut data generating apparatus and non-transitory recording medium recording cut data generating program

Publication Date: 2019.02.05 BROTHER KOGYO KK

AI summary

A cut data generating apparatus configured to generate cut data for a cutting apparatus including a cut mechanism to cut a pattern from a workpiece, the cut data generating apparatus comprising: a controller, the controller being configured to control the cut data generating apparatus to: identify a size of an original pattern to be cut; judge whether the size of the original pattern identified is larger than a size of the workpiece; divide the original pattern into plural divided patterns smaller than the size of the workpiece in case the size of the original pattern is larger than the size of the workpiece; and generate cut data for cutting each of the divided patterns, determine whether at least one of the plural divided patterns divided falls within one workpiece along with another divided pattern, and generate cut data for cutting the divided patterns from one workpiece in case at least one of the divided patterns falls within one workpiece along with another divided pattern.