Cutter for Decor on Tapered Support
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Solution Overview
Problem
The challenge is to eliminate the overlapping of decoration ends on frustoconical supports during the forming process, which results in aesthetic issues and extra thickness, while also ensuring efficient operation and preventing jamming and pollution in the molding process.
Innovation Solution
A cutting machine is designed to cut frustoconical decoration strips without prior cutting, using various extraction tools like rollers, belts, and folding flaps to remove waste portions, and a system for conveying cut decorations into molds, ensuring no overlap and preventing jamming or pollution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If continuous printed bands are used for frustoconical supports, then the decoration can cover the entire surface, but the ends of the decoration overlap significantly after forming, creating aesthetic issues and extra thickness
Solution Approach 1:
The continuous printed band is segmented into individual decoration units by cutting stations that trim the bands between decorations. This segmentation allows each decoration to be positioned precisely on the frustoconical support without overlap, resolving the contradiction between complete surface coverage and precise end alignment.
Solution Approach 2:
The cutting stations perform preliminary trimming of the decoration bands before they are formed onto the frustoconical supports. By pre-cutting the bands to eliminate excess material at the ends, the system prevents overlapping from occurring in the first place, thereby achieving both complete coverage and precise alignment.
2Productivity
If high-speed operation is implemented in the cutting and forming process, then productivity increases, but jamming and pollution of molds may occur
Solution Approach 1:
Extraction tools are introduced to continuously remove trimmed portions from the cutting stations at high speed. By extracting the waste material immediately after cutting, the system prevents jamming in the forming process while maintaining high productivity. The extraction mechanism ensures that no excess material remains to cause pollution or obstruction.
Solution Approach 2:
The extraction tools act as intermediaries between the cutting stations and the forming molds. They capture and remove trimmed portions before these materials can interfere with the forming process, thereby enabling high-speed operation without compromising reliability or causing mold pollution.
3Reliability
If extraction tools are used to remove trimmed portions, then jamming and pollution are prevented, but device complexity increases
Solution Approach 1:
The extraction tools are designed to perform multiple functions: they remove trimmed portions, prevent jamming, and avoid mold pollution simultaneously. By consolidating these functions into a single extraction mechanism, the system achieves improved reliability without proportionally increasing device complexity.
Solution Approach 2:
The extraction tools are positioned and configured to automatically capture and remove trimmed portions directly at the cutting station without requiring additional manual intervention or complex handling systems. This self-service approach maintains process stability while minimizing the added complexity of the extraction mechanism.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively eliminates decoration end overlaps, allows for high-speed operation, and prevents jamming and pollution, resulting in aesthetically pleasing, efficiently produced frustoconical supports with contiguous decoration ends.
Implementation Method 1
The extraction tool comprises means for grasping said portions by contact and means for driving them out of the cutting station
Data Source
Figure 1
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Figure 3
AI summary
The machine has a cutting station (40) provided with a roughing belt (63), and a series of tapered decors (3) that are separated by trapezoid shape portions (31). The cutting station is equipped with a cutting unit arranged for cutting portions between two decors and evacuating units for evacuating portions. The evacuating units have an extraction tool for extracting each portion outside the cutting station. The extraction tool is constituted by a folding shutter arranged in a counter-blade.