Automated Cutting System Void Area Weeding
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Solution Overview
Problem
Existing automated cutting systems for graphics on textiles are inefficient when cutting shapes with fully-enclosed open void areas, as they leave waste graphic material on the carrier material, requiring time-consuming and costly manual 'weeding' processes.
Innovation Solution
The system variably controls the cutting device to apply different pressures and energies, cutting the graphic material around the outer perimeter with lower energy and the void area with higher energy to remove both materials, eliminating the need for manual weeding by automatically cutting through both layers in the void area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a constant cutting force and energy level is used to cut the graphic material, then the outer perimeter of the graphic is cleanly cut, but the waste material in fully-enclosed void areas remains attached requiring manual removal
Solution Approach 1:
The cutting system dynamically adjusts the cutting force and energy level based on the cutting location. The controller varies the cutting parameters between two distinct levels: a first cutting force for the outer perimeter and a second, greater cutting force for void areas. This dynamic adjustment allows the system to automatically remove waste material from enclosed spaces without compromising the precision of the main graphic cut.
Solution Approach 2:
The system changes the cutting parameters (force and energy level) based on the geometric characteristics of the graphic being cut. The controller identifies void areas and applies a different cutting regime (higher energy) specifically to those regions, while maintaining the original cutting parameters for the rest of the graphic. This parameter variation eliminates the need for manual weeding while preserving cutting precision.
2Productivity
If higher cutting energy is applied to remove waste material from void areas, then manual weeding is eliminated, but the carrier material may be damaged or cut through
Solution Approach 1:
The cutting system applies different cutting qualities to different locations on the material. High cutting energy is applied only locally to the void areas where waste removal is needed, while the rest of the material (including the carrier layer in non-void areas) is subjected to the lower, standard cutting force. This localized approach ensures that the carrier material is not damaged while still achieving automatic waste removal from enclosed spaces.
Solution Approach 2:
The controller预先 identifies the geometry of the graphic and determines which areas are fully-enclosed voids before cutting begins. This preliminary analysis allows the system to prepare the appropriate cutting parameters for each location, ensuring that high energy is applied only where needed and that the carrier material is protected from damage throughout the cutting process.
3Manufacturing precision
If manual weeding is performed to remove waste material from void areas, then clean graphics are produced, but labor time and costs increase
Solution Approach 1:
The cutting system performs the waste removal function automatically as part of the cutting process itself. By varying the cutting force based on the graphic geometry, the system self-services the task of removing waste material from void areas without requiring separate manual intervention. This integration of waste removal into the cutting operation eliminates both the time loss and labor costs associated with manual weeding while maintaining high graphic quality.
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
This method automates the removal of waste graphic material from fully-enclosed void areas, reducing manual labor and costs by integrating precise control of the cutting device to cut the graphic and carrier materials within the void area during the manufacturing process.
Implementation Method 1
The cutting machine 24 includes a cutting device 29, such as a laser. The cutting device may also be a knife blade or other similar device capable of cutting material.
Implementation Method 2
The cutting device 29 may be configured to be moved laterally across the material 11 to cut a graphic 25, e.g., 'O ', into the material 11 as it is pulled longitudinally through the machine 24.
Data Source
AI summary
A method for cutting a graphic into a graphic material is disclosed. The method includes automatically controlling a cutting device to cut a desired graphic shape into a graphic material and automatically adjusting the cutting depth of the cutting device between at least a shallower cutting depth and a deeper cutting depth substantially contemporaneously with the cutting the desired graphic shape into the material.