Defective Plate Nesting Layout Using Electronic Defect Maps
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Solution Overview
Problem
The existing plate processing technologies face a high scrap rate due to defects such as folds and holes in the plates, which affect the quality of finished products and lead to the discard of defective products.
Innovation Solution
A preprocessing method that involves acquiring plate information, creating an electronic defect map, and partitioning the plate into small plates based on the available region for nesting and shear cutting, thereby reducing scrap rates and improving production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional plate processing is performed without considering defects, then processing speed is maintained, but scrap rate increases due to defective finished products
Solution Approach 1:
The system performs preliminary defect detection and creates a defect map before the nesting and shear cutting process. By identifying defect locations in advance and incorporating them into the processing plan, the system avoids producing defective finished products while maintaining efficient processing speed.
Solution Approach 2:
The system uses feedback from defect detection to dynamically adjust the nesting layout and cutting plan. The defect information is fed back into the optimization algorithm, which then modifies the processing scheme to avoid defective regions, thereby reducing scrap rate without sacrificing productivity.
2Ease of manufacture
If plate partitioning is performed without defect consideration, then processing simplicity is maintained, but product quality deteriorates due to defective finished products
Solution Approach 1:
The system creates a defect map and identifies valid processing regions before partitioning the plate. This preliminary action ensures that subsequent nesting and cutting operations automatically avoid defective areas, maintaining product quality without significantly complicating the manufacturing process.
Solution Approach 2:
The system applies different processing strategies to different regions of the plate based on defect locations. Valid regions are processed with standard nesting algorithms, while defective regions are excluded or handled differently, ensuring high product quality in the final output.
3Quantity of substance
If the entire plate is used for nesting without defect avoidance, then material utilization is maximized, but finished product quality decreases due to defects
Solution Approach 1:
The system extracts and excludes defective regions from the available processing area by creating a defect map and identifying valid regions. By removing only the defective portions and processing the remaining valid areas, the system minimizes material waste while ensuring high finished product quality.
Solution Approach 2:
The system changes the effective processing parameters by adjusting the available plate dimensions based on defect locations. The optimization algorithm works with modified plate boundaries that exclude defective regions, thereby achieving high material utilization within the valid processing area while maintaining product quality.
Data Source
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AI summary
A nesting and shear cutting preprocessing method for a defective plate, comprising the following steps: acquiring plate information of a plate, wherein the plate information includes defect information and plate dimension information; making an electronic defect map according to the defect information and the plate dimension information, and partitioning out a region available for nesting and shear cutting; and partitioning the plate to obtain small plates according to the region available for nesting and shear cutting. A nesting and shear cutting layout method for a defective plate, a nesting and shear cutting production optimization method for a defective plate, and a system, a computing device, a storage medium therefor. The preprocessing method and the system can reduce the scrap rate of plate processing.