Digital Waste Stripping for Pre-Cut Substrate Conversion
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Solution Overview
Problem
Current digital substrate conversion processes lack efficient automated methods for waste removal, requiring manual intervention and custom tools, which hinders process efficiency and automation.
Innovation Solution
A method and apparatus for automated waste stripping using punch and support tools synchronized with digital job description files, featuring adjustable punch and support tools, a separation edge, and a machine vision system to separate waste from products without manual intervention, enabling efficient automated waste removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional die-stripping methods are used, then waste can be removed from cut substrates, but custom stripping tools and manual intervention are required
Solution Approach 1:
The system uses a digital copy of the substrate geometry from the job description file to generate punch tool paths, replacing the need for physical custom die tools. The controller processes the digital representation of waste areas and translates it into actuation commands for the punch tools, enabling automated waste removal without custom tooling.
Solution Approach 2:
The patent replaces the mechanical die-stripping system with a digitally controlled punch tool system. Instead of using pre-manufactured custom dies, the system uses a controller that reads digital job descriptions and dynamically generates punch paths, substituting mechanical tooling with a programmable control system.
2Productivity
If manual waste removal is used, then flexibility is maintained, but process efficiency decreases
Solution Approach 1:
The system performs waste removal automatically using the digital job description file as its own guide. The controller processes the substrate geometry information and autonomously generates punch tool paths without requiring manual programming or intervention, enabling the system to service itself for different substrate configurations.
Solution Approach 2:
The system prepares the waste removal process in advance by processing the digital job description file to generate punch paths before actual waste removal occurs. The controller pre-calculates the tool paths based on the substrate geometry, so that when the substrate enters the machine, the automated waste removal can proceed immediately without manual setup.
3Manufacturing precision
If custom stripping tools are made for each job, then precise waste removal is achieved, but manufacturing time and cost increase
Solution Approach 1:
The system transitions from static custom dies to dynamic, programmable punch tools. The punch tool paths are generated dynamically based on the digital job description file, allowing the system to adapt to different substrate geometries without physical tool changes. This dynamic approach maintains precision while eliminating tool manufacturing time.
Solution Approach 2:
The system changes the control parameters of the punch tools based on the digital job description rather than changing physical tools. By modifying the actuation commands and punch paths through software, the system achieves precise waste separation for different jobs without the time and cost of manufacturing custom physical tools.
Data Source
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AI summary
A separator (10) for separating waste (820) from product (810; 2302) in a pre-cut substrate (2600) having one or more cut lines. An inlet feeder feeds the substrate (2600) into the separator (10) along a material path. A separation edge (2500) is disposed in a location downstream of the inlet feeder and defines a line below the plane of the material path. A plurality of punch tools (30; 1800; 1900; 2000) above the plane of the material path, upstream of the separation edge (2500), each has an actuator configured to position the tool in an extended configuration with a contact end of the punch tool (30; 1800; 1900; 2000) disposed below the separation edge (2500), and a retracted configuration with the contact end disposed above the plane of the material path. A controller commands each actuator to position the corresponding punch tool (30; 1800; 1900; 2000) contact end synchronized with the position of the pre-cut substrate (2600) to cause the separation edge (2500) to separate the waste (820) from the product (810; 2302) along the cut lines.