Elongate Workpiece Joining and Cutting for Material Waste Reduction
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Solution Overview
Problem
The existing methods for producing elongated workpieces, such as wood profiles, require significant material wastage and costly sorting processes due to the need for cutting raw bars into specific lengths for various products.
Innovation Solution
A process and manufacturing facility that connects elongated output workpieces to form an endless workpiece, allowing for the cutting of workpieces in a successive order and subsequent processing, thereby eliminating the need for post-production sorting and minimizing material wastage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If raw bars are cut to required workpiece lengths in an unsorted sequence to minimize material waste, then material waste is reduced, but additional sorting after cutting is required which increases labor costs and complexity
Solution Approach 1:
The invention applies preliminary action by connecting starting workpieces into a continuous raw bar before cutting. This allows the cutting process to be optimized for minimal material waste without subsequent sorting, as the continuous raw bar can be cut in any sequence. The connection step is performed in advance to enable flexible cutting arrangements.
Solution Approach 2:
The invention merges multiple starting workpieces into a single continuous raw bar through connecting means (such as finger jointing). This merging allows the subsequent cutting process to treat the entire length as one continuous material source, enabling optimal cutting patterns that minimize waste without creating separate sorted stacks for different product types.
2Productivity
If automated sorting machines are used to sort cut workpieces according to products, then sorting efficiency is improved, but manufacturing costs increase significantly
Solution Approach 1:
The invention performs the sorting function in advance by connecting starting workpieces into a continuous raw bar with known composition. This preliminary arrangement allows cutting to produce workpieces in the exact sequence needed for different products, eliminating the need for post-cutting sorting machines and reducing manufacturing costs.
Solution Approach 2:
The invention extracts the sorting function from the post-cutting process and integrates it into the raw bar formation and cutting planning stage. By taking out the sorting requirement from the final processing stage, expensive sorting machines become unnecessary.
3Adaptability or versatility
If manual sorting is used to arrange cut workpieces according to products, then sorting flexibility is maintained, but labor intensity increases
Solution Approach 1:
The invention performs sorting in advance during the raw bar formation stage, where starting workpieces are connected in a predetermined sequence. This preliminary sorting action eliminates the need for manual sorting after cutting, reducing labor time while maintaining flexibility in product mix.
4Loss of substance
If a continuous raw bar is used for cutting multiple workpieces, then material utilization is optimized, but the need for subsequent sorting increases labor requirements
Solution Approach 1:
The invention performs the sorting action in advance by arranging starting workpieces in a specific sequence before connecting them into a continuous raw bar. This preliminary sorting enables optimal material utilization through continuous cutting while eliminating post-cutting sorting labor requirements.
Data Source
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AI summary
The invention relates to a method for manufacturing elongate workpieces (27), in particular workpieces (27) made of wood, wood material, plastic, composite material or the like, for subsequent further processing into at least one object, wherein the method comprises: feeding elongate starting workpieces (13) to a device (17) for connecting the starting workpieces (13), forming a permanent connection between the starting workpieces (13), wherein the starting workpieces (13) are connected together at least at their end faces (28) in order to form an elongate endless workpiece (29), cutting a plurality of elongate workpieces (27) to length from the endless workpiece (29), wherein the elongate workpieces (27) are cut to length in a successive workpiece order from the endless workpiece (29) for the at least one object to be subsequently produced, and carrying out a chip-forming longitudinal machining operation on the starting workpieces (13) and/or on the endless workpiece (29) and/or on the cut-to-length workpieces (27); and to a manufacturing device (10) for manufacturing elongate workpieces (27).