Cutting verification method for at least one fabric sheet, in particular a mattress of fabrics and related cutting system
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Solution Overview
Problem
Current automatic fabric cutting systems require human intervention for verifying the correct alignment of fabric sheets on the cutting plane, leading to increased waste, time, and economic losses due to potential errors in alignment and model verification.
Innovation Solution
An automated method using an image capture device to detect the fabric's position and align it with the cutting plane, eliminating the need for human presence by verifying alignment and model correctness through a control system, which can automatically correct errors and initiate cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an operator manually verifies the alignment of fabric sheets on the cutting plane, then the correctness of cutting can be ensured, but the production time increases and the risk of human error remains
Solution Approach 1:
The patent replaces the manual mechanical verification process with an automated image capture system. A camera captures images of the fabric sheets on the cutting plane, and a control system automatically analyzes the alignment by detecting reference marks and calculating positional deviations, eliminating the need for manual measurement and verification while maintaining high accuracy.
Solution Approach 2:
The system enables self-verification through automatic image capture and analysis. The control system autonomously processes the captured images, compares fabric positions with the cutting model, determines alignment accuracy, and generates verification results without requiring operator intervention, thus reducing verification time while ensuring reliability.
2Reliability
If an operator is present to verify alignment and model correctness, then errors can be detected, but the automation level of the system decreases and safety risks increase
Solution Approach 1:
The patent replaces manual visual inspection and verification with an automated image-based verification system. The control system automatically compares the captured fabric images with the cutting model data, detects alignment errors and model correctness, and generates verification reports, thereby maintaining error detection capability while achieving full automation and eliminating safety risks associated with operator presence.
Solution Approach 2:
The system implements automated feedback by capturing images of the fabric sheets, analyzing their positions against the cutting model, detecting any deviations or errors, and providing verification results back to the control system. This closed-loop feedback mechanism ensures error detection capability is maintained while operating fully automatically without human intervention.
3Manufacturing precision
If manual verification of fabric alignment is performed, then cutting quality can be monitored, but material waste increases due to potential alignment errors
Solution Approach 1:
The patent replaces manual alignment verification with an automated image capture and analysis system that precisely measures fabric positions and orientations. The control system calculates alignment deviations with high accuracy, enabling early detection of misalignment before cutting begins, thus preventing material waste while maintaining cutting quality through automated precision monitoring.
4Reliability
If the cutting head is manually moved to verification points, then alignment can be checked, but the process time increases and operator safety is compromised
Solution Approach 1:
The patent replaces manual movement of the cutting head to verification points with an automated stationary camera system that captures images of the fabric sheets. The control system then automatically analyzes the images to verify alignment, eliminating the need for operators to physically approach the cutting area, thus maintaining verification accuracy while completely removing operator safety risks.
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 solution minimizes errors, reduces production time, and enhances safety by eliminating human intervention, allowing for fully automatic operation and improved cutting quality evaluation.
Implementation Method 1
detecting a snap-shot of the fabric sheet arranged on the cutting plane by means of an image capture device
Data Source
Figure 1
Figure 2~3
AI summary
Cutting verification method for at least one fabric sheet (3) arranged on a cutting plane (2), in a cutting system (1) comprising a support beam (4), movable along a longitudinal dimension of the cutting plane (2), and at least one cutting element (5), coupled to the support beam (3, 4) and movable on the support beam (4), along a transversal dimension of the cutting plane (2). Said method comprises the steps of detecting a snap-shot of the at least one fabric sheet (3) arranged on said cutting plane (2), of loading the snap-shot on a control system (8) by means of an image capture device (6), and of verifying the collimation of at least one point of interest of the at least one fabric sheet (3) with a corresponding point of interest of the cutting plane (2) by means of the control system (8).