Feed Saddle Alignment Correction Using Color Test Marks
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Solution Overview
Problem
Existing cutting machines require manual, time-consuming, and error-prone methods to correct deviations in the alignment of a cutting layer relative to the cutting plane, which are susceptible to human error and lack automation.
Innovation Solution
A method and cutting machine that uses cutting test marks with color-changing sections to determine alignment deviations through a cut pattern, allowing for automated correction via image processing, eliminating the need for complex distance measurements and reducing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual visual assessment and manual correction of feed saddle position are used, then alignment correction can be performed, but the process is time-consuming and requires operator experience
Solution Approach 1:
The patent replaces manual visual assessment and manual adjustment with an automated optical measurement system. Image sensors capture the cut pattern, and a computer evaluates the image to automatically determine alignment deviations and adjust the feed saddle position, eliminating the need for operator experience and visual assessment.
Solution Approach 2:
The system performs self-correction by automatically measuring the cut pattern, calculating alignment deviations, and adjusting the feed saddle without human intervention. The computer-controlled system serves itself by converting the cut pattern information directly into correction actions.
2Ease of operation
If manual correction method is used, then alignment can be adjusted, but errors can occur due to incorrect operation
Solution Approach 1:
The patent replaces manual operation with automated computer-controlled adjustment. The system objectively measures the cut pattern and automatically calculates and executes corrections, eliminating human error and subjectivity while maintaining ease of operation through automated control.
Solution Approach 2:
The system implements closed-loop feedback by measuring the actual cut pattern, comparing it to the intended cut position, calculating deviations, and automatically adjusting the feed saddle to correct the alignment. This continuous feedback loop ensures high accuracy without manual intervention.
3Measurement precision
If complex distance measurement is used to determine alignment deviation, then measurement can be performed, but the method is complex and susceptible to error
Solution Approach 1:
The patent replaces complex physical distance measurements with optical image capture and digital image analysis. Image sensors photograph the cut pattern, and computer algorithms automatically analyze the image to determine alignment deviations, simplifying the measurement process while maintaining or improving precision.
Solution Approach 2:
The system creates an optical copy (image) of the cut pattern and performs measurements on this copy rather than directly measuring physical distances on the material. This digital copying approach simplifies the measurement process and reduces errors associated with physical measurement tools.
Data Source
AI summary
A method for correcting an alignment of a cutting layer made up of stacked, sheet-format product in the form of sheets in relation to a cutting plane of a cutting blade of a cutting machine, and a cutting machine. The cutting machine has a feed saddle for displacing the cutting layer in the direction of the cutting plane of the cutting blade, wherein the feed saddle is adjustable in its alignment in relation to the cutting plane to change the alignment of the cutting layer pressing against the feed saddle in relation to the cutting plane. The respective sheet is provided with at least one cutting test mark, wherein the respective cutting test mark has a coloration changing in the feed direction of the feed saddle.