Flat-Bed Cutting Nesting Around Support Web Wear Constraints
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Solution Overview
Problem
Current methods for nesting workpieces in flatbed machine tools, such as laser cutting machines, face challenges in minimizing material usage, reducing downtime, and optimizing cutting process efficiency, particularly due to issues with support web wear and part quality, which are not adequately addressed by existing nesting algorithms.
Innovation Solution
A computer-implemented method for generating a nesting plan that includes an overlap-free arrangement of workpieces in a two-dimensional planning space, considering spatial support spaces and using evolutionary algorithms to optimize the insertion order and arrangement rules, while evaluating alternative positions to minimize material waste and ensure proper alignment with support points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If workpieces are nested to minimize raw material usage, then material costs are reduced, but cutting process efficiency and support web wear are not adequately optimized
Solution Approach 1:
The patent transforms the nesting problem from a purely 2D geometric packing problem into a multi-dimensional optimization problem by introducing support web positions as additional parameters. The nesting algorithm evaluates multiple candidate solutions based on multiple parameters including material utilization, support web wear, and cutting process efficiency, allowing simultaneous optimization of competing objectives through parameter-weighted evaluation functions.
Solution Approach 2:
The patent adds a new dimension to the traditional 2D nesting problem by incorporating the third dimension of support web height and position into the optimization criteria. By considering support web wear and cutting process efficiency as additional evaluation dimensions, the system transforms a simple area-packing problem into a multi-objective optimization problem that accounts for manufacturing process realities.
2Loss of substance
If traditional nesting algorithms are used to arrange workpieces, then material utilization is optimized, but support web wear and part quality are not adequately considered
Solution Approach 1:
The patent implements feedback mechanisms where the nesting algorithm continuously evaluates candidate arrangements against multiple criteria including support web wear and part quality. The evaluation function provides feedback on the quality implications of each nesting configuration, allowing the algorithm to iteratively improve solutions by selecting arrangements that minimize both material waste and quality degradation.
Solution Approach 2:
The system changes the parameter set from traditional 2D coordinates alone to include support web interaction parameters and quality metrics. By incorporating additional parameters such as distance to support webs, support web wear factors, and part quality indicators into the optimization function, the algorithm can simultaneously optimize material utilization and part quality.
3Reliability
If support spaces are considered in the nesting plan, then support web wear is reduced, but computational complexity increases
Solution Approach 1:
The patent segments the complex multi-objective optimization problem into manageable components: geometric constraint checking, support web wear evaluation, and objective function optimization. By dividing the problem into discrete evaluation modules that can be independently computed and combined, the system reduces computational complexity while still considering support web wear in the overall optimization.
Data Source
Figure 1~2
Figure 3
Figure 4A~4C
AI summary
The invention relates to a method (39) for producing a nesting plan (49A) for controlling cutting process of a flat-bed machine tool (1) for cutting out workpieces (9) from a material sheet (7), the nesting plan (49A) comprising an overlap-free arrangement of sub-areas (9A, 9B, ...) corresponding to the workpieces (9) in a two-dimensional planning space (23) and a spatial arrangement of predetermined support areas (27). After each new insertion of a sub-area (9A, 9B, ...) during the nesting, a packing density assessment and at least one assessment (127, 129A-C), incorporating the position data, of the starting position (54) of the newly inserted sub-area (9A, 9B, ...) are performed in a local search area.