Flexible Material Cutting Layout Recalculation for Roll End Defects
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Solution Overview
Problem
Existing automatic cutting systems for flexible materials in roll form face challenges such as material loss and production downtime due to differences between theoretical and real material conditions, end-of-roll issues, and defects, which require adaptations that often result in significant material waste and productivity losses.
Innovation Solution
A method for automatic cutting that involves developing an initial placement for parts, detecting triggering events like end-of-roll or defects, and recalculating new positions for parts to be repositioned without considering their initial positions, allowing for a new optimized placement that minimizes material loss and maintains production continuity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operator manually splits the placement into two parts to avoid the change zone between rolls, then the number of parts on the roll change is limited, but significant material loss occurs
Solution Approach 1:
The system dynamically recalculates the placement configuration in real-time based on the actual roll end position and defect locations, transforming the static initial placement into an adaptive solution that optimizes material usage while ensuring cutting quality
Solution Approach 2:
The system changes the positional parameters of parts in the placement by recalculating their coordinates relative to the new origin point (roll end or defect location), allowing the placement to adapt to changing material conditions without manual intervention
2Manufacturing precision
If adaptations of the placement are made during production to account for differences between theoretical and real information, then the quality of the cutting result is maintained, but significant material loss and additional production time occur
Solution Approach 1:
The system replaces manual operator intervention with an automated computer-based recalculation mechanism that dynamically adjusts the placement configuration, eliminating the need for manual placement modification while maintaining cutting quality
Solution Approach 2:
The system performs self-adjustment by automatically detecting triggering events and recalculating the placement configuration without external intervention, allowing the cutting process to continue uninterrupted while adapting to real material conditions
3Reliability
If the operator waits for new placement to recut rejected parts, then parts with quality issues are recut, but production time is lost
Solution Approach 1:
The system maintains continuous cutting operation by recalculating the placement configuration on-the-fly and immediately implementing the new configuration, eliminating production interruptions while ensuring only quality parts are produced
Solution Approach 2:
The system performs preliminary recalculation of the placement configuration before actual cutting errors occur by detecting triggering events in advance, allowing the cutting process to continue without interruption
Data Source
Figure 1A~1C
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AI summary
The invention relates to a method and system for automatic cutting of pieces in a flexible material packaged in roll form, comprising the consecutive steps of preparing an initial layout (S1), spreading out (S2) a layer of flexible material on a cutting table, starting (S5) the automatic cutting of pieces in the spread-out material according to the initial layout, in the course of the cutting, upon receiving a triggering event (Evt) for which the layout of at least one of the pieces is no longer suitable for the cutting environment or for which the list of pieces in the initial layout has to be changed, preparing a list of pieces to be kept (S6), and automatic preparation of a new layout (S7) taking account of the position of the pieces to be kept and calculating new positions for all or some of the other pieces without taking account of their positions in the initial layout.