Intelligent typesetting method, intelligent typesetting system and intelligent cutting system for lace materials
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Solution Overview
Problem
The complexity of cutting lace materials due to their soft and deformation-prone nature leads to inefficiencies in manual cutting, and existing automated methods struggle with accurately extracting pattern contours from intricate fabric backgrounds, resulting in waste and low efficiency.
Innovation Solution
An intelligent typesetting method and system that divides the cutting process into outer and inner cutting pieces, identifies waveband points, and optimally arranges these pieces using algorithms like NFP and Minkowski Difference to minimize waste and maximize automation, with the outer cutting pieces marked as defective areas and inner pieces placed in non-defective regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual cutting is used to cut lace patterns, then the cutting precision can be maintained, but the cutting time is long and the efficiency is low
Solution Approach 1:
The lace pattern is segmented into multiple cutting pieces through automatic image segmentation. The system divides the complex lace pattern into distinguishable cutting pieces with clear boundaries, enabling automated processing while maintaining precision. This segmentation allows the cutting process to be broken down into manageable sections that can be processed automatically.
Solution Approach 2:
The patent replaces manual mechanical cutting with an automated system combining image processing and laser cutting. The workflow transitions from manual visual inspection and cutting to automatic pattern recognition, segmentation, and laser cutting execution, significantly improving efficiency while maintaining precision through computer-controlled processes.
2Extent of automation
If existing automatic image segmentation method is used to extract pattern contours, then automation is achieved, but the extraction accuracy is unsatisfactory due to complex fabric background
Solution Approach 1:
The patent applies segmentation by dividing the lace pattern into multiple cutting pieces with clear boundaries. This segmentation approach simplifies the complex fabric background into distinct regions, making contour extraction more accurate. By segmenting the pattern first, the system can then extract contours of individual pieces more reliably than attempting to extract the entire complex pattern at once.
Solution Approach 2:
The system applies local quality by processing different regions of the lace pattern with appropriate methods. After segmentation, each cutting piece is processed individually, allowing the system to focus on local contour extraction rather than being overwhelmed by the global complexity of the entire lace pattern. This local processing approach improves accuracy in extracting contours from complex fabric backgrounds.
3Manufacturing precision
If worker stares at lace cloth for long time to position cutting pieces, then positioning accuracy can be achieved, but visual fatigue occurs and positioning accuracy deteriorates
Solution Approach 1:
The patent replaces human visual positioning with automated image processing and computer vision systems. The system captures images of the lace pattern, processes them through segmentation algorithms, and automatically determines cutting piece positions and laser cutting paths. This eliminates visual fatigue while maintaining or improving positioning accuracy through consistent computer-controlled measurement and positioning.
Solution Approach 2:
The system creates a digital copy of the lace pattern through image capture and processing. Instead of requiring workers to visually inspect the physical lace cloth, the system works with a digital representation that can be analyzed, segmented, and measured without time constraints or human fatigue. This digital copying enables precise positioning calculations to be performed rapidly by computer algorithms.
4Manufacturing precision
If lace material is cut piece by piece manually, then cutting precision is maintained, but the cutting time is long
Solution Approach 1:
The patent replaces manual piece-by-piece cutting with automated laser cutting. The system processes the segmented lace pattern and generates laser cutting paths for all pieces simultaneously. The laser cutting apparatus then executes these paths automatically, cutting multiple pieces in rapid succession without the time loss associated with manual repositioning and handling, while maintaining precision through computer-controlled laser positioning.
Solution Approach 2:
The system achieves continuity of useful action by processing multiple cutting pieces in an automated sequence without interruption. Once the lace pattern is segmented and cutting paths are calculated, the laser cutting process continues continuously through all pieces, eliminating the start-stop nature of manual cutting where workers must repeatedly reposition, measure, and cut each piece individually. This continuous automated process significantly reduces total cutting time.
Data Source
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AI summary
An intelligent typesetting method for lace materials, including: acquiring a lace pattern and a lace cutting piece in real time, wherein the lace cutting piece includes an outer cutting piece and an inner cutting piece; identifying all waveband points on the lace pattern according to a preset waveband point; arranging the outer cutting piece on the lace pattern according to the waveband points, setting the area where the external cutting pieces are arranged on the lace pattern as a defective area; and arranging the inner cutting piece on a non-defective area of the lace pattern. The present invention also relates to an intelligent typesetting system and an intelligent cutting system for lace materials. The outer cutting piece and the inner cutting piece are respectively typeset; the complexity of the typesetting is greatly reduced and the optimized arrangement of the outer cutting piece and the inner cutting piece is realized.