Leather Cutting Layout With Projected Virtual Markings
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Solution Overview
Problem
Current methods for optimizing leather and fabric yield in furniture manufacturing are inefficient, as they either rely on costly automated systems or labor-intensive manual processes, and do not effectively account for the irregularities and imperfections of natural materials like leather hides and fabrics.
Innovation Solution
The use of coordinate transformation tables and virtual markings projected onto the materials by a camera and projector system allows for accurate definition and optimization of cutting patterns, enabling improved yield and reduced labor costs by compensating for camera and projector distortions and imperfections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If manual template placement and marking methods are used, then labor flexibility is maintained, but leather yield optimization is insufficient due to inability to evaluate millions of placement options
Solution Approach 1:
The patent uses digital templates as virtual copies of physical patterns, allowing computerized evaluation of millions of placement configurations without requiring physical template manipulation. The digital representation enables rapid yield optimization through software algorithms while maintaining the essential cutting pattern requirements.
Solution Approach 2:
The patent replaces the manual mechanical process of template placement and marking with a computerized system that uses digital images, software algorithms, and automated marking devices. This substitution enables rapid evaluation of numerous placement options and precise marking without manual labor constraints.
2Productivity
If automated mechanical cutting systems are implemented, then cutting precision and speed improve, but equipment cost and maintenance expenses increase significantly
Solution Approach 1:
The patent employs a semi-automated approach where the operator performs defect marking and template placement guidance, while the system automatically calculates optimal layouts and executes marking. This self-service model reduces dependence on expensive fully automated cutting machines while maintaining high productivity through intelligent software assistance.
Solution Approach 2:
The patent introduces a computerized software system as an intermediary between the operator and the cutting process. The software handles complex yield optimization calculations and provides guidance, acting as a mediator that delivers automated intelligence without requiring expensive automated cutting hardware.
3Measurement precision
If digital image processing is used to capture leather hide boundaries and defects, then measurement accuracy improves, but coordinate distortion from camera and projector affects marking precision
Solution Approach 1:
The patent implements a feedback mechanism where the system captures images of the leather hide, processes the coordinate data, and uses transformation algorithms to correct distortions. The corrected coordinates are then fed back into the marking process, ensuring that virtual templates and marking positions are accurately aligned with the actual leather boundaries and defect locations.
Solution Approach 2:
The patent applies coordinate transformation algorithms that dynamically adjust and correct the coordinate parameters from camera and projector images. By changing and optimizing the coordinate system parameters through mathematical transformations, the system compensates for optical distortions and ensures precise marking positions despite initial measurement errors.
Data Source
AI summary
Methods and systems for processing coverings such as leather hides and fabrics are provided. A system can include a worktable having a surface on which a covering is placeable. An imaging device can be positionable relative to the worktable. The imaging device can be configured to obtain an image of the covering on the surface of the worktable. A projector can be positionable relative to worktable. The projector can be configured to project an image onto the surface of the worktable and the covering on the surface of the worktable. A controller can be in communication with the imaging device and projector. The controller can be configured to correct images taken by the imaging device. The controller can also be configured to correct the images projected onto the surface of the worktable and the covering thereon. The controller can be configured to permit the showing of virtual markings on the covering placed on the surface of the worktable through an image projected thereon by the projector. The covering can then be marked or cut along the virtual markings.