Multi-Section Sheet Processing Apparatus for Flexible Cutting
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Solution Overview
Problem
The existing methods for cutting and creasing sheet processing, such as using a blanking die, are costly and inflexible, especially when processing a variety of small quantities, and are limited by the use of a single blade which restricts processing speed.
Innovation Solution
A sheet processing apparatus with multiple processing sections that use a combination of cutting and creasing tools, allowing for the formation of lines in different directions, and a conveyance mechanism to move the sheet between these sections, enabling flexible and high-speed processing without the need for exclusive dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a blanking die is used for cutting and creasing processing, then the processing can be performed with a single dedicated tool, but it requires preparing an exclusive die for each processing, increasing production cost, safekeeping cost, setup time, and adjusting time
Solution Approach 1:
The patent employs a single plotter-type cutting device that can perform multiple functions including cutting, creasing, and various other sheet processing operations. Instead of using dedicated blanking dies for each operation, the system uses a universal tool with interchangeable blades and adjustable mechanisms that can adapt to different processing requirements, thereby eliminating the need for multiple specialized dies and reducing setup time and costs.
Solution Approach 2:
The cutting device features dynamic and adjustable components, including blades that can be positioned at various angles and depths, and a control system that can adjust processing parameters on the fly. This dynamic capability allows the same device to handle different sheet materials and processing requirements without requiring physical die changes, enhancing versatility while maintaining manufacturing capability.
2Device complexity
If one blade is used for cutting processing, then the device structure can be simple, but the processing speed is limited and cannot be sped up
Solution Approach 1:
The cutting device is divided into multiple independent cutting units, each with its own blade. These segmented cutting units can operate simultaneously or independently, allowing the system to process multiple lines on a sheet at the same time. This segmentation enables parallel processing, significantly increasing productivity while keeping each individual blade unit relatively simple in structure.
Solution Approach 2:
Multiple cutting functions are merged into a single integrated device. Instead of using one blade that must sequentially perform all cutting operations, the system combines multiple blades and cutting mechanisms into one unified plotter device, allowing simultaneous execution of multiple cutting tasks and thereby increasing overall processing speed without excessive complexity.
3Manufacturing precision
If an exclusive blanking die is prepared for each processing, then the processing precision can be ensured, but the production cost and safekeeping cost of the die increase
Solution Approach 1:
Instead of creating physical copies (dies) for each processing type, the system uses a digital control system that stores processing patterns and parameters. The plotter device reproduces the desired cutting patterns by following digital instructions, eliminating the need for expensive physical die fabrication and storage while maintaining high precision through controlled blade positioning and movement.
Solution Approach 2:
A single universal cutting device replaces multiple specialized dies, reducing the total cost of tooling. The device maintains manufacturing precision through its ability to accurately reproduce different cutting patterns using the same physical tooling, thereby eliminating the need for expensive dedicated dies for each processing type while keeping production costs low.
4Adaptability or versatility
If a blanking die is attached and detached frequently, then the process can be changed to accommodate small amounts and many kinds of products, but the setup time cost increases
Solution Approach 1:
The cutting device incorporates dynamic, quickly-adjustable components such as rapidly interchangeable blades and programmable control systems. This allows the device to adapt to different product types and processing requirements without time-consuming die attachment and detachment operations. The system can switch between different cutting patterns through digital programming, eliminating setup time associated with physical die changes while maintaining the ability to handle small batches of diverse products.
Solution Approach 2:
The patent replaces the mechanical die attachment system with a digital control system. Instead of physically attaching and detaching dies, the system uses software-controlled blade positioning and movement patterns to accommodate different products. This substitution eliminates the time-consuming mechanical setup process while preserving the adaptability needed for handling small amounts of many different product types.
Data Source
AI summary
A sheet processing apparatus (1) includes a first processing section (1000), a second processing section (2000), and a third processing section (3000) arranged on a straight line, and conveys a sheet (4200) therebetween. The first processing section (1000) forms a plurality of first processing lines extending in a first direction (an X axial direction) on the sheet (4200), by moving a plurality of tools (1110-1260) to the first direction in relation to the sheet (4200). The second processing section (2000) forms a plurality of second processing lines to a second direction (a Y axial direction) orthogonal to the first direction on the sheet (4200), by moving a plurality of tools to the second direction in relation to the sheet (4200). The third processing section (3000) forms a third processing line (aslant line, curve line) on the sheet, by relatively moving the sheet (4200) and the tool (3110, 3120).