Overlapping Cutting Frame Layout for Angled Rectangular Pieces
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Solution Overview
Problem
Conventional methods for cutting rectangular unit pieces from a base material sheet at a predetermined angle result in low cutting efficiency and high scrap production, leading to increased manufacturing costs, especially when the size of the base material sheet is not in constant proportion to the size of the unit pieces.
Innovation Solution
A method involving a cutting frame with cutters arranged such that opposite side ends coincide, allowing for partial overlapping during the cutting process, with a pitch equal to the spacing distance between cutters, enabling cutting with a pitch less than the length of the cutting frame and reducing material loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rectangular unit pieces are cut at a predetermined angle from a base material sheet using conventional cutting methods, then the cutting process can be performed, but the cutting efficiency is low and a large amount of scrap is produced
Solution Approach 1:
The cutting frame is divided into multiple cutting units, each with cutters arranged at specific positions and angles. This segmentation allows simultaneous cutting of multiple pieces at different orientations, improving cutting efficiency while optimizing material utilization to reduce scrap.
Solution Approach 2:
The invention introduces angular dimension by arranging cutters at different angles (e.g., 45 degrees) relative to the base material sheet. This allows cutting rectangular unit pieces at predetermined angles while maintaining high cutting efficiency through the coordinated arrangement of multiple cutting elements in both linear and angular dimensions.
2Adaptability or versatility
If the size of the base material sheet is not in constant proportion to the size of rectangular unit pieces, then flexibility in manufacturing is maintained, but cutting efficiency varies and scrap production increases
Solution Approach 1:
The cutting frame is designed as a universal cutting system that can accommodate different sizes of base material sheets and produce various sizes of rectangular unit pieces. The multi-functional cutting units with adjustable arrangements enable the system to adapt to different manufacturing requirements while maintaining high cutting efficiency through optimized cutter positioning.
Solution Approach 2:
The invention utilizes parameter changes in the arrangement of cutters (positions, angles, spacing) to optimize cutting efficiency for different base material sheet sizes and unit piece dimensions. By adjusting these parameters, the system maintains high productivity across varying manufacturing conditions while minimizing scrap production.
3Productivity
If cutters are arranged in a conventional array structure on the cutting frame, then the cutting process can be performed, but the pitch for one-time cutting equals the length of the cutting frame, reducing cutting efficiency
Solution Approach 1:
The cutting frame is segmented into multiple cutting units with cutters arranged at specific positions and angles. This segmentation enables the pitch for one-time cutting to be less than the length of the cutting frame, allowing overlapping cutting operations that improve cutting efficiency while the structured arrangement maintains manageable device complexity.
Solution Approach 2:
Multiple cutting units are merged into a single coordinated cutting frame system, where cutters from different units work simultaneously on the base material sheet. This merging allows the pitch to be optimized independently of the full frame length, improving cutting efficiency through coordinated multi-unit operation.
Data Source
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AI summary
Disclosed herein is a method of manufacturing one or more kinds of rectangular unit pieces from a long base material sheet at a predetermined angle through a continuous cutting process using a cutting frame, the method including (a) manufacturing a base material sheet of a laminate structure having two or more stacked sheets and winding the base material sheet on a roll, (b) continuously feeding the base material sheet, wound on the roll, (c) cutting the fed base material sheet using a cutting frame having cutters mounted or formed therein in a structure in which the cutters correspond to rectangular unit pieces to be manufactured, the cutters being arranged such that the shapes of opposite side ends of the cutters coincide with each other when the cutters are successively arranged, the cutting being carried out while the base material sheet is partially overlapped such that a length ('pitch') for a one¬ time cutting process is equal to a spacing distance between the opposite side ends of the cutters in the longitudinal direction are equal to each other at arbitrary heights of the cutting frame, (d) winding a scrap, produced after the cutting of the rectangular unit pieces, on another roll, and (e) transferring the cut rectangular unit pieces.