2D Sheet Nesting Using Pixel Map Pairs for Toolpath Optimization
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Solution Overview
Problem
Existing algorithms fail to optimally nest parts on 2D sheets, leading to wastage of raw material and unnecessary use of new sheets due to inefficient toolpath management, as they cannot fit parts with their toolpaths in available space effectively.
Innovation Solution
A method and system that generate pixel map pairs for each part, including non-superimposable and superimposable maps, to determine optimal positions on a sheet pixel map, allowing toolpaths to overlap and using a finer fitting algorithm to optimize packing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If existing algorithms are used to nest parts on 2D sheets, then the nesting process is simple to implement, but material consumption increases and raw material wastage occurs due to inefficient toolpath management
Solution Approach 1:
The patent segments the toolpath into separate components from the part geometry, allowing independent optimization of each. The toolpath is treated as a separate element that can be positioned independently from the part drawing, enabling more efficient nesting arrangements that reduce raw material wastage.
Solution Approach 2:
The patent introduces a new dimension of optimization by allowing toolpaths to extend beyond part boundaries and overlap with neighboring parts. This dimensional flexibility enables toolpaths to be positioned in unused spaces between parts, maximizing utilization of available sheet area and reducing material consumption.
2Productivity
If toolpaths are allowed to overlap to optimize nesting efficiency, then material consumption decreases, but the complexity of determining optimal positions increases
Solution Approach 1:
The patent performs preliminary actions by generating multiple candidate positions for each part drawing before final nesting. It creates a set of possible locations where parts can be positioned, then systematically evaluates these candidates to identify optimal arrangements where toolpaths overlap efficiently, reducing the complexity of finding the single best solution.
Solution Approach 2:
The patent uses copying by creating multiple virtual copies of part drawings at different positions and orientations. These copies are then evaluated to determine optimal nesting arrangements, allowing the system to explore multiple solutions simultaneously and select the one that maximizes nesting efficiency with overlapping toolpaths.
3Quantity of substance
If parts are nested to maximize space utilization, then fewer sheets are required, but existing algorithms fail to fit parts optimally due to rigid toolpath constraints
Solution Approach 1:
The patent applies dynamics by making the toolpath positioning flexible and adaptive rather than rigid. The toolpaths are allowed to dynamically adjust their positions and orientations independently from the part geometries, enabling optimal fitting of parts on the sheet while maintaining precise manufacturing requirements through controlled flexibility.
Data Source
AI summary
This disclosure relates to method and system for nesting parts in 2-dimensional (2D) sheets. The method includes receiving one or more part drawing copies of a 2D part and a sheet drawing of a 2D sheet. Further, generating sheet pixel map of sheet drawing. For each of the part drawing copies, the method further includes generating a plurality of part pixel map pairs of part drawing copy, each of the plurality of pixel map pairs includes non-superimposable pixel map and superimposable pixel map; and determining a position of the part drawing copy on sheet pixel map where part drawing of superimposable pixel map is non-overlapping with other part pixel maps on sheet pixel map. The method further includes optimizing part pixel maps using finer fitting algorithm and updating superimposable part pixel map with non-superimposable part pixel maps on sheet drawing.