Presser Foot Flattening Flexible Material Edges
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for cutting flexible materials, such as leather or natural skins, face challenges with waves and edge folds that can lead to deformation and interruptions in the cutting process, reducing productivity and quality due to the need for manual corrections and the use of specialized tools that are not adaptable to the specific geometry of each material.
Innovation Solution
A digital representation of the material's contour is created to determine specific flattening directions and distances for each point, using the presser foot of a cutting tool to flatten the edges from the inside out, eliminating the need for additional tools and adapting to the material's geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a treatment cylinder is used to smooth the entire skin surface, then the skin can be flattened, but the process requires specialized equipment and takes a long time
Solution Approach 1:
The presser foot, originally designed only for cutting support, is made multi-functional by adding flattening capability. It combines cutting and flattening operations into a single tool, eliminating the need for separate treatment cylinders and reducing equipment complexity
Solution Approach 2:
The flattening function is merged with the cutting tool's presser foot. The presser foot simultaneously performs both cutting support and surface flattening operations, integrating two previously separate processes into one unified operation
2Manufacturing precision
If a treatment cylinder performs multiple passes to smooth the entire skin surface, then flattening is achieved, but the process duration is extended
Solution Approach 1:
Instead of treating the entire skin surface uniformly, the invention applies flattening only to specific edge zones where waves and folds occur. The presser foot targets localized areas along the contour, performing multiple local flattenings rather than one comprehensive treatment, thereby reducing total process time while maintaining flattening quality
Solution Approach 2:
The invention applies multiple localized flattenings to edge zones rather than a single comprehensive treatment of the entire surface. This partial action approach focuses resources on problem areas, achieving sufficient flattening quality with reduced overall processing time
3Manufacturing precision
If traditional smoothing methods are used, then the skin can be flattened, but the method does not adapt to the specific contour of each skin
Solution Approach 1:
The flattening process is made dynamic and adaptive through digital control. The system uses digital representations of the specific skin contour to dynamically adjust the presser foot's movement path and pressure application, allowing the flattening operation to adapt to each unique skin geometry rather than following a fixed predetermined pattern
Solution Approach 2:
The system incorporates digital feedback by creating a digital representation of the skin contour and using this information to control the presser foot's flattening movements. The digital model provides real-time guidance on where and how to apply flattening pressure, enabling the system to adapt to the specific geometry of each skin piece
4Reliability
If waves accumulate to form edge folds during cutting, then the cutting operation may be interrupted, but productivity is greatly reduced
Solution Approach 1:
The invention performs preliminary flattening of the skin edges before the cutting operation begins. By pre-smoothing the edge zones where waves and folds are most likely to form, the system prevents cutting interruptions caused by edge folds, thereby maintaining continuous operation and high productivity without sacrificing reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method improves the efficiency and speed of flattening, integrates seamlessly into the cutting process, and ensures high-quality cuts by reducing folds and waves without requiring specialized equipment, thus enhancing productivity and cut quality.
Implementation Method 1
When the skin is positioned on the cutting table, it is generally kept pressed against it by a suction system placed under the table
Implementation Method 2
for each selected point of the part digitized contour of the coupon, the application by means of a presser foot of a cutting tool of a flattening of the edges of the coupon according to the direction and the particular distance of flattening established for said point
Data Source
Figure 1~3
Figure 2
Figure 4~5
AI summary
The invention relates to a method for smoothing out the edges of a swatch of flexible material from which parts are intended to be cut. The method involves establishing a digital representation of at least part of a contour (Hc) of the swatch of flexible material (H), establishing a particular direction (Di, Dj) and a particular distance (Vi, Vj) of smoothing for each of the points (Pi, Pj) of the digitized part of the contour of the swatch, and, for each selected point of the digitized part of the contour of the swatch, using a pressure foot of a cutting tool to apply a smoothing of the edges of the swatch in the particular direction and over the particular distance of smoothing that have been established for said point and in a direction of smoothing that is from the inside of the swatch towards the edges thereof.