Continuous Printed-Outline Cutting With Real-Time Alignment
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Solution Overview
Problem
Existing laser cutting machines require periodic pauses for alignment and pre-programmed cutting command data, leading to intermittent cutting action and reduced throughput when cutting pre-printed sheet materials, especially flexible fabrics that may distort during processing.
Innovation Solution
A numerically controlled cutting machine with cameras or optical sensors positioned upstream of the cutting table to detect pre-printed shape outlines and generate cutting command data in real-time, eliminating the need for pre-programmed data and alignment pauses, allowing continuous cutting without distortion compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pre-programmed cutting command data is used with periodic alignment pauses, then cutting accuracy can be maintained, but productivity is reduced due to intermittent cutting action
Solution Approach 1:
The camera captures the printed shape outlines on the sheet material in advance, before cutting begins. This preliminary detection allows the system to pre-process the outline data and generate cutting command data without interrupting the cutting flow, thus maintaining both accuracy and productivity
Solution Approach 2:
The system uses camera feedback to continuously monitor the position and orientation of the sheet material. This feedback loop allows real-time adjustment of cutting command data to match the actual printed outlines, maintaining cutting accuracy while enabling continuous operation without periodic alignment pauses
2Manufacturing precision
If the sheet material is reversed to its start position for data processing, then cutting command data can be generated from captured shapes, but the cutting process is interrupted
Solution Approach 1:
The cutting process continues uninterrupted while the camera simultaneously captures shape outline data. The system processes the captured data in real-time during the feeding process, eliminating the need to stop and reverse the material for data processing, thus maintaining continuous cutting action
Solution Approach 2:
The system separates the data capture function from the cutting function in space and time. The camera captures outlines in one dimension (during feeding) while the cutting head operates independently in another dimension (during cutting), allowing parallel processing without interruption
3Reliability
If pre-programmed cutting command data is required, then consistent cutting patterns can be achieved, but the system cannot adapt to variations in pre-printed shapes
Solution Approach 1:
The system transitions from static pre-programmed cutting data to dynamic real-time data generation. The camera continuously captures the actual printed outlines, and the system dynamically generates cutting command data that adapts to variations in shape position, orientation, and dimensions, while maintaining cutting consistency through real-time processing
Solution Approach 2:
The system changes the parameter source from fixed pre-programmed values to variable real-time captured parameters. By extracting shape outline parameters directly from the printed material via camera detection, the system adapts to parameter variations in each sheet while maintaining consistent cutting quality through automated processing
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
Enables continuous, uninterrupted cutting of pre-printed shapes from sheet materials with improved throughput and accuracy, as the cutting command data is created on the fly, aligning with the printed patterns without manual intervention, and can handle various sheet materials without pre-loading cutting data.
Implementation Method 1
a laser cutter
Implementation Method 2
the laser beam is turned ON and the cutting command data is used to control both the lateral movement of the laser cutting head and the forward and rearward movement of the sheet material over the support roller, to cause the laser to cut the desired outline from the sheet material
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
The invention provides a method of programming and operating a numerically controlled cutting machine to cause it to cut out shapes from a sheet material corresponding to closed path outlines pre-printed on that sheet material. The invention also provides a machine so programmed and operated. The method comprises moving the sheet material (1) from a reservoir (2) of pre-printed sheet material in a constant forward direction (3) past one or more cameras or optical sensors (6) through a cutting command computing zone and over a cutting table (4) where the shapes are to be cut. The one or more cameras or optical sensors (6) detect alignment data and/or continuous line data pre-printed on the sheet material (1) as it moves from the reservoir (2) towards the cutting table (4). The resulting detected data is automatically processed while the sheet material is passing through the cutting command computing zone (50) to calculate cutting command data when no such data has been pre-programmed into the machine or to modify existing cutting command data that has been pre-programmed into the machine, to derive modified cutting command data which establishes and maintains close alignment, when the sheet material (1) reaches the cutting table(4), between the shapes to be cut and the data pre-printed on the sheet material (1).