Projected Template Alignment for Leather Hide Cutting Yield
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Solution Overview
Problem
Current methods for optimizing leather and fabric yield in furniture manufacturing are inefficient, as they rely on manual or expensive mechanical systems that do not fully utilize the irregular shapes and sizes of leather hides and fabrics, leading to suboptimal cutting patterns and increased labor costs.
Innovation Solution
The use of coordinate transformation tables and virtual markings projected onto the materials allows for accurate definition of defects and cutting lines, enabling a computer to optimize template placement and cutting patterns, thereby increasing yield and reducing labor through software-driven processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If manual marking and cutting methods are used, then labor flexibility is maintained, but leather yield optimization is insufficient due to inability to evaluate millions of placement options
Solution Approach 1:
The patent uses digital templates as copies of physical patterns and projects them onto the leather hide. The computer system creates virtual representations of templates and the leather surface, allowing evaluation of millions of placement configurations without physical manipulation. This digital copying enables comprehensive yield optimization that would be impossible with manual methods.
Solution Approach 2:
The patent replaces manual mechanical marking and cutting processes with a computer-based system that uses digital image processing, coordinate transformation, and automated pattern recognition. The mechanical act of physically moving and positioning templates is substituted with digital projection and coordinate-based evaluation, enabling exhaustive search of placement options.
2Manufacturing precision
If automated mechanical cutting systems are implemented, then cutting precision is improved, but the systems become expensive and do not provide significant labor savings
Solution Approach 1:
The patent introduces a coordinate transformation table as an intermediary between the digital template definitions and the physical leather surface. This intermediary structure enables precise mapping of digital coordinates to physical locations without requiring complex automated cutting machinery. The coordinate system acts as a bridge that simplifies the interface between digital planning and physical execution.
Solution Approach 2:
The system projects digital images and coordinate information onto the physical leather surface, creating a visual copy of the cutting pattern that guides manual or semi-automated cutting. This projection copying allows precise pattern transfer without requiring expensive automated cutting equipment, maintaining accuracy while reducing system complexity.
3Loss of substance
If traditional nesting software is used with specified iteration limits, then processing time is controlled, but optimal yield may not be achieved due to insufficient exploration of placement configurations
Solution Approach 1:
The patent replaces iterative software-based nesting algorithms with a direct coordinate transformation approach. Instead of running multiple software iterations to find optimal placements, the system uses mathematical coordinate mappings to directly determine optimal template positions based on the projected digital image, significantly reducing computation time while maintaining or improving yield optimization.
Solution Approach 2:
The system performs preliminary digital mapping and coordinate transformation before physical cutting. By pre-calculating the optimal layout through coordinate transformation tables and projecting the complete pattern onto the leather surface beforehand, the system eliminates the need for time-consuming iterative adjustments during the cutting process.
Data Source
AI summary
Systems, methods, and computer program products for processing coverings such as leather hides and fabrics are provided. A system for processing coverings can include a conveyor having a surface on which a covering can be placed and being rotatable to move the covering in at least one direction. An imaging device can be configured to obtain an image of the covering on the surface of the conveyor. A projector can be configured to project an image onto the surface and the covering. The covering and the projected image can have a positional relationship to one another. A controller can be in communication with the imaging device and projector. The controller can be configured to project and move the projected image of the projector with the covering to maintain a positional relationship of the projected corrected image to the covering upon rotation of the conveyor. Methods are also provided for orienting an image projected onto work surface with a covering on the work surface to align the image and covering.