Quadrangular Unit Cutting Yield Optimization
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Solution Overview
Problem
Existing methods for cutting quadrangular unit pieces from large base materials result in high defect rates and increased manufacturing costs due to inefficient cutting processes, especially when cutting at angles or with varying sizes, leading to significant scrap production and increased waste.
Innovation Solution
A method involving an inspection step to identify defects, calculation of yield using virtual cutting frames, selection of the frame providing maximum yield, and cutting using the selected frame to optimize cutting efficiency and reduce defects, while considering defect patterns and distribution for improved productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large number of quadrangular unit pieces are cut from a base material, then productivity increases, but the defect rate increases leading to more scrap
Solution Approach 1:
The patent applies preliminary action by performing defect inspection on the base material before the cutting process. The inspection unit scans the base material to detect defects, and this information is stored and used to guide subsequent cutting operations. By identifying defect locations in advance, the system can plan cutting patterns that avoid defective regions, thereby maintaining high productivity while reducing scrap production from defective pieces.
2Adaptability or versatility
If cutting is performed at angles or with varying sizes to meet diverse demands, then adaptability increases, but cutting efficiency decreases leading to more scrap
Solution Approach 1:
The patent applies dynamics by implementing a dynamic cutting pattern generation system that adapts to diverse cutting requirements. The system receives various cutting specifications (sizes, angles, quantities) and dynamically generates optimized cutting patterns that accommodate these varying demands while minimizing scrap. The cutting frame can adjust its configuration to cut different sizes and angles, maintaining both adaptability and efficiency through intelligent pattern optimization.
Solution Approach 2:
The patent applies parameter changes by modifying cutting parameters (such as cutting angles, piece sizes, and frame configurations) based on demand requirements. The system can change these parameters dynamically to optimize cutting efficiency for different product specifications while still avoiding defective areas of the base material, thus maintaining both adaptability and productivity.
3Adaptability or versatility
If multiple cutting frames are used to accommodate various sizes, then adaptability increases, but device complexity increases
Solution Approach 1:
The patent applies dynamics by implementing a dynamically reconfigurable cutting frame rather than using multiple fixed cutting frames. The single cutting frame can adjust its parameters (such as cutter positions, cutting angles, and frame dimensions) to accommodate various piece sizes and cutting requirements. This dynamic adjustment capability provides the same adaptability as multiple fixed frames but with significantly reduced device complexity.
Data Source
AI summary
A method of cutting one or more kinds of quadrangular unit pieces having a relatively small size from a quadrangular base material having a relatively large size uses a cutter frame including a plurality of cutters to manufacture the quadrangular unit pieces. The method includes (a) scanning a quadrangular base material in a longitudinal direction and in a lateral direction to check positions of defects on the quadrangular base material, (b) calculating a yield when cutting the quadrangular base material using two or more kinds of cutting frames, (c) selecting one of the cutting frames in which the yield calculated at the calculation step (b) is within a range of upper 30%, and (d) cutting the quadrangular base material using the cutting frame selected at the selection step (c) to manufacture quadrangular unit pieces.