Quilted Panel Cutting with Pattern Centering Control
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Solution Overview
Problem
Large-scale quilting processes face challenges in accurately and automatically cutting panels from quilted material webs without shifting or partially cutting off the quilted patterns, limiting the use of automated systems and increasing labor intensity.
Innovation Solution
An apparatus with a programmable controller that uses a center mark detector and length sensor to align and cut panels, ensuring the quilted patterns are centered, incorporating a cross-cutting apparatus and trimming mechanisms to cut panels to desired lengths and widths while maintaining pattern alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual or semiautomatic cutting processes are used to ensure accurate pattern centering, then manufacturing precision is improved, but productivity deteriorates due to increased labor intensity and slower operation
Solution Approach 1:
The cutting system automatically detects the quilted pattern position and centers it on the panel using sensors and programmable controllers, eliminating the need for manual alignment operations while maintaining high precision pattern centering
Solution Approach 2:
The patent replaces manual mechanical alignment operations with automated optical/electronic detection systems and programmable control mechanisms that automatically position and center the quilted pattern on panels
2Productivity
If automated cutting systems are used to increase productivity, then cutting speed is improved, but manufacturing precision deteriorates as patterns may be shifted or partially cut off
Solution Approach 1:
The system uses sensors to detect the actual position of quilted patterns on panels and feeds this information back to the programmable controller, which automatically adjusts cutting positions to ensure accurate pattern centering while maintaining high-speed automated operation
Solution Approach 2:
The system performs preliminary detection of pattern positions using sensors before the cutting operation begins, allowing the programmable controller to pre-calculate and set the optimal cutting positions to ensure accurate pattern centering
3Productivity
If high-speed multi-needle quilting machines are used to increase production volume, then productivity is improved, but the complexity of the overall system increases
Solution Approach 1:
The cutting system is designed as a universal automated platform that can handle panels of varying sizes and handle types, integrating pattern detection, positioning, and cutting functions into a single multi-functional system that works with high-speed quilting machines
Data Source
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AI summary
A method of cutting a quilted material web (20) into a panel (24) having a quilted pattern (32) therein. A mark (48) is applied to the quilted material web at a location within a width and length of the panel; and the quilted material web is moved in a longitudinal direction with respect to the panel. The mark is detected while moving the quilted material web, and a controller (219) determines, with respect to the mark, cutter positions that define the width and the length of the panel. Thereafter, cutters (120, 150, 152) operated by the controller cut the quilted web material along the width and the length of the panel, thereby cutting the panel from the quilted material web.