Shape Packing Technique Using Block Grouping for Print Production
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Solution Overview
Problem
Existing rectangular packing algorithms are slow and result in inefficient solutions, leading to increased processing time and material waste in applications like print production and manufacturing.
Innovation Solution
The technique involves pre-grouping items of similar size into 'blocks' and using a two-dimensional dynamic programming approach to recursively fill a target shape, avoiding redundant areas of the solution space and optimizing guillotine cuts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing rectangular packing algorithms place individual items and resolve cutting implications, then a solution is determined, but processing time increases and solution efficiency decreases
Solution Approach 1:
The patent segments items into blocks based on their dimensions and grouping characteristics. Instead of processing individual items separately, the algorithm groups compatible items into blocks that can be placed together, reducing the number of placement decisions and cutting operations required. This segmentation approach directly addresses the slow processing speed by reducing the computational complexity of the packing problem.
Solution Approach 2:
The patent performs preliminary actions by pre-processing items to determine their block assignments before the actual packing process. The algorithm calculates which items can be grouped together into blocks in advance, and prepares the cutting patterns that will be needed. This preliminary preparation eliminates the need to resolve cutting implications during the placement phase, significantly reducing processing time.
2Manufacturing precision
If existing algorithms determine optimal placement by exploring all possible placements, then a solution is found, but the quality of solution decreases with increased material waste
Solution Approach 1:
The patent merges multiple items into blocks that are placed together as unified units. By combining compatible items into blocks with optimized dimensions, the algorithm reduces the number of separate placements and minimizes the gaps between items. This merging approach improves solution quality by creating more compact arrangements and reducing material waste compared to placing individual items separately.
Solution Approach 2:
The patent introduces a new dimension to the packing problem by working with blocks rather than individual items. This dimensional change allows the algorithm to operate at a higher level of abstraction, where each block represents multiple items. The block-based approach enables more efficient exploration of the solution space and leads to better packing arrangements with reduced material waste.
3Ease of manufacture
If existing guillotine packing algorithms place one item at a time, then placement is simple, but the number of cuts increases leading to higher production costs and equipment wear
Solution Approach 1:
The patent combines multiple items into blocks that are placed as single units. This merging of items into blocks reduces the total number of placement operations required. Since each block placement typically requires fewer cuts compared to placing individual items separately, the overall number of cuts is reduced, lowering production costs and equipment wear while maintaining manufacturing simplicity.
Solution Approach 2:
The patent segments the packing process into two main phases: block formation and block placement. This segmentation allows the algorithm to handle complexity in the block formation phase and simplicity in the placement phase. By pre-grouping items into blocks, the placement phase becomes simpler and requires fewer cuts, improving productivity without sacrificing ease of manufacture.
Data Source
AI summary
A shape packing technique is introduced that can be applied in various applications such as automated print production. In an example embodiment, items that are to be placed into a target shape are sorted based on size to form item groups that include similarly sized items. Potential blocks including arrangements of one or more items are created from the sorted item groups. A placement solution is then generated by placing the potential blocks in the target shape using a recursive process that avoids redundant placement solutions until all of the potential blocks are placed or no other potential blocks are able to be placed. The placement solution can then be utilized, for example, to control a printer to print multiple images on a substrate and/or to control an automated cutting device to cut the substrate into multiple partitions according to the placement solution.