Method for cutting cut parts, and cutting device
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Solution Overview
Problem
Existing cutting processes for materials like airbags result in excessive material waste due to the need for safety margins and inefficient nesting methods, particularly when cutting multiple layers simultaneously, leading to increased material consumption.
Innovation Solution
A method for cutting cut parts on a single-layer material web that optimizes the arrangement of cutting patterns and pieces by allowing partial placement within repeating sections, eliminating the need for safety distances at the ends of the material web and using a laser cutting device to minimize material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple material web layers are stacked and cut simultaneously with safety margins, then cutting efficiency is improved, but material waste increases significantly
Solution Approach 1:
The cutting process is divided into two independent stages: first, cutting individual layers with optimized nesting patterns, and second, stacking the cut pieces into multi-layer assemblies. This segmentation eliminates the need for safety margins between layers during cutting, as each layer is cut independently without risk of misalignment. The nesting algorithms can fully utilize material width without adding extra margins, significantly reducing material waste while maintaining high productivity through the stacking process.
2Manufacturing precision
If safety margins are added to material web ends for simultaneous multi-layer cutting, then cutting precision is improved, but material consumption increases by 0.5 to 1%
Solution Approach 1:
The material web is pre-marked with cutting patterns and alignment references before the cutting process begins. This preliminary marking enables precise positioning and cutting without requiring additional safety margins at the material ends. The nesting algorithms are designed to utilize the full material width by calculating optimal piece arrangements that account for the marked positions, ensuring high cutting precision while minimizing material consumption.
3Area of stationary object
If conventional nesting methods are used for rectangular material sections, then space utilization is improved, but material waste remains excessive due to safety clearances
Solution Approach 1:
The nesting algorithm dynamically adjusts the arrangement of cut pieces based on the available material width and required piece dimensions. Instead of using fixed rectangular sections with static safety clearances, the system calculates optimal piece positions and orientations to maximize space utilization. The algorithm can rotate, flip, and reposition pieces to fit irregular spaces, eliminating the need for uniform safety margins and reducing material waste while improving space utilization.
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
Significantly reduces material consumption by 0.5 to 1% by optimizing the nesting of cutting patterns and eliminating unnecessary safety margins, achieving efficient and precise cutting of complex shapes with minimal material waste.
Implementation Method 1
a laser beam is focused on the fabric and controlled by computer commands to move within the cutting area to cut a variety of patterns quickly and accurately
Data Source
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AI summary
The invention relates to a method (100) for cutting cut parts (1, 2, 3, 4, 5, 6; 12, 13, 14, 15, 16, 17, 18), wherein the cut parts (1, 2, 3, 4, 5, 6; 12, 13, 14, 15, 16, 17, 18) produce a cutting pattern (7), said method having the following method step: cutting (106) the cut parts (1, 2, 3, 4, 5, 6; 12, 13, 14, 15, 16, 17, 18), wherein the cut parts (1, 2, 3, 4, 5, 6; 12, 13, 14, 15, 16, 17, 18) are arranged in a rectangular, repeating portion (9, 9') of an endless single ply material web (19), wherein the portion (9) at least one cut part (1, 2, 3, 4, 5, 6; 12, 13, 14, 15, 16, 17, 18) or at least one cutting pattern (7) is contained in part (10, 11). The method additionally comprises a computer program product and a device for cutting by means of a cutting tool.