Multi-sided Stone Panel Cutting via Segmented Water Jet and Blade Processes
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Solution Overview
Problem
Conventional methods for manufacturing multi-sided stone panels using water jets are inefficient, with high machining times, high defect rates, significant scrap generation, and high costs due to the need for individual cutting of each panel, which limits market demand and production efficiency.
Innovation Solution
A method involving separate vertical and lateral cutting processes, where continuous linear patterns are cut using a water jet device in a vertical direction and rectilinear lines are cut using a blade cutter on a lateral device, allowing for reduced cutting time, flexible operation modes, and minimized scrap generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a nesting machining method using a water jet is used to cut multi-sided stone panels individually, then the panels can be cut with continuous linear patterns, but the machining speed is slow (0.3 meters per minute for 20mm granite) and machining time is long
Solution Approach 1:
The cutting process is divided into two independent stages: first, a water jet device cuts continuous linear patterns vertically; second, a blade cutter cuts rectilinear lines laterally. This segmentation allows each device to specialize in its optimal cutting type, with the water jet creating precise continuous patterns and the blade cutter providing fast straight cuts, thereby resolving the contradiction between pattern quality and machining speed.
Solution Approach 2:
The invention merges two different cutting technologies (water jet cutting and blade cutting) into a single manufacturing system. The water jet device handles the continuous linear pattern cutting while the blade cutter handles the rectilinear line cutting, combining their advantages to achieve both high precision patterns and high productivity that neither method could achieve alone.
2Shape
If cornering work is performed on multi-sided stone panels using conventional methods, then the panels can be shaped with multiple sides, but the corner is easily damaged and the defect rate increases
Solution Approach 1:
Instead of using a single water jet to cut all sides including corners (which causes corner damage), the invention inverts the approach by using a blade cutter for the lateral cuts that form corners. The blade cutter's ability to make clean straight cuts without the erosive action of water jet prevents corner damage while still achieving the desired multi-sided geometry.
3Adaptability or versatility
If individual cutting of each multi-sided stone panel is performed using conventional water jet methods, then each panel can be customized, but a large quantity of remnants (scraps) is generated
Solution Approach 1:
The water jet device first cuts continuous linear patterns that define the panel boundaries and patterns before the blade cutter makes the final rectilinear cuts. This preliminary action by the water jet creates precise guide lines and initial separations, allowing the blade cutter to follow exact paths and minimize material waste while maintaining customization capability.
4Ease of manufacture
If conventional water jet cutting is used for multi-sided stone panels, then the panels can be manufactured, but the cost is high and efficiency is low
Solution Approach 1:
The system is designed so that the water jet device automatically cuts continuous linear patterns and the blade cutter automatically follows with rectilinear line cutting, with both operations guided by pre-programmed paths. This automated self-service operation eliminates manual intervention for each cut, dramatically improving production efficiency while maintaining manufacturing capability for customized panels.
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
This approach reduces cutting time, enables rapid loading and unloading, allows for automatic or manual operation, minimizes defects, and facilitates mass production with reduced scrap generation, thereby improving production efficiency and product quality.
Implementation Method 1
cutting out stripes in which continuous linear patterns are formed on both sides thereof by cutting an original plate along successively repeated linear paths (continuous linear patterns) while moving a water jet device in a vertical direction
Implementation Method 2
cutting out multi-sided continuously patterned stone panel products in which continuous linear patterns are formed on both sides thereof and the remaining two sides thereof are cut in rectilinear lines by cutting the stripe with a blade cutter, installed on the frame of a lateral cutting device, in rectilinear lines in a lateral direction
Data Source
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AI summary
A method for manufacturing a multi-sided continuously patterned stone panel according to the present invention includes: cutting out stripes (116) in which continuous linear patterns are formed on both sides thereof by cutting an original plate (110) along successively repeated linear paths (continuous linear patterns) (112) while moving a water jet device (120) in a vertical direction; separating the separate stripes (116), and loading each of the separate stripes (116) on a lateral cutting device (130); and cutting out multi-sided continuously patterned stone panel products in which continuous linear patterns are formed on both sides thereof and remaining two sides thereof are cut in rectilinear lines by cutting the stripe (116) with a blade cutter (134), installed on a frame (132) of a lateral cutting device (130), in rectilinear lines in a lateral direction.