Multi-Phase Trim Optimization for Grade Change Handling
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Solution Overview
Problem
Current methods for trim optimization in cutting processes can only address one or two subsequent cutting phases simultaneously and do not effectively consider grade changes, such as coating, leading to inefficiencies and increased trim waste in industries like paper, steel, and polymer production.
Innovation Solution
A method that optimizes subsequent treatment processes by determining processing data for semi-manufactured products across multiple phases, checking feasibility based on productive resources, and generating optimal cutting patterns to minimize trim loss and accommodate grade changes, implemented using software on a computer medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If current trim optimization methods are used for one or two cutting phases, then the optimization process is simple, but the trim waste increases and material efficiency decreases when more than two cutting phases are involved
Solution Approach 1:
The patent segments the cutting process into multiple distinct phases (first cutting phase, second cutting phase, etc.), where each phase can be optimized independently or in combination. This allows the system to handle complex multi-phase cutting operations by breaking them down into manageable segments, thereby reducing overall trim waste without overwhelming computational complexity.
Solution Approach 2:
The patent merges multiple cutting phase optimizations into a unified optimization framework that simultaneously considers first cutting phase, second cutting phase, and any intermediate phases. This integration allows the system to minimize total trim waste across all phases rather than optimizing each phase separately, achieving better material efficiency.
2Manufacturing precision
If grade changes like coating are considered during cutting process, then the production planning accuracy improves, but the calculation complexity and time increase
Solution Approach 1:
The patent performs preliminary actions by pre-defining grade changes (such as coating operations) and their associated parameters before the optimization calculation begins. This allows the system to account for grade changes in the optimization model without performing complex real-time calculations, thereby maintaining high production planning accuracy while reducing calculation time.
Solution Approach 2:
The patent incorporates grade changes as specific parameters in the optimization model, allowing the system to adjust cutting patterns and production planning based on these parameters. By treating grade changes as configurable parameters rather than complex constraints, the system achieves accurate production planning with improved computational efficiency.
3Productivity
If a step-wise process is used for trim scheduling with more than two cutting phases, then the computational load is reduced, but the overall optimization effectiveness and material efficiency decrease
Solution Approach 1:
The patent creates a universal optimization framework that can handle any number of cutting phases (first cutting phase, second cutting phase, and intermediate phases) within a single integrated model. This multi-functional approach eliminates the need for separate step-wise optimization processes, thereby improving overall optimization effectiveness while managing process integration complexity through a unified methodology.
4Manufacturing precision
If classical trim-loss methods based on Gilmore and Gomory are used, then the mathematical approach is well-established, but the geometrical position of end-customer products is not considered leading to suboptimal solutions
Solution Approach 1:
The patent applies local quality by considering the specific geometrical position and characteristics of each end-customer product within the cutting pattern. Rather than treating all products uniformly, the system optimizes cutting patterns based on the local requirements of each product, including their positions and orientations, thereby achieving higher cutting pattern precision while building upon established mathematical methods.
Data Source
AI summary
A method for optimization of subsequent treatment processes is developed. End products having end product data are generated from semi-manufactured products having semi-manufactured product data, and at least part of the semi-manufactured products are processed at least in three phases. The processing data for semi-manufactured products to be processed in the last phase are determined from the end product data, the processing data for the semi-manufactured products to be processed in the first phase are determined, the feasibility of the processing data for at least one intermediate phase is checked based on productive resources of the intermediate phase, and the optimal processing data for the first phase is determined and the processing data for the intermediate phase is generated.