CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to United States Provisional Application No. 63/248,092 which was filed on September 24, 2021, and is incorporated herein by reference.

TECHNICAL FIELD

[0002] The disclosure relates to a material cutting press and method. More particularly, the disclosure relates to a press for cutting material such as vinyl, leather or fabric for automotive interiors or other upholstery applications.

BACKGROUND

[0003] There are numerous machines available for cutting vinyl, leather, and other materials for the automotive industry, for example. For example, laser cutting machines, knife cutting machines, press cutting using dies, and waterjet cutting all may be used for such materials. Common issues for many of these technologies are the cutting operation is relatively slow or the technology is old and inefficient.

SUMMARY

[0004] In one exemplary embodiment, a material cutting machine includes a conveyor system that is configured to longitudinally transport a board supporting material to a press operation area. The machine further includes a frame that supports a transfer beam over the press operation area, a tool rack system that is configured to store multiple tools that are adjacent to the press operation area, and a press that is slidably supported for lateral movement on the transfer beam. The press is configured to support a die cutting tool. The press includes a rotary tool drive that is configured to change an angular orientation of the tool relative to the material. The press has an actuator that is configured to extend the tool toward the board to cut the material. The machine further includes a tool changer that is configured to exchange the tools between the tool rack system and the press. [0005] In a further embodiment of any of the above, the frame includes a bridge assembly that is arranged over the press operation area. The press is configured to engage the material with the die cutting tool while reacting a portion of the die cutting tool against the bridge assembly during a cutting operation.

[0006] In a further embodiment of any of the above, the frame includes lateral beams that support a table that is arranged in the press operation area. The board is configured to support the board during the cutting operation.

[0007] In a further embodiment of any of the above, the conveyor system includes a feed conveyor and a return conveyor that are respectively arranged before and after the press operation area. Multiple boards are configured to move from the feed conveyor to the return conveyor.

[0008] In a further embodiment of any of the above, the conveyor system includes a central convey that is arranged between the feed and return conveyors and beneath the press operation area. The feed and return conveyors are configured to move vertically between the press operation area and the central conveyors.

[0009] In a further embodiment of any of the above, the frame includes fixed supports to which the transfer beam is mounted.

[0010] In a further embodiment of any of the above, the transfer beam is mounted to supports. The supports are movable longitudinally through the press operation area.

[0011] A method of cutting patterns of material with a die includes conveying material relative to a press operation area, laterally positioning a press over the material to a desired location, rotating a die cutting tool to a desired orientation relative to the material, advancing the die cutting tool to cut a pattern from the material, laterally moving the press to a tool rack system, and automatically exchanging the die cutting tool for another die cutting tool that has another pattern and that is arranged on the tool rack system.

[0012] In a further embodiment of any of the above, the material conveying step is performed in the X-direction, the press laterally positioning step is performed in the Z- direction, the die cutting tool rotating step is performed about the Y-direction, the die cutting tool advancing step is performed in the Y-direction, and the press laterally moving step is performed in the Z-direction. [0013] In a further embodiment of any of the above, the die cutting tool exchanging step is performed in the X-, Y- and Z-directions, and each of the steps of the method are fully automated.

[0014] In a further embodiment of any of the above, the material conveying step includes conveying a board that supports the material onto a table that is arranged in the press operation area.

[0015] In a further embodiment of any of the above, the press laterally positioning step and the die cutting tool rotating step are performed to arrange the die cutting tool above a defect-free portion of the material.

[0016] In a further embodiment of any of the above, the die cutting tool advancing step includes engaging the material with the die cutting tool while reacting a portion of the die cutting tool against a bridge assembly that is arranged over the press operation area.

[0017] In a further embodiment of any of the above, the method includes a step of advancing the material beneath the die cutting tool to another die cutting position subsequent to performing the die cutting tool advancing step.

[0018] In a further embodiment of any of the above, the method includes a step of advancing the die cutting tool over the material to another die cutting position subsequent to performing the die cutting tool advancing step.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The disclosure can be further understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0020] Figure 1 is a front perspective view of a material cutting machine with the material arranged prior to being fed into the machine by the operator.

[0021] Figure 2 illustrates the machine with the material being examined by a vision system while being fed into a press operation area.

[0022] Figure 3 illustrates a side perspective side view of the machine showing a press with a die cutting tool arranged on a transfer beam.

[0023] Figure 4 is an enlarged view of the press illustrated in Figure 3. [0024] Figures 5A-5C are respectively first and second perspective views and a cross-sectional view through the press shown in Figure 4.

[0025] Figure 6 illustrates a portion of a conveyor system used to transfer a board supporting the material into and out of the machine at a lowered position.

[0026] Figure 7 illustrates a locating system for locating the board with respect to the press.

[0027] Figure 8 is a front view of the machine shown in Figure 1.

[0028] Figure 9 illustrates a perspective side of the machine depicting a portion of the tool rack system and the return conveyor.

[0029] Figure 10 is a perspective view of the tool rack system, and also illustrating X-, Y- and Z-directions.

[0030] Figure 11 is a perspective view of a tool changer used to transfer a tool from the tool rack system to the press.

[0031] Figure 12 is an enlarged perspective view of the tool changer transferring a tool between the tool changer and the tool rack system.

[0032] Figure 13 is a bottom perspective view of an example tool.

[0033] The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible. Like reference numbers and designations in the various drawings indicate like elements.

DETAILED DESCRIPTION

[0034] An example material cutting press is illustrated in Figures 1 and 2. The machine 10 includes a conveyor system 12 that transfers a board 14 supporting material 16 into and out of the machine 10 for cutting. In the example, there are multiple boards 14 used in the system 12, e.g., three. In one example, the material 16 can be vinyl, leather or other materials, such as woven fabrics. The material 16 may be provided in a single layer or stacked in multiple layers depending upon the type of material. [0035] The machine 10 includes a frame 18 having vertical pillars 20 supporting a bridge assembly 21. The bridge assembly 21 includes longitudinal beams 23 rigidly supporting a plate 25. The bridge assembly 21 may serve as a reaction surface for a press 30, which will be appreciated from the description below. Other reinforcements to the plate 25 may be provided, if desired, to enhance the rigidity of the bridge assembly 21 The press 30 supports a material cutting die that has a shape of a pattern to be cut from the material 16.

[0036] The conveyor system 12 includes a feed conveyor 12a that feeds the board 14 and its material 16 through a vision system that includes one or more cameras 22. The camera(s) 22 scan the material 16 as it passes into the machine 10 to a press operation area beneath the bridge assembly 21. The cameras 22 are in communication with a controller (not shown), which uses image processing to inspect the material 16 to determine its shape and locations of any defects, which are used in determining where to position the tools 26 to cut the material in the most efficient manner and devoid of defects.

[0037] A tool rack system 24 is provided adjacent to the board 14 supporting the material 16 beneath the bridge assembly 21. The tool rack system 24 holds various die cutting tools 26 having cutting dies shaped to provide patterns of cut material for the particular application, such as various panels of a seat cover. A tool changer 27 transfers the tools 26 between the press 30 and the tool rack system 24. In one example, multiple presses 30 are used to speed operation. In such cases, it may be desirable to provide a tool rack system on either side of the machine, one tool rack system 24 for each press 30. Although two presses are shown in the Figures, only one tool rack system is shown for simplicity.

[0038] The machine 10 is automated such that once the material is loaded onto the conveyor by an operator, the machine will automatically feed the material into the press operation area beneath the bridge assembly 21, maximize material usage by determining where to locate and orient each cutting tool, automatically load and unload tools onto the press, diecut the material with the tools, and unload the material from the press operation area when the cutting operation has been completed.

[0039] Referring to Figure 3, the machine 10 includes a table 28 for supporting the board 14 during the cutting operation of the material 16. Beams 80 are arranged below the table 28 to counteract the forces from the press 30 during the pressing operation (performed in Y- direction). A transfer beam 32 is arranged laterally (Z-direction) above the table 28 and supports one or more presses 30 that are moved along the transfer beam 32 to the desired location. The transfer beam 32 is supported at either end by a support 34 that rides along rails 36 in response to transfer beam drive 38. Thus, the transfer beam 32 can move longitudinally (X-direction) over the material 16, while the presses 30 can move laterally (Z-direction) over the material 16. X-, Y-, Z-axes, which are indicative of directions, are also shown in connection with the tool rack system 24 shown in Figure 10.

[0040] Referring to Figure 4, the transfer beam 32 includes a transfer beam rail 40 arranged on one side of the transfer beam 32 to carry both presses 30. However, it should be understood that the presses 30 may be arranged on opposite sides of the transfer beam if desired. The presses 30 are supported on the transfer beam rails 40 by guide blocks 44, which may incorporate the press drive mechanism 42 (shown schematically) for moving the presses 30 along the transfer beam rails 40. In one example, the press drive mechanism 42 is a linear motor having a primary component that rides one the tool slide and a secondary component that provides sections along the tool slide. Such systems are available from Siemens, for example.

[0041] Referring to Figures 5A-5C, the cutting tools 26 must be adjustable about their axes so that the dies can be oriented as efficiently as possible with respect to the contours and defects of the material 16. Accordingly, a rotary tool drive 46 is supported on the guide block 44. The rotary tool drive 46 includes a motor 48 having a drive gear 50. The drive gear 50 meshes with a driven gear 52 that is affixed to a rod 62 that supports a tool holder 64. The rod 62 is arranged for rotation with respect to a shaft 63 that is slidable supported by bushings in the guide block 44 (Fig. 5C).

[0042] A linear actuator 60 is connected to an end of the rod 62 opposite the tool holder 64. A bracket 54 supports a bridge 56 having a reaction flange 58. A bracket 54 supports a vertical slide (there is a spacer, not shown, between 54 and 56) which supports the reaction flange bracket 58. During pressing the reaction bracket 58 is allowed to extend until it contacts the overhead bridge assembly 21, particularly the plate 25, such that the bracket 58 is reacted by the bridge 56. During a pressing operation, the linear actuator 60 extends in the Y-direction to advance the tool 26 toward the material 16. During extension, the reaction flange 58 may abut the overhead bridge assembly 21, particularly, the plate 25. [0043] The tool holder 64, which supports the tool 26, cooperates with a quick- change assembly 66 having a release flange 72, which cooperates with the collar 68 on the tool holder. The collar 68 may include balls that selectively cooperate with an annular groove 70 in a stem 132 of the tool 26 (Fig. 12) to temporarily lock the tool in the tool holder 64. The release flange 72 cooperates with the collar 68 and is movable in the Y-direction in response to operation of a quick-change actuator 74 that translates movement via a rod 76 through slides 78 slidably received in the guide block 44. In particular, the spring-loaded collar 68 is actuated by the release flange 72. The collar 68 grips the tool via a set of balls (not shown) within the collar 68. The balls engage the tool via the groove 70 (Fig 12). The balls are released when release flange 72 is actuated. The release flange 72 works in conjunction with the tool holder 64, however, it may be part of the tool changer assembly instead. The movement locks and unlocks the tool 26 to the tool holder 64.

[0044] Referring to Figures 6 and 7, another example machine 10 is shown, which includes a more compact frame 18'. In this example machine, the transfer beam 32 is fixed with respect to the frame 18'. Fewer support beams 80 are needed beneath the table 28 to provide a lower reaction surface. A belt drive system 82 moves the board 14 longitudinally between the longitudinally fixed transfer beam 32 in order to position the tools 26 with respect to the material 16 in the longitudinal, X-direction rather than moving the transfer beam 32. The belt drive system 82 includes rails 84 that slidably support guides 86. The guides 86 include a bracket 88 having a locator 90 that clamps the board 14 relative to a feature 92 to maintain positioning of the board 14 and its supported material 16 during the pressing operation as the belt drive system 82 moves the material 16 for die cutting.

[0045] Referring to Figures 6, 8 and 9, the conveyor system 12 can be seen in more detail. The feed conveyor 12a and return conveyor 12c are movable vertically from feed and return positions using a linkage system 13. A central conveyor 12b remains at a fixed position below the beams 80 in one example. The belt drive system 82 transfers the board 14 between the feed and return conveyors 12a, 12c when those conveyors are raised and operating.

[0046] The feed and return conveyors 12a, 12c are raised to transfer the boards 14 in and out of the machine 10 during the pressing operation. Once the material 16 and its die cut pieces have been removed from the board 14 at the return conveyor 12c, the return conveyor 12c is lowered to feed the board 14 beneath the beams 80 back to the feed conveyor 12a, which is in its lowered position as well. The feed conveyor 12a can then be raised again with its board 14 so the operator can load new material 16 onto the board 14 for cutting.

[0047] Referring to Figure 8, one tool rack system 24 is shown supporting various tools 26 having different die shapes. The tool changer 27 is mounted on the rack and movable in X- and Y- directions for transferring the tools 26 between the tool rack system and the presses 30 to speed operations.

[0048] Referring to Figure 10, the tool rack system 24 is constructed from a framework 94 of universal, readily available construction elements, for example. The framework 94 includes vertical and horizontal rails 96, 98 that are rigidly secured to one another. The tool changer 27 is supported by a cross member connected to vertical slide assemblies 104 arranged on opposing vertical rails 96. Operation of a vertical drive 100 moves the cross member up and down in the Y-direction. A horizontal drive 102 removes the horizontal slide assembly 106 that supports the tool changer 27 in the longitudinal X-direction. Tool racks 108 are joined to opposing vertical rails 96 to support various stationary tool holders 110 upon which the tools 26 are mounted.

[0049] An example tool changer 27 is illustrated in Figure 11. The tool changer 27 includes a post 112 mounted to the horizontal slide assembly 106. The post supports a plate 114 having an elongated window 116. An arm 118 is supported by an actuator 128' that is arranged within the window 16. The actuator 128 rotates the arm 118 180° during tool change operations. Opposing ends of the arm 118 each include a tool gripper 120 having opposing fingers 122 biased toward one another by a spring 124. The fingers 122 clamp about a stem 132 of the tool 26 (Fig. 12), but the stem 132 can be pulled from the tool gripper 120 once the tool 26 is mounted in the tool holder 64 or stationary tool holders 110.

[0050] The actuator 128 is supported relative to the plate 114 and its elongated window 116 by slides 126. A second actuator 130 moves the first actuator 128 and its supported arm 118 laterally in the Z-direction so that the tool gripper 120 can move the tool 26 into and out of the stationary tool holder 110 and immediately beneath the tool holder 64 on the press 30. The rotary actuator 128 is supported via a slide 126 which is attached to plate 114. The horizontal slide 126 is pneumatically operated. The rotary actuator 128 may be provided by a servo motor to ensure accuracy. [0051] Referring to Figure 12, the stem 132 of the tool 26 is shown in more detail. The stem 132 includes the annular groove 70, as previously described, for selectively interlocking with the tool holder 64 and its quick-change assembly 66. One end of the stem 132 includes splines 134 that rotationally affix the stem 132 to the tool holder 64 so that the tool 26 can be rotated in response to the rotary tool drive 46 to its desired orientation. The stem 132 includes a neck 136 provided between upper and lower collars 135, 137. The tool gripper 120 grips the neck 136 between the upper and lower collars 135, 137 leaving the splines 134 exposed for the tool holder 64. An annular space is provided beneath the lower collar 137 for being received in a mouth 138 of the stationary tool holder 110.

[0052] Referring to Figure 13, the tool 26 may include a stripper plate 142 that is movable with respect to its supporting structure to strip the cut material from the die 148, which is arranged at an opening 146 of the stripper plate 142. The stripper plate 142 reacts against springs 144.

[0053] It should also be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will benefit herefrom. Although particular step sequences are shown, described, and claimed, it should be understood that steps may be performed in any order, separated or combined unless otherwise indicated and will still benefit from the present invention.

[0054] Although the different examples have specific components shown in the illustrations, embodiments of this invention are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples.

[0055] Although an example embodiment has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of the claims. For that reason, the following claims should be studied to determine their true scope and content.