Zebra

Video
Application
Software
Process
Manufacturing process

Application

Patterned or motive printed textiles are by far not regular in the cause of a fabric roll. Distortions can run straight line to a curve, the repeat size of pattern varies within the roll. The cut-order (marker) needs imput of the actual course of the pattern with its distortions and irregularities (skew & bow). This happened in the past not automaticly. Not only the visual power of humans judgment was needed by interaction, but also a great expense of technology (hardware/software), often combined with a limitation of matching methods.

Software

ZEBRA creates by a new developed image recognition the premise to replace the intervention of man. This means that with ZEBRA in almost all practical applications of pattern-matching cut automatic processes can be realized in industries like apparel, automotive, upholstered furniture, promotional products. Pattern sizes (within the fabric working width) does not matter. All methods ofmatching processes can be executed by ZEBRA.

Matching of the 3rd generation

ZEBRA optimizes components. Besides a camera (scanner) the system consists of software, the conveyor tables with cradle for material entry and discharge and the cutting-system. The workflow was designed that way, that the capacity of the cutter is fully exploited and thus determines the capacity level of the production plant.

Process

The „matching process“ takes place automatically and in parallel to the cutting processes. Thereby ZEBRA reaches maximum productivity in system and user. The entire system can be offered in a launch configuration for individual orders and small series and is also - if required - scalable. Thus ZEBRA can be upgraded to meet capacity requirements afterwards.

The Marker

ZEBRA expects a cut-order (marker) in which the single patters are layout in accordance with an average pattern repeat of the processed fabric so that the ready cuts will fit together to a predetermined appearance in the finished product. The data-transfer (markers) takes place via standardized interface formats (AAMA, ASTM, ISO), which every modern CAD system can provide today. The naming-convention of the orders can - optimally used - automatically configure many system settings already when reading in. For large series ZEBRA offers the possibility to automatically select from a pool of markers with the best patternrepeat approach to the present fabric in use.

The manufacturing process

1 ZEBRA requires no further preparation to process the material to cut. The patterned flat material (e.g. as fabric) is drawn directly from the edge-controlled cradle into the manufacturing process.

2 During the feed-in the fabric passes through the scanner. The entire area is recognized for one cutting-window and then analyzed using a hightech image recognition software to compute a pattern grid according to the actual running pattern. This grid can be determined by defining a pattern repeat or by combining several pattern units to a group. The use of color-filters (software) when using low-contrast pattern recognition can be effectively controlled via parameters. This creates a high level of detection reliability. Slightly wavy fabrics ZEBRA can compensate to scale.

3 The cut-order is optional read in via barcodes. The associated marker (with cut parts/pieces) will be adjusted in the 1st cutting window automatically to the current pattern image (stripes, checks, distinctive pattern). The individual pieces/pattern can be edited in the position (x, y, tilt and rotation), which may be of advantage in case of large printed patterns. It also displays internal lines of pattern. All positional changes in the marker ZEBRA transfers depending on the local pattern repeat image in real time onto the geometry of the cut parts.

4 The first material (fabric) segment is conveyed into the cutting window and automatically perfectly cut in accordance with the pattern flow of the fabric. Here, the scanner captures at the same time the next material segment and ZEBRA analyzeses the new pattern history. If long markers are processed they will be cut in sections corresponding to the cutting window size. If the end of the marker is reached an automatic separating cut is performed which can be aligned to the fabrics pattern. Thus a bale change can take place during cutting. The cutting path is automatically optimized in order to achieve the best possible use of the cutter capacity and cutting quality. The system monitor displays all processing stages and the course of cutting operation in real time.

As the process continues ZEBRA feed-out the cut pieces in the sorting area. At the same time the next cutting window is loaded and a new fabric segment is scanned. By this process of overlapped operations ZEBRA achieves, including staffing, the highest productivity.

Material supply with edge control
Material is detected automatically when passing the scanner
Buffer zone: The material image is interpreted, the marker adapted
Automatic cutting of the pattern aligned marker
Sorting. Optional: Pick-up can be software supported All sub-processes run parallel in time!