Page 276 - Industrial Cutting of Textile Materials

Automated single-ply processing of styles from intricate pattern textiles 263

Fully automated systems use separate scanning cameras fixed on the cutter
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(VisionCut by Gemini, ContourVision by Gerber, ‘Simulate, Print & Cuť by Zund,
and others). As the cutter feeds the fabric, the cameras scan its pattern and send the im-
age to the pattern-matching software. The software recognizes printed contours (iden-
tifies areas of contrast between the pattern pieces to be cut and a rest of the fabric)
or picks up fiducial marks. The actual position and dimensions of the printed shapes
are thus recognized and taken into account for further processing. The identification
and matching of the printed shapes is fully automatic. It can also be supervised on
the screen during the process. The cutting is started in real time immediately after the
image is processed, not creating/using a marker. Fully automated processing ensures
continuous cutting of a fabric fed from a material roll.
The hardware and software components of the pattern-matching system can
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be installed on any single-ply conveyor cutter (VisionCut system by Gemini ) or
are a part of the ‘scan-to-cuť system (ContourVision system with a cutter Z1 by
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Gerber ).
16.4.5 Auxiliary tools to ease pattern-matching process

Several new auxiliary tools are developed to ease and speed up the pattern-matching
process. Some of them are used in manual pattern matching, but others are used to
perform semiautomated and fully automated pattern matching.

16.4.5.1 Grid representing fabric pattern
Grid as a representative of the ideally placed fabric pattern can be projected on the
fabric ply by help of overhead projector. It helps to align pattern of the top fabric ply
creating multi-ply spreads (see Section 15.3.1.2).
Grid, as the only representative of the fabric pattern, can be created and used
matching striped and checked patterns on PC screen. In this case, the pattern pieces
are placed in the marker in accordance with the lines of the grid.
Grid also can be used to represent the repeat of the pattern and to determine posi-
tion (coordinates) of the fabric ply on the cutting surface. Firstly, the fabric ply laid
on the cutting table is scanned or photographed to get its image on PC screen. Then,
the grid is created above the image to show separate repeats of the pattern and to see
clearly the distortions of the fabric ply structure/design. In creating a maker in a semi-
automated way, pattern pieces are placed on the image of the fabric ply, following grid
lines representing imperfect fabric structure/design on the cutting table.

16.4.5.2 Fiducial marks (registration marks)
In cutting textiles with large patterns/images placed in their area, the accurate place-
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ment of the components can be determined by use of fiducial marks printed on the
fabric. By the help of a CCD camera, installed directly in the cutting head of the cutter,
the fiducial marks are identified and measured. Following their placement, the pattern
pieces are centred, scaled, and slightly distorted to perform their further precise cut-
ting in accordance with the fabric pattern.