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COPRA®
DecalCutter: |
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| Precision Cutting of Ceramic Decals | ||||||||||||||||||||||||||||
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COPRA® DecalCutter with vision system Decals for the ceramic industry are usually printed on large-sized sheets of paper. However, this process requires the printed sheet to be cut into single transfers for further application on the whiteware. The COPRA® DecalCutter is a highly effective and accurate device for the cutting of decal transfers. It is the result of continuous development and improvement of proven manufacturing techniques using computer-aided technology and integrating vision systems. It allows one person to perform 5 manufacturing steps simultaneously: piling, perforating, separating and sorting/quality control. The COPRA® DecalCutter gets rid of a common problem other devices such as guillotines have: misplacement of the cutting line. It generates cutting curves of highest and repeatable accuracy – from the first cut. Considering a capacity of up to 35 printing sheets per minute, this device represents a very effective method of producing decal transfers.
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Cutting curves of an optimally used |
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Easy to Use |
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The user interface of the integrated AutoCut software is very user-friendly. Even unexperienced persons are able to operate the device successfully. Operating the COPRA® DecalCutter does not require any specialized computer knowledge.
In the unlikely case of malfunctions, your data M service technician is able to log into your COPRA® DecalCutter System via a remote service module which is optionally available. He will track the error quickly by using a wide range of checking functions. This will reduce possible down-times to a minimum. |
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Digitising the cutting lines |
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A printed sheet with decal transfers is laid on the desk. The operator sketches the cutting lines on a transparent piece of paper
lying on top and starts the scanning process.
An integrated vision system automatically scans the whole paper sheet. Optimum cutting curves are calculated automatically by the control unit. |
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Sketching the cutting |
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Scanning the lines and |
Perforating the |
Stackpiling |
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More than 600 sheets per hour |
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After the scanning process, up to 35 sheets can be fixed pneumatically on the cutting desk. Considering a typical stitch distance of 1,3mm that is kept constant and independent of the feeding speed, the perforation head reaches a speed of 130mm/s.
Depending on the length of the cutting lines the decals can be taken off after 1-2 minutes in blocks and the desk can be charged with a new stack of transfers. The perforation head can now immediately start with the perforation process as the cutting curves have already been |
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High Precision Cutting |
| The enormous advantage of using COPRA® DecalCutter for the production of ceramic decals lies in its high efficiency and accuracy. The tracking curve data that are scanned and stored in the control unit during the first run are sent to the perforation unit with a neglectable tolerance of ± 0,2mm. |
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Based on the knowledge of image processing systems and mechanical engineering, a decal cutting machine has been developed to assist the decorating process. Modern transfer application machines have started to become more popular and required precisely cut decals. This requirement could be solved by data M´s Engineering's decal cutting machine which was showed in a redesigned version at the Ceramitec 97-show in Munich. Although the first type of machine has been very successful - about 20 machines have been installed in different parts of Europe - a new and upgraded type can cut about 70% faster than its predecessor. This means a quick payback of investment while still giving accurately perforated decals. The working principle is both simple and effective.
Perforated decals. Programming the machine is simple operation and a windows-based control unit is used:
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The cutting programmes are stored on a personal computer and can be recalled whenever required. The CNC-control unit gives a constant stitch distance by synchronising the perforating unit with the linear actuators. In addition data M Engineering provides its customers with software development for man/machine interfaces, design and manufacturing of special-purpose machines as well as image processing systems for quality control and production processes. At their office in Taufkirchen south of Munich, data M uses modern tools for software development and machine design. The use of 3D design systems allows prototypes to be visualised and design to be optimised before parts are machined. Because of the significant growth in business the company is planning to move into larger facilities end of this year.
2 views of Decal Cutting Machine (with video camera on the top and perforating unit)
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Fast Facts : Copra® DecalCutter |
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Technical Data: Copra® DecalCutter | |||||||||||||||||||||||||||||||||
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data
M Engineering GmbH . Am
Marschallfeld 17 . D-83626 Valley/Oberlaindern, Germany |
The cutting machine detects the contour to be perforated using a built-in camera and
perforates it automatically. The perforating unit can be moved in the XY-plain and is
capable of cutting complex shapes and up to 50 sheets can be cut simultaneously without
the need of stapling.
