METHOD FOR MEASURING A THICKNESS OF A FILM OR PLATE, SYSTEM FOR MANUFACTURING A FILM OR PLATE OF THIS TYPE, AND METHOD FOR OPERATING A SYSTEM OF THIS TYPE

Abstract

The invention relates to a method for measuring a thickness (d) of a film (90) or sheet (90), wherein the film (90) or sheet (90) is cut as an article of manufacture made from a block material intended as a source material (80), in particular, from a block of foam. The source material has a source-material length (81, 85) extending in the longitudinal direction (x; x), a source-material width extending in the latitudinal direction (y) (82, 86) and a source-material height extending in the vertical direction (z) (83, 87). In this method, the source material is conveyed along the longitudinal direction (x; x) to a cutting unit (50) in order to cut the source material. The cutting unit (50) cuts the film (90) or sheet (90) out of the source material along the longitudinal direction (x; x). In addition, in order to determine the thickness (d) of the film (90) or sheet (90), the thickness (d) along the vertical direction (z) is determined. Furthermore, the invention relates to a system for manufacturing a film (90) or sheet (90), as well as a method for operating such a system.

Claims

1. Method for determining a thickness (d) of a film (90) or sheet (90) made of foam, wherein the film (90) or sheet (90) is cut as an article of manufacture from a foam block (80) provided as a source material, wherein the source material has a source-material length (81, 85) extending in the longitudinal direction (x; x), a source-material width (82, 86) extending in the latitudinal direction (y) and a source-material height (83, 87) extending in the vertical direction (z), wherein: for cutting the source material, the source material is conveyed along the longitudinal direction (x; x) to a cutting unit (50) and the cutting unit (50) cuts out the film (90) or sheet (90) from the source material along the longitudinal direction (x; x), and wherein: to determine the thickness (d) of the film (90) or sheet (90), the thickness (d) along the vertical direction (z) is determined, characterized in that the thickness (d) of the film (90) or sheet (90) is determined in that: a measured value representing a preliminary source-material height (83; 87) before cutting the source material and a measured value representing a subsequent source-material height (87) after the source material has been cut are measured, and the thickness (d) of the film (90) or sheet (90) is determined from the difference between the measured value representing the preliminary source-material height (83; 87) minus the measured value representing the subsequent source-material height (87).

2. Method for determining a thickness (d) of a film (90) or sheet (90) according to claim 1, characterized in that the preliminary source-material height (83; 87) and the subsequent source-material height (87) are measured by a measurement device (60, 64, 65, 66, 67, 70, 71), preferably an optical measurement device, in particular, with regard to the longitudinal direction (x; x) and latitudinal direction (y) at the same measurement-target point.

3. System for manufacturing a film (90) or a sheet (90) made of foam as an article of manufacture made from a foam block (80) provided as a source material, in particular, from a foam block, wherein the source material has a source-material length (81, 85) extending in the longitudinal direction (x; x), a source-material width (82, 86) extending in the latitudinal direction (y) and a source-material height (83, 87) extending in the vertical direction (z); with: a conveyor unit (30) for conveying the source material along the longitudinal direction (x; x), with a cutting unit (50) for cutting out the film (90) or the sheet (90) from the source material along the longitudinal direction (x; x), with a blade bar with a circumferential blade or oscillating blade and with a measurement device (60, 64, 65, 66, 67, 70, 71) for measuring on a surface of a measurement object, wherein the conveyor unit (30) is set up in such a way that, in order to cut the source material, the source material is conveyed along the longitudinal direction (x; x) past the cutting unit (50), characterized in that the measurement device (60, 64, 65, 66, 67, 70, 71) is set up and arranged for measuring the source-material height (83, 87) in such a way that the measurement device (60, 64, 65, 66, 67, 70, 71) can measure a preliminary source-material height (83; 87) before cutting the source material and a subsequent source-material height (87) after cutting the source material wherein the systems further comprises a control unit, whereby the control unit determines the thickness (d) of the film (90) or sheet (90 from the difference between the measured value representing the preliminary source-material height (83; 87) minus the measured value representing the subsequent source-material height (87).

4. System for manufacturing a film (90) or a sheet (90) according to claim 3, characterized in that a linear machine table is provided which comprises the conveyor unit (30) and is set up for the support of the source material, and that the conveyor unit (30) is set up on the support side of the linear machine table in a reversing manner along the longitudinal direction (x) and back against the longitudinal direction (x).

5. System for manufacturing a film (90) or a sheet (90) according to claim 3, characterized in that a rotary table is provided, which comprises the conveyor unit (30) and is set up for the support of the source material, wherein the conveyor unit (30) is designed as a circumferential contact surface (21) of the rotary table and is set up to be circumferentially moveable along the longitudinal direction (x).

6. System for manufacturing a film (90) or a sheet (90) according to claim 3, characterized in that a central roller (40) is provided to receive the source material formed as a round block, and that the conveyor unit (30) is formed by the central roller (40) in such a way that the central roller (40) can be driven in the direction of rotation for conveying the source material.

7. System for manufacturing a film (90) or a sheet (90) according to claim 3, characterized in that the measuring device (60, 64, 65, 66, 67, 70) is arranged in relation to the longitudinal direction (x; x) at only a single measurement-device position and for measuring the preliminary source-material height (83; 87) before cutting the source material and for measuring the subsequent source-material height (87) after cutting the source material at this single measurement-device position, in particular, on a measuring plane spanned by the latitudinal direction (y) and vertical direction (z).

8. System for manufacturing a film (90) or a sheet (90) according to claim 3, characterized in that the measurement device (64, 65, 66, 67, 71) is arranged at least at one first measurement-device position and at a second measurement-device position in relation to the longitudinal direction (x; x), wherein, preferably, the measurement device (64, 65, 66, 67, 71) for measuring the preliminary source-material height (83; 87) before cutting the source material is set up at the first measurement-device position in addition to being set up at the second measurement-device position for measuring the subsequent source-material height (87) after cutting the source material, and wherein, preferably, the measurement device (64, 65, 66, 67, 71) is formed by a first measurement sensor arranged at the first measurement-device position and by a second measurement sensor arranged at the second measurement-device position.

9. System for manufacturing a film (90) or a sheet (90) according to claim 3, characterized in that the cutting unit (50) is set up to be adjustable for adjusting its vertical position in the vertical direction (z).

10. System for manufacturing a film (90) or a sheet (90) according to claim 3, characterized in that the cutting unit (50) is integrated into a cutting-unit holder (53), wherein the cutting-unit holder (53) is connected to a stationary fixed machine stand (10), preferably also that the cutting-unit holder (53) is adjusted by an angle of inclination (a), in particular, from ?5? to 30?, preferably from 0? to 7?, rotating around the latitudinal direction (y) against the longitudinal direction (x; x) and pivotable backwards.

11. System for manufacturing a film (90) or a sheet (90) according to claim 3, characterized in that a pressure roller (54) is provided for pressing a surface of the source material against the vertical direction (z), wherein the pressure roller (54) is arranged, as viewed in the longitudinal direction (x; x), in front of the cutting unit (50), preferably further that the pressure roller (54) is integrated into the cutting-unit holder (53).

12. System for manufacturing a film (90) or sheet (90) according to claim 11, characterized in that the pressure roller (54) is set up to be adjustable in the vertical direction (z), preferably separately and independently of the cutting unit (50), with it thereby being furthermore preferred, that the pressure roller (54) is set up to be adjustable in the longitudinal direction (x; x), preferably separated and independent of the cutting unit (50).

13. System for manufacturing a film (90) or sheet (90) according to claim 11, characterized in that the measurement device (66) is relatively invariably connected to the pressure roller (54).

14. System for manufacturing a film (90) or sheet (90) according to claim 10, characterized in that the measurement device (65) is relatively invariably connected to the cutting-unit holder (53).

15. System for manufacturing a film (90) or sheet (90) according to claim 3, characterized in that the measurement device (60, 70) is independently stationary fixed, or that the measurement device (64) is relatively invariably connected to the machine stand (10).

16. System for manufacturing a film (90) or sheet (90) according to claim 3, characterized in that the measurement device (60, 64, 65, 66, 70) for measuring the source-material height (83, 87), as viewed in the longitudinal direction (x; x), is set up and arranged in front of the cutting unit (50).

17. Method for operating a system for manufacturing a film (90) or a sheet (90) made of foam as an article of manufacture made from a foam block, wherein the film (90) or the sheet (90) is cut out of the foam block (80) intended as a source material, in particular, from the foam block, by means of the cutting unit (50), and wherein, for quality control of the cut film (90) or sheet (90), a method for determining a thickness (d) of a film (90) or sheet (90) is carried out.

18. Method for operating a system according to claim 17, characterized in that, depending on a result of the method for determining the thickness (d) of the film (90) or sheet (90) with respect to a preceding layer, the cutting unit (50) is adjusted with respect to its position in relation to the source material, in particular, in the vertical direction (z), for cutting a subsequent layer.

19. Method for operating a system according to claim 17, characterized in that the measurement device (60, 64, 65, 66, 67, 70, 71) is used to detect the source-material length in the longitudinal direction (x; x).

20. Method for operating a system according to claim 17, characterized in that a conveying speed of the source material is adjusted depending on a position of the source material detected by the measurement device (60, 64, 65, 66, 67, 70, 71).

21. Method for operating a system according to claim 17, characterized in that a vertical position of the cutting unit (50) is adjusted depending on a position of the source material detected by the measurement device (60, 64, 65, 66, 67, 70, 71).

22. Method for operating a system according to claim 17, characterized in that the film (90) is removed from the system after cutting, preferably continuously, or that the sheet (90) is removed from the system after cutting.

Description

[0057] Further favourable and preferred embodiments result from the following description with reference to the figures. The figures, which only reflect exemplary embodiments, show:

[0058] FIG. 1 a system for manufacturing a sheet made of a block material in a schematic lateral view in a first state shortly before a first cut of a sheet from the block material;

[0059] FIG. 2 the system of FIG. 1 in a second state during the first cut of a sheet from the block material;

[0060] FIG. 3 the system from FIG. 1 in a third state shortly after the first cut of a sheet from the block material;

[0061] FIG. 4 the system from FIG. 1 in a further state after the first cut of a sheet from the block material and shortly before a further cut of another sheet from the cut remaining block material;

[0062] FIG. 5 a block material as a source material in a schematic perspective view;

[0063] FIG. 6 the block material from FIG. 5 after a cut, split into a sheet and into the cut remaining block material;

[0064] FIG. 7 further exemplary embodiments of a system as shown in FIG. 1 in a schematic lateral view;

[0065] FIG. 8 another exemplary embodiment of a system for manufacturing a sheet made of a block material in a schematic perspective view in a first state shortly before a first cut of a sheet from the block material;

[0066] FIG. 9 the system from FIG. 8 in a further state after the first cut of a sheet from the block material with the cut remaining block material; and

[0067] FIG. 10 a system for manufacturing a film sheet made of a block material in a schematic lateral view.

[0068] FIG. 1 shows the system 1 for manufacturing a film or a sheet 90 schematically in a lateral view. The same system 1 is shown in the same view in different states with regard to the manufacturing status of a film or a sheet 90 in FIG. 2 to FIG. 4. In the exemplary embodiment shown here, which is therefore the preferred embodiment, the article of manufacture is a sheet 90. The sheet 90 is shown as an example in FIG. 4 on the right, wherein the sheet 90 of the system 1 is discharged as an article of manufacture. In addition, the sheet 90 is also shown in FIG. 2 as a partially finished partial product, as well as in FIG. 3 as a finished article of manufacture resting on a residue of the source material (cut remaining block material 84). For example, the step of removing the sheet 90 as an article of manufacture from the system 1 can be done manually or automatically, for which the system 1 can also have a removal device for removing a film or a sheet 90 that is not shown.

[0069] As an alternative to manufacturing sheets 90, the system 1 can also be set up for manufacturing films, wherein the films can, for example, be continuously discharged. The manufacturing a film is shown by way of example in FIG. 10, which shows a further embodiment of a system 1 for manufacturing a film or a sheet in relation to the film 90 indicated by a dashed line. In the following, however, the invention is mainly described using the example of manufacturing sheets 90, wherein the advantages can also be transferred to manufacturing films 90.

[0070] The system 1 is equipped for manufacturing sheet 90 made of a block material 80. The block material 80 is the source material of the manufacturing process, wherein the block material 80 in the exemplary embodiment shown here and thereby being preferred is a foam block.

[0071] The block material 80 has a source-material length 81, which extends in the longitudinal direction x. In addition, the block material 80 has a source-material width of 82 extending in the latitudinal direction y and a source-material height of 83 extending in the vertical direction z. The directions mentioned are based on the orientation of the system 1 itself. A corresponding coordinate system is shown in FIG. 1 to FIG. 4. The dimensions of the block material 80 mentionedsource-material length 81, source-material width 82, source-material height 83are based on this coordinate system. A foam block as block material 80 is shown as an example in FIG. 5 in a perspective view in the uncut state to illustrate these dimensions. Furthermore, FIG. 6 shows a perspective view of a foam block that has already been cut, i.e., the remaining block material 84 that has been cut, and a cut sheet 90, wherein the cut surface 88 of the remaining block material 84 is indicated with hatching. The remaining block material 84 cut has corresponding dimensions, namely source-material length 85, source-material width 86, source-material height 87. These dimensions are also referred to as source-material dimensions because the cut remaining block material 84 can again be provided as a source material for a subsequent further cut of a sheet 90 (see FIG. 4). The source-material lengths 81 or 85 and the source-material widths 82 or 86 of the block material 80 or the cut remaining block material 84 are usually the same size. The source-material height 83 of the source material before cutting (block material 80) is of course greater than the source-material height 87 of the source material after cutting, i.e., the cut remaining block material 84. Specifically, the source-material height 87 is smaller than the source-material height 83 by the thickness d of the sheet 90.

[0072] The dimensions can be viewed in FIG. 5 and FIG. 6, as well as partially in the block material 80 arranged on the system 1 and the remaining block material 84 cut. For the sake of clarity, however, those dimensions have not been designated in FIG. 2 and FIG. 4.

[0073] It should be noted that the dimensions do not always run optimally along the directions described and orientated to the system 1longitudinal direction x, latitudinal direction y, vertical direction z, in particular, not the source-material length 81 and the source-material width 82. However, as shown here, a rectangular foam block is regularly used as block material 80, the length, width and height of which runs along the longitudinal direction x, latitudinal direction y, and vertical direction z. Where applicable, however, a certain predetermined inclination of the rectangular block material 80 can also be desired, particularly in the case of harder source material so that the source-material length 81 of the cuboid block material 80 may not run perfectly along the longitudinal direction x, but slightly inclined to it, and the source-material width 82 may not run perfectly along the latitudinal direction y, but slightly inclined to it. If such an inclination is desired and deliberately carried out, it can also be taken into account in the measurement tasks described below.

[0074] Basically, the longitudinal direction x runs along a support table 20 of the system 1, on which the block material 80 is to be positioned for manufacturing the film or the sheet 90. The block material 80 can be conveyed along the longitudinal direction x. In this respect, the longitudinal direction x can also be referred to as the conveying direction. For this purpose, the system 1 comprises a conveyor unit 30. Furthermore, the longitudinal direction x can also be referred to as the direction of production since the sheet 90 to be manufactured is also produced along the longitudinal direction x with regard to the manufacturing process. In this respect, the system 1 can in principle also be divided into two areas, namely a catchment area 3 and a discharge area 4 (FIG. 1 to FIG. 4 and FIG. 7). The source material is provided in catchment area 3, which is cut in the form of sheet 90 on the system 1 for the article of manufacture. Accordingly, the area in the direction of production behind a corresponding cutting unit 50 is the discharge area 4, in which the finished sheet 90 is then discharged.

[0075] In the exemplary embodiment shown in FIG. 1 to FIG. 4, the conveyor unit 30 is designed as a moveable, driven support carriage 31. The support carriage 31 can be moved back and forth in the longitudinal direction x, as indicated by the double arrow in the support carriage 31. The speed of the conveyor unit 30 or the support carriage 31 in the longitudinal direction x can also be referred to as the feed speed or conveyor speed. The support carriage 31 provides an essentially flat contact surface for the support of the block material 80. The contact surface extends in the horizontal plane spanned by the longitudinal direction x and the latitudinal direction y. The contact surface can also be formed by a perforated sheet, together with a cavity arranged in front of the contact surface as viewed in the vertical direction z, in which a negative pressure, for example, a technical vacuum, is set up. In this way, it can be ensured that the regularly soft block material 80 rests stably and firmly on the contact surface and does not slip, even if the cutting process of the block material 80 described later occurs.

[0076] The latitudinal direction y is generally perpendicular to the described longitudinal direction x and perpendicular to the conveying direction along which the block material 80 is conveyed for the purpose of cutting in the system 1. The latitudinal direction y and the longitudinal direction x span a horizontal plane, which runs regularly parallel to hall floor 2, on which hall floor 2 system 1 is regularly placed as intended.

[0077] The vertical direction z, in turn, is the third perpendicular direction in the sense of a Cartesian coordinate system, as can be seen from the exemplary embodiments in accordance with FIG. 1 to FIG. 4 (and FIG. 7). The vertical direction z runs vertically from the hall floor 2 upwards. Along the vertical direction z runs the height of the block material 80, i.e., the source-material height 83, which is of central interest for the present invention. According to the proposal, it is necessary to determine a thickness d of the produced film or sheet 90, which thickness d basically corresponds to the extension of the cut film or sheet 90 in the same vertical direction z. Since the Cartesian coordinate system is based on the system 1 itself, as described, this naturally applies in the event that the produced, i.e., cut, sheet 90 rests on the support table 20, for example. If the sheet 90 is changed in its orientation or position, or is transported away, it can also be that the thickness d to be determined no longer extends in the vertical direction z.

[0078] FIG. 8 and FIG. 9 show an alternative system 1 for manufacturing a film or a sheet 90. Another alternative system 1 is shown in FIG. 10. Whereas the system 1 in FIG. 1 to FIG. 4 as well as in FIG. 7 are designed as a reversing table with a support carriage 31 that can be moved back and forth in the longitudinal direction x; the system 1 in FIG. 8 and FIG. 9 is designed as a rotary table with a round support table 20.

[0079] The system 1 in accordance with FIG. 1 to FIG. 4 and FIG. 7 comprises a support table 20 designed as a linear machine table. This linear machine table comprises the conveyor unit 30 and is set up for the support of the source material. The conveyor unit 30 is set up on the support side of the linear machine table (support table 20) along the longitudinal direction x and backwards in a reversing manner against the longitudinal direction x.

[0080] The system 1 in accordance with FIG. 8 and FIG. 9 has a support table 20 designed as a rotary table, which support table 20 comprises the conveyor unit 30 and is set up for the support of the source material. In the exemplary embodiment shown, the conveyor unit 30 itself is formed by the support table 20, wherein the conveyor unit 30 is designed as a circumferential contact surface 21 of the rotary table and is set up to be circumferentially moveable along the longitudinal direction x. In principle, it is also possible to set up the depicted rotary table also in a reversing manner against the longitudinal direction x. The rotary table can also be equipped with a perforated sheet on the support side, in front of which, as viewed in the vertical direction, a vacuum can be applied in order to keep the source material positionally and firmly on the rotary table.

[0081] The support table 20 in accordance with FIG. 8 and FIG. 9, which is designed as a rotary table, provides the contact surface 21 for the block material 80 to be cut. The support table 20 is designed as a circular ring and can be moved in the circumferential direction of the circular ring. In this respect, the moveable part of the support table 20 in the system 1 in FIG. 8 and FIG. 9 also forms the conveyor unit 30 of the system 1 simultaneously. Accordingly, in the exemplary embodiment in accordance with FIG. 8 and FIG. 9, a different system of directions is used than in FIG. 1 to FIG. 4 and FIG. 7: The reference x indicates the circumferential direction as the longitudinal direction x. The support table 20 can move along this longitudinal direction x, which is why the longitudinal direction x can also again be referred to as the conveying direction as well as the direction of production of the sheet 90 or film. The vertical direction z extends vertically upwards again from the hall floor, which is not shown or not designated. In the vertical direction z, the thickness of the cut film or sheet 90 must be specified again. Furthermore, the latitudinal direction y is orientated towards the radial direction of the support table 20, which is designed as a rotary table.

[0082] FIG. 10 also shows a coordinate system for orientation that deviates from the Cartesian coordinate system and is similar to that in FIG. 8 and FIG. 9. The system 1 shown in the exemplary embodiment of FIG. 10 does not have a support table 20, but rather the source material 80 is arranged as a round block on a central roller 40. The system 1 in accordance with FIG. 10 therefore has the central roller 40 for receiving the source material formed as a round block. The conveyor unit 30 of the system 1 is designed by the central roller 40 itself in such a way that the central roller 40 can be driven in the direction of rotation to convey the source material. The direction of rotation of the central roller 40 is the same as the indicated longitudinal direction x.

[0083] The central roller 40 of the system 1 is therefore a driven roller which can convey the block material 80 circumferentially along the longitudinal direction x, as indicated by the central arrow in the central roller 40. In this respect, the central roller 40 in the case of the system 1 in FIG. 10 also forms the conveyor unit 30 of the system 1 and actively conveys the block material 80 itself. The central roller 40 and thus the block material 80 can alternatively be passively driven by the provision of the round block driven, separate drive rollers 41. The system of directions is again based on the system 1: the longitudinal direction x runs according to the conveying direction of the driven central roller 40 or along the circumference of the source material formed as a round block 80; the latitudinal direction y is perpendicular to the longitudinal direction x, in FIG. 10 into the drawing plane; the vertical direction z is radial from the centre in the form of the centre of the central roller 40.

[0084] The directions shown in FIG. 8 and FIG. 9 as well as in FIG. 10 in the sense of the respective non-Cartesian coordinate system represent only an exemplary momentary snapshot. These are local coordinate systems. In principle, the moment or point in the respective system 1 or 1 in which the film 90 or sheet 90 was just cut is of interest. This is because the present invention has special advantages in determining the thickness d of the cut film 90 or sheet 90.

[0085] In the exemplary embodiment in accordance with FIG. 10, the source-material height 83 corresponds to the wall thickness of the hollow cylinder block material 80. The source-material height 83 is thus indicated in the radial direction with respect to the round block and in FIG. 10 as viewed in the direction of rotation (longitudinal direction x) shortly before the cutting unit 50 by means of the dashed double arrow. In this respect, the vertical direction z is also the radial direction of the source material 80, which is available as a hollow cylinder. The source-material height 87 after cutting the block material 80, i.e., as viewed in the longitudinal direction x just behind the cutting unit 50, is also indicated by a dashed double arrow. The illustration of block material 80 is only exemplary in FIG. 10. Even if it appears that the source-material height 83 before the cutting of the block material 80 and the source-material height 87 after the cutting of the block material 80 are the same, in reality, the subsequent source-material height 87 after cutting is always reduced by the thickness d of the film 90 compared to the preliminary source-material height 83 before the cutting of the block material 80.

[0086] The source-material width of the block material 80 (not shown) in FIG. 10 corresponds to the height of the hollow cylinder, which represents the geometrical shape of the source material 80. The source-material length, on the other hand, is not relevant for the exemplary embodiment in accordance with FIG. 10. It can be regarded as the circumferential source-material length 80, which is designed as a round block and thus as a hollow cylinder. In the exemplary embodiment of FIG. 10, in contrast to the preceding systems 1 or 1 of FIG. 1 to FIG. 4, or FIG. 7, or FIG. 8 and FIG. 9, not a sheet 90 but a film 90 is produced as the article of manufacture on the system 1. The film 90 is indicated by the dotted line in FIG. 10 and is produced continuously until the source material 80 in the form of the round block 80 is used up. In this respect, the film 90 is produced almost endlessly, or to be more specific, the film 90 has a length that corresponds to a multiple of the circumference or the source-material length 80, which is designed as a round block.

[0087] The described orientations of the dimensions source-material length 81, source-material width 82, as well as a source-material height 83 in relation to the three directions longitudinal direction x or x, latitudinal direction y, and vertical direction z refer primarily to the condition of the block material 80 or the cut film or sheet 90 immediately after or before or during the cutting process. At the moment when the block material 80 has just been cut, as shown by way of example in FIG. 3, the cut sheet 90 rests on the cut remaining block material 84 as viewed above in the vertical direction z. The dimensions of the height, width and length, both of the sheet 90 as well as of the cut remaining block material 84, which is available in a subsequent pass as new block material to be cut, are then orientated in this state shown in FIG. 3 as precedingly described along the three directions longitudinal direction x or x, latitudinal direction y, and vertical direction z.

[0088] As a general rule, the following method is followed for manufacturing a film 90 or sheet 90 for all of the systems 1, 1, 1 shown in accordance with FIG. 1 to FIG. 4, FIG. 7, FIG. 8, FIG. 9, or FIG. 10: The source material provided as block material 80 is processed in such a way that the film 90 or the sheet 90 as the article of manufacture is cut out of the block material 80 along the longitudinal direction x or x. For this purpose, the block material 80 is conveyed along the longitudinal direction x or x to a cutting unit 50 for cutting the source material. The conveyor unit 30 ensures the conveyance of the block material 80 to the cutting unit 50. For the cutting itself, the source material 80 is then passed by this cutting unit 50 or by a cutting tool integrated in the cutting unit 50, wherein the film 90 or the sheet 90 is cut out of the block material 80 along the longitudinal direction x or x.

[0089] As indicated in FIG. 1 to FIG. 4, or FIG. 7, as well as in FIG. 10, the cutting unit 50 may have a cutting wedge 51, which the block material 80 is passed by with the aid of the conveyor unit 30. As known from prior art and described at the beginning, a circumferential blade can be guided in the cutting wedge 51. The alternative cutting tools mentioned above are also generally applicable to the systems 1, 1, 1 shown.

[0090] The cutting unit 51 splits the block material at its top side, resulting in the cut-off film or sheet 90, which is peeled off the block material. The tip of the cutting wedge 51 points in the opposite longitudinal direction x to the block material to be cut 80 (FIG. 1 to FIG. 4 and FIG. 7) or tangentially to the block material 80 in accordance with FIG. 10, which is designed as a round block.

[0091] In addition, as indicated in the further exemplary embodiment of the system 1 in FIG. 8 and FIG. 9, the cutting unit 50 can also be designed as a circumferential blade 52 without support in a cutting wedge, but, for example, only guided between an upper and a lower brace. The circulating blade 52 is also continuously driven according to the principle of a rotating saw. The circulating blade 52 moves in relation to the system 1 in a radial direction, i.e., as viewed in the latitudinal direction y, and thus transversely to the block material to be cut 80 fed to the cutting unit 50 and the circulating blade 52. Sawing or wire cutting can also be used.

[0092] The film 90 or the sheet 90 is cut out of the block material conveyed along the longitudinal direction x or x by means of the cutting unit 50 along the longitudinal direction x or x.

[0093] Cutting unit 50 is integrated into a cutting-unit holder 53 in accordance with FIG. 1 to FIG. 4 (as well as FIG. 7) in the system 1. The cutting-unit holder 53 is, in turn, connected to a machine stand 10. The machine stand 10 is stationary and permanently connected to the hall floor 2.

[0094] In the exemplary embodiment presented here, and in this respect the preferred exemplary embodiment, the cutting unit 50 is set up to be adjusted in the vertical direction z in order to be capable of adjusting the vertical position of the cutting unit 50, in particular, the cutting wedge 51. For this purpose, the cutting-unit holder 53 can be moved forward and backwards in the vertical direction z, as indicated by the double arrow in the cutting-unit holder 53.

[0095] The adjustability of the vertical position of the cutting unit 50 is necessary in order to also be able to produce a plurality of sheets 90 or, alternatively, a plurality of layers of film 90 from the source material in the form of the block material 80. For example, the source-material height of 83 or 87, i.e., the height of the block material 80, decreases with each cut layer. As a result, it is necessary to track the cutting unit 50 downwards in the opposite vertical direction z so that another layer of a film 90 or another sheet 90, for example of the same thickness d, can be cut out.

[0096] In order to keep the quality high during the cutting process itself, a pressure roller 54 is also provided for pressing the surface of the source material formed as block material 80 in the vertical direction z against the vertical direction z. As a result, the block material 80 is held downwards in the opposite vertical direction z. The block material 80 cannot therefore stand out from the support table 20 or the support carriage 31 since the pressure roller 54 ensures a counter-holding downwards. This is particularly important because the cutting unit 50 in general, or in this case the cutting wedge 51, exerts relevant forces on the block material 80 during cutting.

[0097] The pressure roller 54 is a driven roller in the exemplary embodiment shown here, which is therefore preferred. This also supports the conveyance of the block material 80 and thus also of the cut sheet 90 in the longitudinal direction x, i.e., in the direction of production, by the pressure roller 54.

[0098] The pressure roller 54 is arranged, as viewed in the longitudinal direction x, in front of the cutting unit 50. In this context, the arrangement in the longitudinal direction x in front of the cutting unit 50 refers to the fact that the section of the pressure roller 54 acting on the block material 80, i.e., where there is contact between the pressure roller 54 and the upper surface of the block material 80, is arranged in front of the operative section of the cutting unit 50: i.e., in front of the tip of the blade in the cutting wedge 51. The feature does not mean that the entire extension of the pressure roller 54 in the longitudinal direction x must be in front of the entire cutting unit 50. Rather, in the present case, and in this respect, the pressure roller 54 is preferably integrated into the cutting-unit holder 53, into which cutting-unit holder 53 the cutting unit 50 is also integrated.

[0099] In addition, the pressure roller 54 is also set up to be adjustable in the vertical direction z, as indicated by the double arrow in the pressure roller 54. In the exemplary embodiment of the system 1 in accordance with FIG. 1 to FIG. 4 (also like in the case of the system 1 in accordance with FIG. 7) shown here and thereby being preferred, the pressure roller 54 is separated in the vertical direction z and is set up independently of the cutting unit 50, which is also adjustable in the vertical direction z. In this way, different sheets 90 or also films 90 of different thicknesses can be manufactured as flexibly as possible on the same system 1 by simply adjusting the vertical position of the pressure roller 54 or the pressure roller 54 in relation to the cutting unit 50.

[0100] It is also possible for the pressure roller 54 to be adjustable in an angular offset to the vertical direction z. Rotating at a small angle around the latitudinal direction y against the longitudinal direction x, the pressure roller 54 can then not be moved exactly along the vertical direction z, but up or back down by this small angular offset. In this way, the position of the 54 pressure roller can also be adjusted in the x-direction, i.e., in the longitudinal direction x.

[0101] By adjusting the vertical position of the 54 cutting-unit holder and thus also all the other components integrated into it, the process for manufacturing 90 films or 90 sheets can be improved. For example, cutting-unit holder 54 can initially assume a first vertical position, which is optimized to the desired thickness d of the article of manufacture in the form of film 90 or sheet 90. After successful cutting of sheet 90, the cutting-unit holder 54 can then be moved up in the vertical direction z to assume a second, higher vertical position. The remaining block material 84 can then be quickly moved back as viewed against longitudinal direction x, to the front of cutting unit 50. Since there is no risk of collision between the cutting unit 50 or cutting wedge 51 and the cut remaining block material 84 due to the upwardly shifted cutting-unit holder 54, the travel speed of the support carriage 31 can also be set very high against the longitudinal direction x. In addition, when the block material 80 is returned to its starting position in front of the cutting unit 50, it is no longer necessary to guide the block material 80 at a specified ideal and rather moderate feed speed adapted to the cutting process for a further, subsequent cutting process. By specifically adjusting the feed speed of the support carriage 31, for example, if the cutting unit 50 is moved to a higher vertical position, the manufacturing speed of the overall process can be considerably increased.

[0102] As can be seen from the angle of inclination a shown only in FIG. 1, the cutting-unit holder 53 can be pivoted by an angle of inclination a around the latitudinal direction y against the longitudinal direction x and back, i.e., again in the longitudinal direction x. In the illustration in accordance with FIG. 1, the cutting-unit holder 53 can therefore be pivoted back counterclockwise from an upright orientation around the angle of inclination a as shown. It is also possible to pan clockwise back to a perfect upright alignment that is not shown. The cutting-unit holder 53 can be pivoted between ?5? and +30? at the angle of inclination a, measured between the vertical direction z back against the longitudinal direction x, as shown in the figure. The state of ?5? (not shown) refers to a pivot of the top side of the cutting-unit holder 53 from the state shown in FIG. 1 in the longitudinal direction x to beyond the vertical direction z, namely by 5?.

[0103] The pivoting of the cutting-unit holder 53 means that the cutting unit 50 is also pivoted and thus the cutting instrument, i.e., the cutting wedge 51 with a circumferential blade, can be adjusted at an angle. This is favourable depending on the block material to be cut 80, in particular, its hardness, as well as the parameter of the desired thickness d of the sheet to be cut 90 or also the film 90.

[0104] Even though the angle of inclination a is indicated only within the scope of FIG. 1, the cutting-unit holder 53 is inclined by the angle of inclination a in FIG. 2 to FIG. 4 as well as in FIG. 7.

[0105] In principle, it is well known that the cutting process or the entire manufacturing process of the film 90 or sheet 90 is subjected to quality control. It is customary to check the thickness d of the film produced 90 or sheet 90, for example to see whether the film 90 or sheet 90 has the desired thickness d. To illustrate, FIG. 5 shows the block material 80 as a source material with its original dimensions source-material length 81, source-material width 82, and source-material height 83, while FIG. 6 shows the cut remaining block material 84 with the resulting dimensions after a single cutting process to manufacture the single sheet 90 source-material length 85, source-material width 86, and source-material height 87. Furthermore, in view b) the cut single sheet 90 is shown together with its dimensions in the form of the thickness d, the sheet length 91, and the sheet width 92.

[0106] Quality control, particularly of the thickness d of the cut sheet 90 or also the film 90 can be crucial. For example, in the case of continuous manufacture of a plurality of sheets 90 or continuous film 90, the cutting unit 50 or the corresponding cutting tool (e.g., the cutting wedge 51 or the circumferential blade 52) must be adjusted regularly. For example, the block material 80 as a source material changes its source-material height 83 or 87 with each cut off layer in the form of a sheet 90 or a layer of film 90. This can be seen by the overview of FIG. 1 with FIG. 4, wherein, in FIG. 1, the source material still has a source-material height 83, while in FIG. 4, after cutting off the sheet 90 shown on the right, the cut remaining block material 84 now only has a source-material height 87, which is lower than the source-material height 83. Accordingly, the cutting unit 50 or the cutting wedge 51 in FIG. 4 must be set lower during the subsequent cutting process than precedingly during the initial cutting process in accordance with the arrangement in FIG. 1.

[0107] In order to cut a plurality of sheets of 90 or a plurality of layers of film 90 from a single block material 80 as a source material, values are regularly given to the system 1, 1, 1 or a corresponding control unit at the beginning in order to determine which values the cutting unit 50 is to be adjusted (i.e., lowered regularly) so that a plurality of sheets 90 of the same thickness d or one film 90 with a uniform thickness d can be cut. The determination of the actual thickness d of the cut sheet 90 or film 90 can then serve to prevent a consequential error. This is because if a sheet 90 is in reality cut thinner than originally desired and adjusted accordingly, and then the cutting unit 50 is only adjusted accordingly, this can lead to consequential errors and, under certain circumstances, to the fact that all sheets 90 have too little thickness d after cutting. If, however, the actual thickness d of the cut sheet 90 is checked, then the adjustment of the cutting unit 50 can be adjusted accordingly in the case of a sheet 90 or film 90 that is cut too thin or also too thick.

[0108] The present invention provides a remedy and brings advantages in quality control and automation of the process of production of the 90 film and 90 sheet respectively. Thus, in the present case, it is proposed that the thickness d of the film 90 or sheet 90 is no longer determined in such a way that the film 90 or sheet 90 is measured directly on the film as the article of manufacture. Rather, the thickness d of the film 90 or sheet 90 is determined by first measuring the preliminary source-material height 83 before cutting the block material 80 and then the subsequent source-material height 87 after cutting the block material 80, and then by determining the thickness d of the film 90 or sheet 90 to be determined from the difference between the preliminary source-material height 83 minus the subsequent source-material height 87. The measurement of the subsequent source-material height 87 after the cutting of the block material 80 corresponds to the measurement of the height of the cut remaining block material 84 in the vertical direction, e.g.

[0109] In accordance with the proposal, an indirect measurement method is therefore be provided. It is no longer measured directly on the article of manufacture to be measured, namely the film 90 or sheet 90. As a result, many disadvantages associated with a direct measurement method on the product can be avoided. For example, in prior art, when discharging film 90 or the sheet 9 by means of discharge devices, it is possible to impact the film 90 or the sheet 90, which is regularly formed from soft foam material. Too much pulling on the film 90 or sheet 90, for example, can lead to thinning of the article of manufacture. In accordance with this, if measurements were taken at such a point, a thinner thickness would be determined than the actual thickness d of the film 90 or sheet 90 to be determined. The proposed method and the described and thus preferred exemplary embodiments in systems 1, 1, 1 do not have such disadvantages. In the case of the systems 1, 1 and 1, it is also favourable to dispense with the need for elaborate additional devices, which is used, for example, to guide the material of the produced film 90 or sheet 90 in order to obtain correct measurement results in the case of direct measurement of this film 90 or sheet 90. For example, it is not necessary to determine the sheets for the systems 1, 1, 1 shown.

[0110] In addition, the systems 1, 1, 1 shown and the proposed method are much more flexible as regards manufacturing completely different films 90 or sheets 90 on the same system 1, 1 and 1. Thus, the direct measurement methods of prior art, which are directly aimed at the article of manufacture to be measured, are also set up for the respective article of manufacture in the form of film 90 or sheet 90, in particular, with regard to their expected thickness d. The optical measurement devices, for example, are calibrated to the expected thickness. When changing from a first film thickness to a second, for example, larger film thickness, a time-consuming adjustment of the method and even of the systems 1, 1, 1 is regularly necessary. Since, however, as shown in the present case, it is no longer the article of manufacture that is measured, but rather the source material in the form of the block material 80 and the thickness d of the produced film 90 or sheet 90 is detected by calculating the difference, these disadvantages of prior art do not apply. Even in manufacturing completely different thicknesses of films 90 or sheets 90, the framework conditions for measuring the source material in the form of the block material 80 are similar. On the one hand, the dimensions of the block material 80 used can regularly be known in advance and the optical measuring methods can be specifically adapted to these general conditions, even if films of different thicknesses 90 or sheets 90 are to be manufactured from the block materials 80. However, this is not absolutely necessary, since the measurement devices used can also have a constant distance to the measurement object, i.e., to the surface of the block material 80. This is particularly the case when the measurement devices are carried when the cutting unit 50 is placed.

[0111] The systems 1, 1, 1 are therefore particularly favourable when a sheet thickness is changed (change of the thickness d of the sheet to be manufactured 90 or also the film 90).

[0112] For example, it is also not possible to use the heights directly, i.e., the preliminary source-material height 83 before cutting the block material 80 and the subsequent source-material height 87 after cutting, but rather measured values representing these heights. For example, optical measurements can be taken so that the measurement signal path is representative of the corresponding height. Furthermore, the surface of the block material 80 can be measured and a distance of this surface to the substrate on which the block material 80 rests, i.e., to the contact surface 21 or to the outer shell of the central roller 40, can be known, from which the height of the block material 80 can then be determined.

[0113] Values such as the height adjustment of a cutting-unit holder 53 that can be moved in the vertical direction z can also be known and included in the measurements, for example if the measurements were originally calibrated to the height of the support table 20 or the contact surface 21.

[0114] As can be seen from the illustrations of the exemplary embodiment of the system 1 from FIG. 1 to FIG. 4, a measurement device 60 is provided for carrying out the described measurement steps. The measurement device 60 is stationary. Measurement device 60 is permanently mounted on the hall floor 2. For this purpose, measurement device 60 comprises a measurement device stand 61, which is permanently mounted on hall floor 2. This means that measurement device 60 is independently stationary. In the arrangement in accordance with FIG. 1 to FIG. 4, measurement device 60 is therefore not connected to the other components of the system 1 in terms of its structural components. However, it is favourable to have at least one communication connection. In this way, by means of a control unit of the system 1, conclusions can be drawn about the control of the process by means of the values measured with the measurement device 60 and adjustments can be made in a targeted manner. The measurement device 60 is set up for measuring on a surface of a measurement object, specifically in the exemplary embodiment shown for measuring on the upper surface of the block material 80 as viewed in the vertical direction z.

[0115] Even if the depicted measurement device 60 is stationary, it could also be stationary only with regard to some of its components in space. In particular, it is possible to set up the measurement device in a moveable manner in the vertical direction z, despite its independence from the other components of the system 1. The distance to the measurement object can then be kept at a constant level.

[0116] The point on the measurement object where the desired measurement is carried out by means of measurement device 60, or in general within the scope of the present application, is also generally referred to as the measurement-target point. In contrast to this, when we talk about the measurement-device position, we are basically referring to the position of the measurement device 60. The measurement-device position basically describes where the measurement device 60 is spatially arranged. The measurement-device position thus refers to the three coordinates of the measurement device 60, i.e., their position in relation to the longitudinal direction x, latitudinal direction y and vertical direction z. As a rule, however, the same measurement-device position can mean that the measurement device 60 only has the same position with respect to the longitudinal direction x and latitudinal direction y, while the position in the vertical direction z can be adjusted between the measurements for example. Under certain circumstances, one and the same measurement device 60 can drive towards different measurement-target points from one measurement-device position, thereby measuring them. On the one hand, this is conceivable through the use of a line sensor that can measure a plurality of measurement-target points at the same time in relation to the latitudinal direction y of the block material 80. On the other hand, a measurement device 60 can also measure different measurement-target points in the longitudinal direction x at different points in time successively at the same measurement-device position on the measurement object in the form of block material 80, which passes by and is to be measured.

[0117] In the present exemplary embodiment of the system 1 shown in FIG. 1 to FIG. 4, the measurement device 60 is arranged at a single measurement-device position. The measurement device 60 in accordance with FIG. 1 to FIG. 4 is not changeable with regard to its measurement-device position. The measurement device 60 is arranged in relation to the longitudinal direction x at only a single measurement-device position and is set up there to measure both the preliminary source-material height 83 before cutting the source material and the subsequent source-material height 87 after cutting the source material at this single measurement-device position. The measurement is carried out along a measuring plane spanned by the latitudinal direction y and vertical direction z.

[0118] The measurement device 60 is an optical measurement device. In the present case, a laser-based measurement sensor 62 is used to measure optically on the surface of the block material 80, as indicated by the beam cone 63.

[0119] As a result, the measurement device 60 comprises only a single measurement sensor. A plurality of measurement sensors can also be installed within the scope of a measurement device 60, for example, at a single measurement-device position.

[0120] In particular, it is also possible to integrate a plurality of measurement sensors into one measurement device 60 over the width of the system 1 extending in the latitudinal direction y, i.e., distributed along the source-material width 82, 86, or to provide a plurality of independent measurement devices. It is also possible to integrate a line sensor, which covers a larger measuring range as viewed in the latitudinal direction y. Also distributed over the length, i.e., along the longitudinal direction x, x or along the source-material length 81, 85, a plurality of measurement sensors can be provided to form a measurement device. This is the case, for example, with the measurement device 71 shown in FIG. 10 with two measurement sensors (laser-based measurement sensors 62) at two different measurement-device positions.

[0121] Alternative arrangements to the described measurement device 60, namely the arrangements of measurement devices 64, 65, 66, and 67, are shown in FIG. 7. FIG. 7 basically shows the system 1 for manufacturing the sheet 90 as an article of manufacture from the block material 80 intended as a source material, as it has also been shown and described in FIG. 1 to FIG. 4. Accordingly, reference can be made to the preceding and also the following embodiments in this regard. The system 1 in accordance with FIG. 7 shows alternative arrangements of measurement devices 64, 65, 66 and 67. In the system 1, therefore, there are deviating measurement-device positions from those in accordance with the illustration of the system 1 in FIG. 1 to FIG. 4. In one go, FIG. 7 illustrates four different alternative or potentially complementary arrangements of a measurement device in a single illustration. In the system 1, the four measurement devices 64, 65, 66 and 67 can in principle be provided individually and used for the favourable measurement of the thickness d of the sheet 90. Measurement devices 64, 65, 66 and 67, as well as the measurement device 60 shown within the scope of FIG. 1 to FIG. 4 could also be provided for a plurality of times together or in different combinations in the system 1. For the sake of clarity and simplification, the illustration of block material 80, which is to be cut into sheets 90, has been dispensed with in FIG. 7.

[0122] In a first alternative variant to the measurement device 60 in accordance with FIG. 1 to FIG. 4, the measurement device 64 is relatively invariably connected to the machine stand 10indicated as variant a) in FIG. 7. The measurement device 64 is connected to the machine stand 10 via the measurement-device suspension 68. Since the machine stand 10 is stationary and permanently connected to the hall floor 2, the measurement device 64 is also stationary.

[0123] In another variant, the measurement device 65 is relatively invariably connected to the cutting-unit holder 53indicated as variant b) in FIG. 7. Due to the vertical displacement of the cutting-unit holder 53, which has already been described above and is also present in the embodiment in accordance with FIG. 7, the measurement device 65 can therefore also be moved vertically and is therefore no longer absolutely stationary. It is favourably ensured that the measurement device 65 always has the same position relative to the cutting unit 50 or the cutting wedge 51.

[0124] In another variant, the measurement device 66 is invariably connected to the pressure roller 54 with regard to its relative position-indicated as variant c) in FIG. 7. Due to the vertical displacement of the pressure roller 54, which has already been described above and is also present in the embodiment in accordance with FIG. 7, the measurement device 66 can therefore also be moved vertically and is therefore no longer absolutely stationary. Insofar as the pressure roller 54, as shown here, is also set up independently of the cutting-unit holder 54 or vertically moveable relative to it, it is favourably guaranteed that the vertical position of the measurement device 66 is individually adjustable, namely independently of the cutting unit 50 or the cutting wedge 51. It is also favourable to ensure that the measurement device 66 always has the same position relative to the pressure roller 54. In this way, the distance of the measurement device 66 to the measurement object, i.e., to the block material 80, can also be kept constant.

[0125] In another variant, the measurement device 67 is invariably connected to the cutting unit 50 or the cutting wedge 51 with regard to its relative position-indicated as variant d) in FIG. 7. The orientation of the measurement device 67 is such that the measurement takes place, as viewed in the longitudinal direction x, behind the cutting unit 50 or the cutting wedge 51. In contrast to the measurement devices described above, measurement device 67 is no longer arranged in catchment area 3 of the system 1 with regard to its measurement-device position, but rather in discharge area 4.

[0126] The alternative measurement devices 64, 65, 66, 67 shown here are, like the measurement device 60 shown in FIG. 1 to FIG. 4, also optical measurement devices with a laser-based measurement sensor 62 (beam cone 63). This also applies to the two measurement devices 70 and 71 (laser-based measurement sensor 62 with a beam cone 63) shown within the scope of system 1 shown in FIG. 8 and FIG. 9 as well as within the scope of system 1 shown in FIG. 10.

[0127] The measurement devices 60, 64, 65, 66, 67, 70, 71 shown and thereby being preferred are all set up for measuring on the upper surface of the block material 80 as viewed in the vertical direction z in order to be able to measure the source-material height 83 or 87. Furthermore, the measurement devices 60, 64, 65, 66, 67, 70, 71 are set up and arranged in such a way to measure the source-material height 83, 87 that the respective measurement device 60, 64, 65, 66, 67, 70, 71 can measure both a preliminary source-material height 83 before cutting the block material 80 and subsequently also a subsequent source-material height 87 after the cutting of the block material 80 (i.e., the height of the cut remaining block material 84).

[0128] The measurement device 71 in accordance with the exemplary embodiment of the system 1 shown in FIG. 10 is arranged at a first measurement-device position and at a second measurement-device position in relation to the longitudinal direction x. This is achieved by the fact that a laser-based measurement sensor 62 is provided as a first measurement sensor at the first measurement-device position and another laser-based measurement sensor 62 as a second measurement sensor at the second measurement-device position. The measurement device 71 designed in such a way is set up for measuring the preliminary source-material height 83 before cutting the source material at the first measurement-device position and set up for measuring the subsequent source-material height 87 after cutting the source material at the second measurement-device position.

[0129] It is also conceivable that the other systems 1 and 1 (cf., FIG. 1 to FIG. 4, FIG. 7, as well as FIG. 8 and FIG. 9) could be arranged with a plurality of measurement sensors, such as a first measurement sensor for measuring the preliminary source-material height 83 before cutting the source material at the first measurement-device position and a second measurement sensor for measuring the subsequent source-material height 87 after cutting the source material at of the second measurement-device position.

[0130] In principle, it is particularly favourable, as shown by the exemplary embodiments in accordance with FIG. 1 to FIG. 4 with regard to measurement device 60, as well as with regard to measurement devices 64, 65 and 66 of variants a), b) and c) from FIG. 7, as well as with regard to measurement device 70 in FIG. 7 and FIG. 8, that the measurement device 60, 64, 65, 66, 70 for measuring the source-material height 83, as viewed in the longitudinal direction x, x, is set up and arranged in front of the cutting unit 50 This area in front of cutting unit 50 can also be referred to as catchment area 3 of the system 1, 1 or 1. In the catchment area 3, the block material 80 is still in the uncut state, which is why the exact measurement of the source-material height 83 before cutting is recommended there. The area behind cutting unit 50 can also be referred to as discharge area 4 of the system 1, 1 or 1, because it is there that the article of manufacture in the form of film 90 or sheets 90 is regularly removed from the system 1, 1, 1. There, in accordance with prior art, the thickness d of the product (film 90 or sheet 90) is measured directly on a regular basis. Since there is no arrangement of measurement devices in the systems 1, 1, 1 shown above, the removal of the article of manufacture can be carried out more easily, and the systems 1, 1, 1 can be designed to be more compact overall.

[0131] In the system 1 shown in FIG. 8 and FIG. 9, the cutting unit 50, which is designed as a circumferential blade 52 supported only by braces, can also be adjusted in the vertical direction z. Furthermore, it is also conceivable to equip the system 1 with regard to the cutting unit 50 in such a way that the circumferential blade 52 can also be set at an inclined position (pivoted by the latitudinal direction y) in relation to the block material 80 to be cut, meaning setting it into an angle of attack again.

[0132] This also applies analogously to the cutting unit 50 shown and described within the scope of the system 1 in FIG. 10. The corresponding cutting wedge 51 could also be set up to be adjustable in the vertical direction z. The cutting wedge 51 can then be moved closer to the central roller 40 or back again. In the present case, however, and in this respect, it is preferred, that the central roller 40 can be moved in the direction of cutting wedge 51 and thus advanced. It is also possible to change the angle of attack of the cutting wedge 51 for cutting the block material 80, which is designed as a round block.

[0133] By means of the systems 1, 1 and 1 shown for manufacturing sheets 90 and films 90 respectively from block material 80 of foam, the favourable method for determining a thickness d of a film 90 or sheet 90 can be carried out according to the proposal. As part of the proposed method, the film 90 or sheet 90 is cut as an article of manufacture from the block material 80 (foam block) intended as a source material. In order to cut the source material, the source material is conveyed along the longitudinal direction x or x to the cutting unit 50, wherein the cutting unit 50 in turn cuts out the film 90 or sheet 90 from the source material along the longitudinal direction x, x. The thickness d of the cut film 90 or sheet 90 to be determined is then measured by it, in that: [0134] the measurement devices 60, 64, 65, 66, 67, 70, or 71 measure a preliminary source-material height 83 before cutting the block material 80 and a subsequent source-material height 87 after cutting the block material 80, and [0135] the thickness d of the film 90 or sheet 90 is determined from the difference of the preliminary source-material height 83 minus the subsequent source-material height 87.

[0136] Measured values representing the respective height can also be measured, such as the transit time of an optical measurement signal for example, and these can then be calculated accordingly analogue so that finally the thickness d of the film 90 or sheet 90 can be deduced.

[0137] The systems 1, 1, 1 comprise additional evaluation units not shown for the execution of the method, which convert the calculation operations such as the calculating the difference or the conversion of measurement signals of the measurement devices 60, 64, 65, 66, 67, 70, or 71 into corresponding thickness values.

[0138] In addition, the systems 1, 1, 1 also comprise control units (not shown), by means of which the manufacturing process of films 90 and sheets 90 running on the corresponding system 1, 1, 1 can be controlled. For this purpose, the control units can preferably also be arranged in a communication connection with the evaluation unit or the measurement devices 60, 64, 65, 66, 67, 70, or 71. For example, the detection of the thickness d of the cut films 90 or sheets 90 can be used on the one hand for quality control of the article of manufacture, but on the other hand also for controlling the further manufacturing process in terms of regulation.

[0139] If, for example, the goal is to produce a sheet 90 of thickness d=10 mm, then the result known from capturing the thickness d of a first cut sheet 90 can be favourably used to control the following cuts. For example, the source-material height of 83 is usually known as the initial variable of the process, which is originally the source material available as block material 80. Cutting unit 50 is then set to a specific first vertical position in order to obtain the intended cut to achieve a thickness d of 10 mm. The system 1, 1, 1 is then regularly adjusted in such a way that, after a first cut, the cutting unit 50 is adjusted with regard to its vertical position, and the cutting unit 50 is adjusted to a second vertical position, thereby being reduced by 10 mm. If, as proposed, the actual thickness d resulting from the first cut, in the example mentioned above 8 mm, is detected, the vertical adjustment of the cutting unit 50 (e.g., the vertical displacement of the cutting-unit holder 52) can be adjusted for the subsequent cut. In this way, consequential errors can be successfully avoided.

[0140] According to the proposal, a method of operation can therefore be carried out on the described systems 1, 1, 1, wherein the film 90 or the sheet 90 is cut out of the block material 80 (foam block) intended as a source material by means of the cutting unit 50, and wherein, for the quality control of the cut film 90 or sheet 90, a precedingly or subsequently described method is carried out to determine a thickness d of a film 90 or sheet 90.

[0141] It is particularly favourable if the system 1, 1, 1 is operated in such a way that, depending on the result of the method for determining the thickness d of the film 90 or sheet 90 in relation to a preceding layer, the cutting unit 50 is adjusted with regard to its position in relation to the source material, in particular, in the vertical direction z, in order to cut a subsequent layer. Specifically, the cutting unit 50 is adjusted more or less downwards against the vertical direction z as described, depending on the thickness d detected.

[0142] In the case of the systems 1, 1, 1 shown, it is particularly favourable that the respective measurement devices 60, 64, 65, 66, 67, 70, 71 are set up and arranged for measuring the source-material length 81, 85. This makes it possible to use a method for operating the system 1, 1, 1 in which the source-material length is determined in the longitudinal direction x, x by means of the measurement device 60, 64, 65, 66, 67, 70, 71. Thus, by measuring on the block material 80, the respective measurement device 60, 64, 65, 66, 67, 70, 71 can determine a starting point at which the block material 80 enters the measuring range and an end time upon discharge of the block material 80, from which the source-material length 81, 85 can be determined. It is possible to dispense with the provision of additional light barriers in the 1, 1, 1 system, which would otherwise take over this task. In the exemplary embodiment of the round block in FIG. 10, the circumference of the block material 80 can be determined in this way, wherein it is not the entry and discharge of the block material 80 itself that can be detected, but of a reference point rotating with the block material 80.

[0143] This basic detection of the extension in the longitudinal direction x, x or generally the position of the block material 80 in that direction can also be used to control the manufacturing process. Thus, in the case of the systems 1 in accordance with FIG. 1 to FIG. 4 and FIG. 7, as well as in the case of the system 1 in accordance with FIG. 8 and FIG. 9, the knowledge of the position of the block material in the longitudinal direction x, x can be used to adjust the conveying speed, particularly to increase it when there is no cutting of the block material 80. The conveying speed can then also be reduced in the inlet and outlet areas with the cutting tool, while the conveying speed can be increased even in the middle area when the cut is made.

[0144] The systems 1, 1, 1 can be operated favourably by adjusting the conveying speed of the source material in the longitudinal direction x, x depending on the position of the source material detected by the measurement device 60, 64, 65, 66, 67, 70, 71. Overall, this can improve cutting thickness tolerances and increase manufacturing speeds.

[0145] In addition, favourable control of the shown systems 1, 1, 1 can be achieved by adjusting a vertical position of the cutting unit 50 in the vertical direction z depending on the position of the source material detected by the measurement device 60, 64, 65, 66, 67, 70, 71.

[0146] All in all, with the presented and described systems 1, 1, 1, a favourable manufacture of films 90 or sheets 90 from the block material 80 is possible, by running the described method for measuring the thickness d of the film 90 or sheet 90 on the system 1, 1, 1 and using the result to control the manufacturing method. For example, by vertically adjusting the cutting unit 50 at appropriate moments, or also by correcting and changing an originally specified vertical adjustment of the cutting unit 50 for cutting a subsequent sheet 90 or the position of a film 90 on the basis of the detected thickness. Accordingly, the present invention makes it possible to further improve the manufacturing process of films 90 or sheets 90 made of block material in such a way that the manufacturing process can be further automated and more reliable with regard to a uniform quality of the articles of manufacture.

REFERENCE LIST

[0147]

TABLE-US-00001 1, 1, 1 system 2 hall floor 3 catchment area 4 discharge area 10 machine stand 20 support table 21 contact surface 30 conveyor unit 31 support carriage 40 central roller 41 drive rollers 50 cutting unit 51 cutting wedge 52 circumferential blade 53 cutting-unit holder 54 pressure roller 60, 64, 65, measurement device 66, 67, 70, 71 61 measurement device stand 62 laser-based measurement sensor 63 beam cones 68, 69 measurement-device suspension 80 block material 81, 85 source-material length 82, 86 source-material width 83, 87 source-material height 84 remaining block material cut 88 cut surface 90 sheet 90 film 91 sheet length 92 sheet width x, x longitudinal direction y latitudinal direction z vertical direction d thickness of the film or the sheet