Printing control system based on universal controller

Abstract

The invention relates to the technical field of printing control systems, and discloses a printing control system based on a universal controller, comprising a central controller unit used for generating a corresponding control instruction according to a printing task; the motion control unit is used for driving and adjusting the roller speed of each printing unit; the color management unit is used for acquiring the color information of the printed product in real time and adjusting the output parameter of each color according to the real-time color information; the ink supply and cleaning unit is used for adjusting the supply amount of ink according to printing requirements and regularly cleaning according to a set period; and the user interface unit is used for operation setting and printing state display. The printing equipment has high universality, integration degree and control uniformity, it is ensured that the printing equipment can flexibly adapt to the printing requirements of various paperboards, the printing precision is improved, and the high printing requirement is met.

Description

Technical Field

[0001] The present invention relates to the technical field of printing control systems, and in particular to a printing control system based on a universal controller. Background Art

[0002] In the current cardboard printing industry, the existing cardboard printing equipment is relatively simple in printing format and lacks versatility, resulting in the need to frequently replace equipment or adjust printing parameters during the printing process of cardboards of different specifications and materials. This not only increases the complexity of operation, but also increases production costs.

[0003] The reason is that the existing printing equipment has a low degree of integration because it lacks a unified control system to accurately control printing parameters such as ink volume, printing speed, pressure, etc. This decentralized, non-integrated control method makes it difficult for each link in the printing process to form a synergistic effect, which not only affects printing efficiency, but also makes it difficult to maintain consistent printing quality. Especially when dealing with high-precision printing tasks, existing equipment is even more difficult to meet the printing needs of high-quality cardboard printing products.

[0004] In addition, since printing parameters cannot be uniformly controlled, problems such as ink waste and cardboard damage often occur during the printing process, further increasing printing costs. At the same time, since the equipment lacks intelligent and automated functions, operators need to invest a lot of time and energy in monitoring and adjusting, which not only increases labor costs, but also limits the improvement of production efficiency.

[0005] Therefore, in view of the problems that the existing printing control system has poor versatility, low integration, and cannot adapt to the printing of cardboards of various specifications, it is now necessary to provide a printing control system based on a universal controller. Summary of the invention

[0006] The present invention aims to provide a printing control system based on a universal controller to solve the problems of low integration of existing printing control systems, difficulty in adapting to various printing needs, low versatility, and affecting production efficiency and printing quality.

[0007] In order to achieve the above object, the present invention adopts the following technical scheme:

[0008] The present invention is used to provide a printing control system based on a universal controller integration, so as to dynamically adjust the printing parameters according to the printing color information obtained in real time, thereby controlling the speed and position of the roller, ensuring that the printing equipment can adapt to the printing needs of various paperboards, so that the printing control system has universality, high integration, can uniformly control the printing parameters and has higher printing accuracy, and meets higher printing needs. Specifically, it is a printing control system based on a universal controller, which specifically includes a central controller unit for generating corresponding control instructions according to the printing task; a motion control unit for driving and adjusting the roller speed of each printing unit; a color management unit for obtaining the color information of the printed product in real time and adjusting the output parameters of each color according to the real-time color information; an ink supply and cleaning unit for adjusting the ink supply according to the printing needs and cleaning regularly according to the set cycle; a user interface unit for operation settings and printing status display.

[0009] The principles and advantages of this solution are:

[0010] The reason why existing printing equipment cannot achieve high integration and improve versatility is that, firstly, printing operations mostly rely on printing equipment, and different printing equipment often have different design standards, operating interfaces and functional characteristics, resulting in poor compatibility between devices. When trying to integrate equipment from different sources and brands together, they often face problems such as interface mismatch and data exchange failure. This not only affects the normal use of the equipment, but also increases the cost of maintenance and upgrades, thereby limiting the versatility and high integration of the equipment.

[0011] Secondly, since the control systems of existing printing equipment are mostly supported by foreign technology, if you want to improve the integration of equipment, you need a complete management system to support it. However, in the actual market environment, in order to improve the accuracy or functionality of printing equipment or other requirements, a separate targeted control system is often used, and there are often compatibility or adaptability problems between the control systems. In addition, the users, maintainers and managers of the equipment may also belong to different departments or teams, resulting in obstacles to the transmission and communication of information. However, the scheduling, maintenance, and repair of equipment require a high degree of coordination, which makes it difficult to synchronize and stabilize the operation of the entire system, further limiting the universality and integration of equipment.

[0012] Third, in order to reduce production costs, batch production is often used in actual production. Therefore, the printing parameters of this batch will be set first and will not be modified. Based on the production consideration that the larger the quantity, the lower the cost, there is no desire to adjust production to multiple specifications. However, with the current market demand for small batches and multiple varieties, batch production can no longer meet the requirements and is prone to backlogs and waste.

[0013] Therefore, it is difficult for the control system of printing equipment in the prior art to achieve high integration to meet the requirements of universal and high-precision bidirectional printing. However, this solution adopts a universal controller to obtain and analyze the data in real time during printing, so as to dynamically adjust the printing parameters, thereby ensuring that the printing equipment can flexibly use the printing requirements of various paperboards without considering compatibility or coordination issues, so that the system has high universality, integration and control uniformity, and makes printing more accurate, ensuring that the printing resolution is improved to the micron level, and can meet more stringent printing needs and market demands. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is a structural diagram of embodiment 1 of the present invention. DETAILED DESCRIPTION

[0015] The following is further described in detail through specific implementation methods:

[0016] Embodiment 1

[0017] Basically as attached Figure 1 As shown: A printing control system based on a universal controller can obtain printing color information in real time and dynamically adjust printing parameters by integrating a universal controller to accurately control the speed and position of the roller, thereby ensuring the system's wide adaptability to various types of paperboards, achieving highly integrated, unified universal printing control, improving printing accuracy, and meeting higher standards of printing requirements. Specifically, it includes a central controller unit, which is used to generate corresponding control instructions according to printing tasks. A motion control unit, which is used to drive and adjust the roller speed of each printing unit. A color management unit, which is used to obtain the color information of the printed product in real time and adjust the output parameters of each color according to the real-time color information. An ink supply and cleaning unit, which is used to adjust the ink supply according to printing requirements and clean regularly according to the set cycle. A user interface unit, which is used for operation settings and printing status display.

[0018] In this embodiment, the motion control unit includes a roller drive module and an encoder feedback module. The roller drive module is used to drive the rollers of each printing unit to rotate at a set speed and adjust the roller speed according to the output parameters.

[0019] The encoder feedback module is used to monitor the actual rotation speed and position of the roller in real time, and generate feedback information to be transmitted to the central controller unit. In this embodiment, the encoder feedback module includes an encoder provided on each roller shaft.

[0020] The color management unit includes a color monitoring module, a color correction module and a synchronization control module. The color monitoring module is a sensor provided on the printing path, which is used to monitor the color information of the printed product in real time. In this embodiment, the color information includes pattern color and parameters such as ink supply, concentration and roller pressure, wherein the pattern color is usually expressed in the form of RGB, CMYK or Lab color space.

[0021] The color correction module is used to compare the current color information with the standard color information (i.e., the set target color information) according to the acquired color information, and calculate the color error. In this embodiment, the color error can be calculated based on the CIELAB color space or other color difference measurement methods. The corresponding output parameters are generated according to the color error, and the corresponding output parameters are sent to the motion control unit to adjust the speed and position of the roller in real time according to the monitored color information to ensure the accuracy and integrated controllability of printing, meet various printing needs, and improve versatility.

[0022] In this embodiment, the output parameters include ink parameters and control information, wherein the ink parameters include ink supply, concentration and roller pressure; and the control information includes roller speed and roller position.

[0023] In this embodiment, the color information of the printed product is obtained and compared with the standard color to calculate the color error. The ink supply can be adjusted according to the color error to change the depth of the printed product color, thereby making the printed product more accurate. The adjustment expression of the ink supply is ΔV=K V ×ΔE; where K V The proportional coefficient indicates the ratio of the color error to the ink supply adjustment. This value can be flexibly set according to the actual situation. When the supply increases, the color becomes darker; when the supply decreases, the color becomes lighter.

[0024] The ink concentration directly affects the color saturation of the printed product. Therefore, the concentration is adjusted according to the color saturation of the picture. The concentration adjustment expression is ΔC = K C ×(target saturation - current saturation); where K C is the proportional coefficient. As the supply increases, the color becomes darker; as the supply decreases, the color becomes lighter.

[0025] Roller pressure affects the transfer efficiency of ink and the color uniformity of printed products. When the pressure increases, the ink transfer is more complete, but it may cause the color to be too dark or damage the surface of the printed product; when the pressure decreases, the ink transfer decreases and the color becomes lighter. Therefore, the adjustment of roller pressure needs to be based on the current paper type and equipment to pre-set the adjustment strategy, and then adjust it accordingly. The adjustment method is to calculate the color error quantization value ΔE through the current color information and standard color, and calculate the adjustment amount of roller pressure according to the color error and the preset adjustment strategy, which is expressed as

[0026] ΔT=K T ×ΔE×f(T t ,T0,C t ,R); where K T is the proportionality factor, which is used to convert the color error into the pressure adjustment amount and can be set according to the characteristics of the printing equipment and the required accuracy; T t is the current roller pressure, T0 is the target pressure; C t is the current ink density; R is the paper type.

[0027] According to the size and direction of the color error, the roller speed and position that need to be adjusted are determined. The roller speed can be adjusted by calculating the speed adjustment amount through the PID (proportional-integral-differential) control algorithm. The speed adjustment amount is expressed as

[0028] Δu(K)=K p ·e(K)+K i ∑e(i)+K d [e(K)-e(K-1)];

[0029] In the formula, K p is the proportional coefficient, e(K) is the color error at the current moment, K i is the integration coefficient, K d is the differential coefficient; ∑e(i) is the accumulated error from the initial moment to the current moment; [e(K)-e(K-1)] is the rate of change of the color error.

[0030] The roller position is adjusted by the position adjustment amount, and the roller drive system is adjusted by the position adjustment amount, that is, fed back to the motion control unit to change the roller speed and position. Among them, when the color error is larger, the position adjustment amount is larger. The position adjustment amount includes the position amount and the direction amount. The position amount ΔP is expressed as

[0031] ΔP=λ×ΔE+α×(ΔE′ / Δt)×β(f,A);

[0032] Wherein, λ is the proportional coefficient of color error converted to position adjustment; ΔE is the quantized value of color error; ΔE' / Δt is the rate of change of color error over time, which can be obtained by continuously measuring color error and calculating the ratio of its difference to time; α is the influence coefficient, which is used to adjust the influence of color error change rate on position adjustment; f is the vibration frequency of the current printing equipment; A is the amplitude of the current printing equipment; β is the influence coefficient of vibration frequency and amplitude on position adjustment, which can be determined by experimental data.

[0033] The direction quantity is based on the various components of the color error (such as L, a, b * ) is compared with the standard color to determine the adjustment direction. In this embodiment, the color difference meter is used to measure to obtain the color error, and the color brightness L, the red-green tone a, and the yellow-blue tone b * By calculating the single color difference, the deviation value of each component is obtained, and the adjustment direction of the direction quantity is obtained. At the same time, the comprehensive difference calculation is performed in three dimensions to obtain the color error.

[0034] The synchronous control module is used to adjust the printing position of each printing unit. In this embodiment, the printing position of each printing unit is synchronously adjusted according to the output parameters obtained in real time to reduce the error between the printing units. In this embodiment, an error compensation mechanism can be set to detect and correct errors in real time.

[0035] The ink supply and cleaning unit includes an intelligent ink supply module and an automatic cleaning module. The intelligent ink supply module is used to automatically adjust the supply of each color ink according to printing requirements. That is, it automatically adjusts according to the ink parameters obtained in real time to adapt to different printing requirements, reduce operator intervention, improve production efficiency, and ensure stable ink supply during the printing process, avoiding problems such as uneven color and breakpoints during the printing process, and effectively improving printing quality. At the same time, through precise supply control, the module can avoid ink waste and reduce printing costs.

[0036] The automatic cleaning module is used to regularly clean the parts to be cleaned according to the set cycle. In this embodiment, according to the actual frequency of use, the cleaning cycle can be set according to actual needs, and when the set cleaning cycle is reached, the cleaning is automatically started. The cleaning process includes but is not limited to spraying cleaning liquid, brushing, flushing and other steps on the nozzle, ink roller, rubber cloth and other parts to ensure that the parts to be cleaned are thoroughly cleaned, avoid residual ink and dirt, ensure the cleanliness and transfer efficiency of the ink roller, avoid clogging or drying, and ensure printing quality and clarity.

[0037] The user interface unit includes a touch screen module and a remote monitoring module. The touch screen module is used for users to input printing tasks, set printing parameters, and display and monitor the printing status. The remote monitoring module is used to achieve remote control, including remote viewing and remote settings, to improve operability and convenience.

[0038] In this embodiment, since the existing printing control system has different standards between printing devices of different brands and designs, the interfaces do not match, and data exchange is difficult, it is difficult to integrate the equipment, increase the maintenance and upgrade costs, and thus limit the versatility and integration. In addition, since the existing printing equipment control systems mostly rely on foreign technology, the compatibility between the systems is poor. At the same time, equipment users, maintainers, and managers may have communication problems such as information asynchrony, resulting in poor coordination in equipment scheduling, maintenance, and repair, affecting the stable operation of the system, and further limiting the versatility and integration of the equipment. At present, in order to reduce costs, printing often adopts batch production, but with the increase in market demand for small batches and multiple varieties, batch production has been difficult to meet the requirements and is prone to backlogs and waste.

[0039] This solution breaks through technical limitations and inherent production thinking patterns. By integrating a universal controller, it can obtain printing color information in real time and dynamically adjust printing parameters such as roller speed and position, thereby ensuring that the printing equipment can flexibly adapt to the printing requirements of various cardboards. The system has a high degree of versatility, integration and control uniformity, significantly improving printing accuracy and meeting more stringent printing needs.

[0040] Embodiment 2

[0041] Different from the first embodiment, in this embodiment, the user interface unit is also used to alarm and display the fault. When a device fails, the touch screen module will alarm and display the corresponding fault information or fault code, including the fault type, fault code, fault occurrence time, etc., so that the operator can quickly view and identify and take timely measures. At the same time, an indicator light (such as a red light) may light up to visually remind the operator that the device is in a fault state. The operator can view detailed fault information or historical alarm records through the display screen of the touch screen module to conduct in-depth analysis and processing of the fault, improve processing efficiency, and reduce labor intensity and maintenance time.

[0042] The remote monitoring module is also used to diagnose faults remotely. In this embodiment, the remote monitoring module is connected to the device through remote communication technology to achieve remote monitoring and fault diagnosis of the device. When a device fails, it can perform fault diagnosis on its own and generate corresponding maintenance suggestions or alarm information. Operators or maintenance personnel can remotely view the fault information and alarm records of the device through the remote monitoring module, so that they can understand the operating status and fault conditions of the device before arriving at the site, so as to make timely maintenance decisions, reduce repetitive workload, improve maintenance efficiency, and provide strong guarantees for the stable operation of the equipment.

[0043] In this embodiment, fault alarm, remote operation and remote fault diagnosis are realized through the touch screen module and the remote monitoring module, and the existing data and experience are fully utilized for comprehensive judgment, and fault diagnosis and alarm are carried out quickly and timely, thereby improving troubleshooting efficiency and reducing maintenance costs. At the same time, remote operation is realized and system flexibility is enhanced, thereby optimizing production efficiency and improving service quality.

[0044] The above is only an embodiment of the present invention, and the common knowledge such as the known specific technical solutions and / or characteristics in the solution is not described in detail here. It should be pointed out that for those skilled in the art, without departing from the technical solution of the present invention, several modifications and improvements can be made, which should also be regarded as the protection scope of the present invention, and these will not affect the effect of the implementation of the present invention and the practicality of the patent. The scope of protection required by this application shall be based on the content of its claims, and the specific implementation methods and other records in the specification can be used to interpret the content of the claims.

Claims

1. A printing control system based on a universal controller, characterized in that: It includes a central controller unit, which is used to generate corresponding control instructions according to the printing task; a motion control unit, which is used to drive and adjust the roller speed of each printing unit; a color management unit, which is used to obtain the color information of the printed product in real time and adjust the output parameters of each color according to the real-time color information; an ink supply and cleaning unit, which is used to adjust the ink supply according to the printing demand and clean it regularly according to the set cycle; User interface unit, used for operation settings and printing status display.

2. A printing control system based on a universal controller according to claim 1, characterized in that: The motion control unit includes a roller drive module and an encoder feedback module; the roller drive module is used to drive the roller of each printing unit to rotate at a set speed, and adjust the roller speed according to the output parameters; the encoder feedback module is used to monitor the actual rotation speed and position of the roller in real time, and generate feedback information to be transmitted to the central controller unit.

3. A printing control system based on a universal controller according to claim 1, characterized in that: The color management unit includes a color monitoring module, a color correction module and a synchronization control module; the color monitoring module is a sensor arranged on the printing path, which is used to monitor the color information of the printed product in real time; the color correction module is used to generate corresponding output parameters according to the acquired color information, and send the corresponding output parameters to the motion control unit; the synchronization control module is used to adjust the printing position of each printing unit.

4. A printing control system based on a universal controller according to claim 1, characterized in that: The ink supply and cleaning unit includes an intelligent ink supply module and an automatic cleaning module; the intelligent ink supply module is used to automatically adjust the supply amount of each color ink according to printing requirements; the automatic cleaning module is used to regularly clean the part to be cleaned according to a set cycle.

5. A printing control system based on a universal controller according to claim 1, characterized in that: The user interface unit includes a touch screen module and a remote monitoring module; the touch screen module is used for the user to input printing tasks, set printing parameters, and display and monitor the printing status; the remote monitoring module is used to achieve remote control.

6. A printing control system based on a universal controller according to claim 2, characterized in that: The encoder feedback module includes an encoder arranged on each roller shaft.

7. A printing control system based on a universal controller according to claim 3, characterized in that: The output parameters include ink parameters and control information; the ink parameters include ink supply volume, concentration and roller pressure; the control information includes roller speed and roller position.

8. A printing control system based on a universal controller according to claim 7, characterized in that: The roller speed is adjusted by the speed adjustment amount, and the roller position is adjusted by the position adjustment amount; the speed adjustment amount is expressed as Δu(K)=K p e(K)+K i Σe(i)+K d [e(K)-e(K-1)]; In the formula, K p is the proportional coefficient, e(K) is the color error at the current moment, K i is the integration coefficient, K d is the differential coefficient; Σe(i) is the cumulative error from the initial moment to the current moment; [e(K)-e(K-1)] is the rate of change of the color error; The position adjustment amount includes a position amount and a direction amount, wherein the position amount ΔP is expressed as ΔP=λ×ΔE+α×(ΔE' / Δt)×β(f,A); where λ is the proportional coefficient of color error converted to position adjustment; ΔE is the quantized value of color error; ΔE' / Δt is the rate of change of color error over time; α is the influence coefficient; f is the vibration frequency of the current printing device; A is the amplitude of the current printing device; β is the influence coefficient; The direction quantity is determined by comparing each component of the color error with the standard color to determine the adjustment direction.

9. A printing control system based on a universal controller according to claim 8, characterized in that: The ink supply adjustment expression is ΔV=K V ×ΔE; where K V is the proportionality coefficient; The concentration adjustment expression is ΔC = K C ×(target saturation - current saturation); where K C is the proportionality coefficient; The roller pressure is adjusted by calculating the color error quantization value ΔE through the current color information and the standard color. According to the color error and the preset adjustment strategy, the roller pressure adjustment amount is calculated, which is expressed as ΔT = KT × ΔE × f (T t ,T0,C t ,R); where K T is the proportionality coefficient; T t is the current roller pressure, T0 is the target pressure; C t is the current ink density; R is the paper type.

10. A printing control system based on a universal controller according to claim 5, characterized in that: The user interface unit is also used to alarm and display faults; the touch screen module is also used to alarm and view faults; and the remote monitoring module is also used to diagnose faults remotely.

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