Efficient processing system for glass plates
Patent Information
- Application Number
- CN202480032509.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2023-05-26
- Filing Date
- 2024-05-14
- Publication Date
- 2025-12-26
AI Technical Summary
Existing glass plate processing technology suffers from material waste, image printing mismatch due to dimensional changes, low printing efficiency, and inability to adapt to dimensional changes caused by wear of the grinding disc.
The algorithm employs a nested approach to optimize cutting, combining recognition, matching, scaling, trimming, and alignment units. It uses sensors to detect and automatically adjust images to adapt to segments of different shapes and sizes, achieving efficient image printing.
Reduce material waste, improve image printing accuracy and efficiency, adapt to dimensional changes caused by wear of the grinding disc, and achieve high-quality glass plate processing.
Smart Images
Figure CN121219652A_ABST
Abstract
Description
[0001] The object of the present invention is a high-efficiency processing system for glass sheets.
[0002] During the processing process, the glass sheet undergoes successive processing steps, which are necessary to obtain the finished product. The finished product is a glass having different dimensions and shapes according to the intended use.
[0003] Generally, the processing of a glass sheet involves the following steps: cutting, mechanical processing, decoration, drying and tempering.
[0004] First, a desired segment is cut from a glass sheet using a glass cutter and tools that make use of techniques known in the field of glass processing. Such a segment is generally very similar in shape and size to the final product, but requires further processing.
[0005] The obtained segment has not yet reached the exact dimensions and final characteristics required for its use.
[0006] Subsequently, the segment obtained from the initial sheet undergoes mechanical processing necessary for finishing the edges or surfaces of the segment. The mechanical processing step can be carried out by means of grinding or milling or other processes capable of removing portions of vitreous material by friction discs or abrasive parts of higher hardness.
[0007] After mechanical processing, the segment represents a substrate for subsequent processing.
[0008] However, after a certain number of grinding cycles, the abrasive disc tends to wear out, losing effectiveness: as a result, the grinding power decreases and, consequently, the ability to remove vitreous material from the edges of the obtained segment decreases.
[0009] Therefore, for the same length of mechanical processing cycles, an un-worn abrasive disc will remove more material, while a more worn abrasive disc will remove less material. It follows that, depending on the operating conditions of the abrasive disc, the final dimensions of the substrate obtained after mechanical processing vary within the tolerance threshold.
[0010] The next step is to decorate the substrate.
[0011] In the prior art, the substrate is decorated by means of digital inkjet printing: the ink is dispensed and deposited on the substrate from nozzles belonging to the print head; the print heads are placed side by side to form a printing bar.
[0012] Patent application No. 201800009570, filed by the same applicant, shows a device for decorating a glass sheet by means of inkjet printing. In addition to describing the steps of digitally inkjet printing the glass sheet, the document introduces a plate preheating step: the aforementioned preheating step takes place before the ink is dispensed from the nozzles. Such a preheating step allows the deposited ink to dry faster.
[0013] Therefore, a substrate pre-heating step is also known in the prior art.
[0014] Subsequently, the decorated substrate is subjected to a final ink drying and toughening, so as to obtain, at the end of the process, a properly decorated substrate that complies with the application and has sufficient mechanical features.
[0015] The processing process starting from a glass sheet has some critical elements.
[0016] First of all, the glass processing processes known in the prior art generate, in the cutting step, a non-negligible amount of offcuts that lead to material and economic waste.
[0017] Furthermore, a requirement for the printing to be done in a sufficient quality manner during the decoration step is that the selected image is printed on the substrate with a predetermined resolution; furthermore, the image must be printed correctly in terms of position and rotation of the substrate to be decorated.
[0018] However, as mentioned in the previous paragraph, the result of the mechanical processing is subject to some variations in the final shape and size of the obtained substrate. Although such variations are within the tolerance range that allows the use of the substrate, the printing of the image can not perfectly match the obtained substrate. For example, the same printing settings can perfectly apply to decorate a substrate ground with a non-worn grinding disc, and vice versa, but can not be sufficiently precise for a substrate ground with a more worn grinding disc.
[0019] Furthermore, in the prior art, the processing of the substrate, and in particular the printing step, is carried out by taking one substrate at a time, which is inefficient in terms of yield and productivity. Therefore, the entire processing process, and in particular the substrate printing step, can be improved.
[0020] In view of the above considerations, the performance of a glass substrate printer and of a relative control system can certainly be improved in order to achieve high performance in terms of output quality, precision and printing efficiency, while limiting the amount of rejects.
[0021] Furthermore, in view of the same considerations, the entire processing process starting from a glass sheet can be improved in terms of efficiency.
[0022] The object of the present invention is to provide a processing system for glass sheets and for printing glass substrates that can overcome the limitations of the prior art.
[0023] The features and advantages of the present invention will be more fully apparent from the following detailed description of embodiments of the present invention, as illustrated in the accompanying drawings, which are shown by way of non-limiting example and in which: Figure 1 A top view of a processing system according to an embodiment is shown in a simplified depiction.
[0024] Figure 2 a schematic view of the operation of the processing system of Figure 1 is shown.
[0025] Figure 3 an embodiment of a printing unit included in the processing system of Figure 1 is shown.
[0026] The aim of the present invention is a high-efficiency processing system for glass plates with high-quality output.
[0027] In the course of the present disclosure, the term "plate" is intended to mean a plate-shaped glass object comprising two main faces (one upper main face and one lower main face) and a plurality of lateral faces, wherein the distance between the main faces is much smaller than the distance between the lateral faces; the term "segment" is intended to mean a portion obtained by cutting the plate; "printing" is preferably intended to mean a digital inkjet printing process of the type known in the art, wherein an image is received as input and the dispensing of ink drops at determined positions on a substrate is controlled by the action of a unit to reproduce the image received as input on the aforementioned substrate. Finally, "shape" is intended to mean the spatial configuration of an object, attributable to a conventional geometric shape or combinations thereof.
[0028] Advantageously, the processing system according to the present invention makes it possible to reduce the amount of waste and, therefore, waste.
[0029] Advantageously, the processing system according to the present invention makes it possible to obtain image prints on substrates having different shapes and sizes, matching each substrate with a respective decoration.
[0030] Advantageously, the processing system according to the present invention makes it possible to adapt the image (and, therefore, the decoration to be applied to the substrate) to the dimensional variations, for example, according to the mechanical processing process.
[0031] Advantageously, the processing system according to the present invention makes it possible to rotate the image in order to adapt the printing to the orientation of the substrate.
[0032] Advantageously, the processing system according to the present invention makes it possible to perform such a printing process simultaneously on several substrates.
[0033] Figure 1 a simplified depiction of an embodiment of a high-efficiency processing system (A) for plates comprising a plurality of processing machines arranged in sequence is shown. Figure 1 the simplified depiction relates to a preferred but not exclusive embodiment of the system (A) according to the present invention.
[0034] The system (A) comprises: a mobile stage (P) having a direction of transport (T).
[0035] The plate (L) is moved along the direction of transport (T) on the mobile stage (P).
[0036] According to a first embodiment, the mobile stage (P) comprises a conveyor belt associated with a mobile device arranged to move the panel (L) on the outer surface of the conveyor belt: as a result, the panel (L) translates in the conveying direction (T) at the conveying speed (V).
[0037] In an alternative embodiment, the mobile stage (P) comprises a series of cylindrical drums arranged parallel to each other and perpendicular to the conveying direction (T); such drums are associated with a mobile device configured to move the panel (L) on the outer surface thereof, so that the panel (L) translates in the conveying direction (T) at the conveying speed (V).
[0038] The mobile device associated with the mobile stage (P) is configured to very advantageously enable the translation of the panel (L) while minimizing unwanted oscillations and vibrations that could interfere with the integrity of the panel and the final quality of the decoration.
[0039] The panel (L) coming from a station upstream of the system (A) with respect to the conveying direction (T) is positioned on the mobile stage (P) in order to undergo the following processing steps as illustrated below. The above-mentioned upstream station can be a processing station, a storage warehouse, a conveyor or a mobile device or UGV.
[0040] The first processing step according to the present application is a high-efficiency cutting step operated by the cutting device (1).
[0041] The cutting device (1) is configured to cut the panel (L) conveyed by the mobile stage (P) into a plurality of sections (C).
[0042] According to the purposes of the present application, the cutting device (1) is advantageously optimized by means of a control system configured to obtain a plurality of sections (C) within the panel (L). That is, the purposes of the present application include an algorithm integrated with the control system of the cutting device: the above-mentioned algorithm is configured to cut a plurality of sections (C) within the panel (L).
[0043] The sections (C) obtained from the panel (L) can all have the same shape, or they can present different shapes.
[0044] The algorithm integrated into the control system is otherwise referred to as a nesting algorithm: this algorithm receives as input the dimensions of the surface (S) of the panel (L) and the shape (F) of each section (C) to be cut, processes the combination of sections (C) that best optimizes the surface of the panel (L), and sends operating commands to the cutting tool based on the combination of sections (C) processed by means of the control device.
[0045] The plurality of sections (C) identified within the panel (L) by the nesting algorithm enables a very advantageous reduction in the amount of waste produced.
[0046] The application of the nesting algorithm advantageously allows the entire surface (S) of the plate (L) to be exploited in order to reduce material waste.
[0047] The cutting operations are preferably, but not exclusively, performed by means of a CNC or computer numerical control type cutting machine. CNC type cutting machines are known in the prior art.
[0048] A plurality of segments (C) can be obtained from the plate (L), which are subjected to subsequent machining steps.
[0049] After the cutting step, the segments (C) are conveyed from the moving table (P) along a conveying direction (T) towards one or more machines configured for mechanical machining; At the downstream of the cutting step, each segment (C) is finished by means of mechanical machining.
[0050] The mechanical machining device (2) comprises abrasive elements, preferably discs or other appropriately shaped elements, which operate on the surface of the segments (C) and preferably along the edges and the corners, so as to make them smoother and more easily controllable; according to other embodiments, the mechanical machining serves to impart specific surface characteristics to each segment (C) cut from the plate (L).
[0051] Furthermore, the mechanical machining can also affect the internal part of the segments (C), even removing material throughout the thickness of the internal part of the segments (C); therefore, the mechanical machining machine (2) is also configured to perform this type of action on the segments (C).
[0052] The mechanical machining can be performed by means of grinding, milling or other techniques known in the art configured to modify the appearance, the dimensions or the surface or internal characteristics of the segments (C).
[0053] Generally, these operations involve removing vitreous material to finish the segments (C); for example, the mechanical machining device (2) makes it possible to remove sharp edge portions, so as to make each segment (C) safer to hold and more easily controllable.
[0054] Furthermore, the mechanical machining device (2) makes it possible to remove vitreous material within the surface of each segment (C) so as to obtain internal voids; the aforementioned internal voids can present different dimensions and geometries. In particular, the internal voids can implement a function or can impart preferred aesthetic characteristics to the segments (C).
[0055] In this case, in other words, the mechanical machining step causes the removal of vitreous material even throughout the thickness of the segments (C).
[0056] The machining at the edge of the section (C) and the machining within the section (C) can advantageously be combined by the machining device (2).
[0057] As mentioned in the previous paragraph, the abrasive element can wear after a certain number of work cycles; therefore, a section (C) machined with an un-worn abrasive element will undergo a greater material removal than a section (C) ground with a more worn element, in the same amount of time.
[0058] Therefore, for the same shape (F), the dimensions of each section (C) can vary within a tolerance range, due to the machining process of the machining device (2).
[0059] Subsequently, the plurality of sections (C) is moved along the conveying direction (T) towards the printing unit (3).
[0060] The printing unit (3), located downstream of the machining device, receives the plurality of sections (C) as input.
[0061] The printing unit (3) is configured to decorate each of the sections (C) in single-pass mode. That is, the sections (C) are decorated during their conveyance on the moving table (P) without interrupting their conveyance.
[0062] According to the present application, the sections (C) are conveyed on the moving table (P) without being arranged in a precise order and without being aligned with each other: the plurality of sections (C) can be conveyed towards the printing unit (3) simultaneously. In the processing system subject of the present application, the printing unit (3) first comprises an identification unit (4) of the shape (F) of the sections (C) and a matching unit (5).
[0063] The identification unit (4) comprises a plurality of sensors configured to detect the shape (F) of each of the sections (C) entering the printing unit (3); for example, but not exclusively, the sensors are image sensors. Preferably, but not exclusively, the identification unit (4) comprises an imaging system comprising at least one camera. Other detection and imaging tools known in the art can also be used.
[0064] The shape (F) of each section (C) can be defined by a set of parameters, such as the length of the sides and the amplitude of the angles comprised therebetween; that is, the set of parameters uniquely defines the specific shape (F) of the section (C): sections (C) having different shapes (F) have different sets of parameters.
[0065] The expected dimension (D') is defined as the value assumed by the set of parameters defining the shape (F) of the section (C) under optimal machining conditions; that is, under ideal conditions, with un-worn abrasive means, the value assumed by the set of parameters corresponds to the expected dimension (D') of the shape (F).
[0066] On the contrary, the actual size (D") is defined as the value assumed by the same set of parameters under non-ideal machining conditions; an example of non-ideal machining conditions is when the abrasive disc used during the machining process is worn. In this specific case, the worn disc removes less glassy material, so the actual size (D') is greater than the expected size (D').
[0067] Wear is one of the causes that can determine an expected size (D') different from the actual size (D") at the end of the machining process; other phenomena (not listed here, but easily thought of by the person skilled in the art) can interfere with the machining process, thus affecting the actual size (D") of each section (C).
[0068] The recognition unit (4) is therefore also configured to detect the actual size (D") of each section (C); in fact, the recognition unit (4) comprises a data acquisition and processing system configured to detect the actual size (D") of each section (C) of the shape (F). Preferably, the imaging system comprises at least one camera; alternatively, the imaging system comprises other types of imaging and detection systems known in the art.
[0069] The shape (F) detected for each section (C) is converted into a shape signal (S(f)) which is sent to the matching unit (5). That is, the shape (F) allows the matching unit (5) to establish the matching of the section (C) with the corresponding image (I), as described in the following paragraphs.
[0070] The matching unit (5) is configured to match each shape signal (S(f)) with the respective image (I): in this step, each section (C) advantageously corresponds to the correct decoration selected in the database on the basis of the shape (F) of that section (C) itself, which matches the correct image (I).
[0071] Very advantageously, the object of the present application allows to obtain a shape (F)-image (I) matching for each section (C); the printing unit (3) automatically processes the above matching and allows to decorate the sections (C) of different shapes (F) with the corresponding image (I). Therefore, the process is efficient, versatile and not limited to specific shapes (F).
[0072] The recognition unit (4) and the matching unit (5) are configured to operate in series by detecting the shape (F) and the actual size (D") of the sections (C) arranged in succession along the conveying direction (T) on the moving table (P).
[0073] The recognition unit (4) and the matching unit (5) are also configured to operate in parallel, detecting the shape (F) and the actual size (D") of the sections (C) arranged in parallel along the conveying direction (T) on the moving table (P).
[0074] Finally, the recognition unit (4) and the matching unit (5) are configured to operate by detecting the shape (F) and the actual dimensions (D") of the segments (C) arranged in different ways on the mobile table (P).
[0075] The printing unit (3) according to the present application also comprises a processing unit (6) arranged to adapt the image (I) to be matched to the segments (C) by the matching unit (5) to the specific segment (C) passing through the printing unit (3).
[0076] In order to adapt the image (I) to be printed on each segment (C) having a shape (F), the processing unit (6) advantageously comprises at least one of: - a scaling unit (7) - a trimming unit (8).
[0077] That is, the processing unit (6) can comprise only the scaling unit (7), or only the trimming unit (8), or both the scaling unit (7) and the trimming unit (8).
[0078] In other words, in a first embodiment, the system (A) according to the present application comprises: a processing unit (6) comprising only the scaling unit (7). Alternatively, in a second embodiment, the system (A) according to the present application comprises only the trimming unit (8).
[0079] Also alternatively, in a third embodiment, the system (A) according to the present application comprises both the scaling unit (7) and the trimming unit (8).
[0080] The scaling unit (7) and the trimming unit (8) are configured to perform the adaptation of the image (I) to the specific shape (F) of the segment (C) in different ways.
[0081] The scaling unit (7) and the trimming unit (8), if both are present in the processing unit (6), are activated alternately by the operator; that is, the operator can decide to activate the scaling unit (7) or the trimming unit (8) depending on the final print to be obtained on the segment (C).
[0082] In fact, the purpose of the processing unit (6) is to obtain a print of the image (I) that perfectly adapts to the specific geometric characteristics of each segment (C), taking into account the specific shape (F).
[0083] The operation of the above-mentioned scaling unit (7) and trimming unit (8) is described in detail in the following paragraphs.
[0084] The scaling unit (7) is configured to adapt the dimensions of the image (I) matched to the shape (F) by the matching unit (5) to the actual dimensions (D") of the segment (C) of the shape (F).
[0085] The scaling unit (7) therefore receives the information transmitted by the recognition unit (4): in particular, the scaling unit (7) is configured to receive the information relating to the actual dimensions (D") acquired and transmitted by the processing unit (4).
[0086] The scaling algorithm integrated in the scaling unit (7) is configured to compare the actual dimensions (D") with the expected dimensions (D") of the section (C) of the shape (F) and to perform the scaling of the image (I) on the basis of the actual dimensions (D").
[0087] That is, the scaling algorithm is advantageously configured to perform a controlled overall or partial deformation of the image (I) described above.
[0088] One of the methods that the scaling algorithm can adopt involves dividing the image into a grid or mesh of triangles, each of which represents a unit on which a scaling or deformation operation can be performed.
[0089] The present disclosure will not delve into the operational details of the scaling algorithm.
[0090] That is, the scaling unit (7) is advantageously arranged to adapt the image (I) to the shape (F) and in particular to its actual dimensions (D"): for sections (C) for which the actual dimensions (D") are greater than the expected dimensions (D"), the image (I) is deformed by enlargement; for sections (C) for which the actual dimensions (D") are less than the expected dimensions (D"), the image (I) is deformed by reduction.
[0091] In the following paragraphs, reference will be made to the term "scaling" to indicate the action of adaptation of the image (I) performed by the scaling unit (7).
[0092] On the other hand, the trimming algorithm (8) is configured to perform the adaptation of the image (I) without deforming it after the image (I) has been printed onto the section (C). The trimming algorithm (8) works by refining or in other words by cutting out the portion of the image (I) to be printed on the section (C). That is, if the actual dimensions (D') of the section (C) having the shape (F) are less than the expected dimensions (D'), the trimming algorithm integrated in the trimming unit (8) is configured to crop the image (I) on the basis of the actual dimensions (D') detected in order to obtain a trimmed image (Ir).
[0093] Unlike what has been described for the scaling unit (7), the trimming unit (8) operates by removing portions of the image (I); preferably, but not exclusively, the trimming algorithm operates by trimming or in other words cropping portions of the image (I) in order to obtain a trimmed image (Ir). That is, by means of the trimming unit (8), the edges of the image (I) can advantageously be cropped and therefore not printed by the printing unit (3).
[0094] Therefore, the trimming unit (8) receives the information transmitted by the recognition unit (4): in particular, the trimming unit (8) is configured to receive the information relating to the actual size (D") acquired and transmitted by the processing unit (4).
[0095] Therefore, the trimming algorithm integrated in the trimming unit (8) advantageously enables to obtain a trimmed image (Ir) that perfectly matches the actual size (D") of the respective section (C). The present disclosure will not describe in detail the trimming algorithm, but will be introduced from a functional point of view.
[0096] In the following paragraphs, reference will be made to the term "trimming" to indicate the action of adapting the image (I) performed by the trimming unit (8).
[0097] In the case of trimming, the effect obtained at the end of the printing step is deliberately different from the effect obtained by scaling: by means of the trimming algorithm, a portion of the image (I) must be removed to obtain the trimmed image (Ir). Therefore, the scaling unit (7) and the trimming unit (8) represent two different and alternative methods for adapting the image (I) to the section (C), which the operator can pre-select depending on the result to be obtained.
[0098] Therefore, as a summary of the above, after determining the necessary scaling of the image (I) or the desired trimming, the scaling unit (7) and the trimming unit (8) are able to send to the printing unit (3) the operating commands so that the image (I) adapted to the actual size (D") according to the method selected by the operator is correctly printed on the respective section (C).
[0099] The printing unit (3) subject of the present invention also comprises an alignment unit (9) configured to determine the correct positioning of the image (I) or of the trimmed image (Ir) on each section (C).
[0100] In fact, when leaving the cutting device (1) and the mechanical processing device (2), the alignment of the sections (C) with respect to the direction of transport (T) is not checked. That is, considering the direction of transport (T), the sections (C) can be perfectly aligned and ready to receive the printing ink, or they can be misaligned with respect to the direction of transport (T).
[0101] In the absence of the alignment unit (9), the image (I) or the trimmed image (Ir) will not be perfectly printed on the respective section (C), but will be rotated by an angle (a), and the greater the angle of rotation of the section (C) with respect to the expected alignment with respect to the direction of transport (T), the greater the angle.
[0102] The alignment of the sections (C) with respect to the direction of transport (T) can be verified in various ways by exploiting sensor systems and algorithms known to the person skilled in the art.
[0103] Patent application No. 102016000022779 in the same applicant's name discloses an example of a method for detecting the alignment of a substrate inside a printer; the above patent application not only shows a method for detecting the alignment of a substrate, but also shows a method for rotating an image to be printed on the substrate, in order to compensate for any misalignment of the substrate with respect to the direction of transport (T).
[0104] According to this method, a reference system is defined as the coordinates of the reference of the substrate to be printed moving through the printer along the direction of printing. Such coordinates are compared with a set of virtual coordinates imparted to the image to be printed: the virtual coordinates correspond to the correct alignment of the substrate with respect to the direction of printing.
[0105] If the two sets of coordinates coincide, no correction is made. On the contrary, if the two sets of coordinates do not coincide, the algorithm determines the rotation of the image so that it is correctly printed on the substrate.
[0106] With reference to the alignment unit (9) subject of the present application, the appropriately selected reference system is able to detect a set of real coordinates (x, y, z) that identify a segment (C) on which the printing operation is to be performed; such segment (C) is moved through the printing unit (3) by the moving table (P) in the direction of transport (T).
[0107] Each segment (C) corresponds to an image (I) imparted with properties by the matching unit (5), scaled by the scaling unit (7) or trimmed by the trimming unit (8): a set of virtual coordinates (xv, yv, zv) corresponding to the correct alignment of the segment (C) along the direction of transport (T) is imparted to such image (I) or trimmed image (Ir).
[0108] If the set of real coordinates (x, y, z) and the set of virtual coordinates (xv, yv, zv) coincide, the alignment unit (9) does not perform any operation; on the contrary, if the set of real coordinates (x, y, z) and the set of virtual coordinates (xv, yv, zv) do not coincide, after identifying the angle of rotation (a) between the two sets, the alignment unit (5) determines that the image (I) or the trimmed image (Ir) is rotated by the same angle (a) around its main axis.
[0109] Very advantageously, the action of the scaling unit (7) or the trimming unit (8) and the alignment unit (9) is able to obtain a high-precision printing of the image (I) on the segment (C); in some industries, including the production of motor vehicles, it is necessary to obtain a glass printing as precise as possible, in order to avoid compromising the driving experience and to protect critical components and connecting elements from UV radiation.
[0110] The scaling unit (7), the trimming unit (8) and the alignment unit (9) are configured to operate on segments (C) arranged in series on the mobile stage (P). The scaling unit (7), the trimming unit (8) and the alignment unit (9) are also configured to operate on segments (C) arranged in parallel on the mobile stage (P). Finally, the scaling unit (7), the trimming unit (8) and the alignment unit (9) are configured to operate on segments (C) arranged in different ways on the mobile stage (P).
[0111] Furthermore, the printing unit (3) according to the present application has a control unit (10) configured to receive input information from the matching unit (5), the scaling unit (7) or the trimming unit (8) and the alignment unit (9).
[0112] That is, the matching unit (5) sends to the control unit (10) information associated with the shape (F) - image (I) matching of each segment (C); furthermore, the scaling unit (7) or the trimming unit (8) transmits to the control unit (10) information related to the image to be printed on the respective segment (C) as a function of the adaptation mode of the image (I) to the matching segment (C); finally, the scaling unit (9) sends to the control unit (10) information related to the rotation (a) that can need to be performed on the image (I) or the trimmed image (Ir) before the printing operation. The control unit (10) processes the above information and sends the direct printing command to at least one printing bar (31).
[0113] With reference to Figure 3 , the printing unit (3) comprises at least one printing bar (31) positioned above the mobile stage (P); each printing bar (31) in turn comprises a plurality of print heads (32) connected to an ink reservoir and placed side by side in a direction perpendicular to the direction of transport (T).
[0114] Each print head (32) comprises a plurality of nozzles (33) configured to distribute ink from top to bottom on each of the segments (C).
[0115] The nozzles (33) are digitally controlled by the control system (10).
[0116] That is, the control unit (10) processes the information received from the matching unit (5), the scaling unit (7) or the trimming unit (8) and the alignment unit (9) and, on the basis of this, sends operating commands to the print bar (31); for each set of information [shape (F) - image (I) matching; actual size (D'); adaptation mode of the image (scaling or trimming) to the segment (C); angle (a)], the control unit (10) sends activation commands to the print head (32) and, in particular, to the individual nozzles (33), so that these are activated at the precise moment to dispense ink, which corresponds to the precise position on the segment (C).
[0117] The result is a high-precision printing of the image (I) appropriately adjusted in size and adapted on the basis of the actual size (D") on each segment (C).
[0118] Each print bar (31) is positioned above the moving plane (P); preferably each print bar (31) is arranged perpendicular to the direction of transport (T). The ink is dispensed from the nozzles (33) belonging to the print bar (31) towards the moving plane (P) so that it is deposited on each segment (C), defining a printing front (H).
[0119] That is, the printing front (H) of each print bar (31) is identified by the ink dispensed by the nozzles (33) belonging to the print bar (31) and, therefore, also perpendicular to the direction of transport (T).
[0120] The printing unit (3) can therefore operate on segments (C) arranged in series along the direction of transport (T) on the moving plane (P): when each segment (C) on the moving plane (P) is transported in the direction of transport (T), the printing front (H) of each print bar (31) in this configuration affects one segment (C) at a time.
[0121] The printing unit (3) can also operate on segments (C) arranged in parallel along the direction of transport (T) on the moving plane (P).
[0122] According to this configuration, at least two segments (C) are placed side by side along a transverse direction (X) horizontal and perpendicular to the direction of transport (T) and advance from the moving plane (P) in the direction of transport (T). In this second configuration, the printing front (H) of each print bar (31) affects at least two segments (C) moving through the printing unit (3). That is, the ink is dispensed by the nozzles (33) belonging to the print bar (31) so that it is deposited on each of the segments (C): from this, the same print bar (31) simultaneously contributes to printing the image (I) matching the shape (F) of each segment (C) passing below it in the direction of transport (T).
[0123] The printing unit (3) can also operate on segments (C) arranged in different ways on the mobile table (P).
[0124] The technical result is to be able to print a plurality of segments (C) conveyed by the mobile table (P) along the main conveying direction (T) with very high precision and efficiency.
[0125] The segments (C) printed and output by the printing unit (3) are dried by means of a drying device (11) to allow the ink deposited on the glass to dry.
[0126] The drying device (11) can comprise UV or IR lamps directed towards the mobile table (P); alternatively, the drying can be carried out by means of ventilation devices configured to direct air knives from above to below towards the printed segments (C).
[0127] In another alternative embodiment, as shown in Figure 3 , the drying can be carried out simultaneously with the printing operation, interposing the drying devices, such as IR or UV lamps or fans, with the printing bars (31).
[0128] In an alternative embodiment, the segments (C) can undergo a heating step before the printing step: this preheating step, by means of specific preheating devices (12), allows the ink to dry more quickly, which is then dispensed by the printing unit (3); the preheating is particularly useful in applications that require the dispensing of thick layers of ink on the segments (C) in order to obtain highly opaque decorations, preventing the phenomenon of migration of the ink on the surface of the segments (C).
[0129] Finally, the printed and dried segments (C) are tempered by means of specific tempering devices (15) known in the state of the art to obtain vitrification of the ink and to obtain the final structural characteristics of the segments (C).
[0130] The system according to the present application finally comprises a quality control system (13).
[0131] The quality control system (13) described above can be located upstream of the tempering devices (15) with respect to the main conveying direction (T), as shown in Figure 1 and Figure 2 ; alternatively, the quality control system (13) can be located downstream of the tempering devices (15) with respect to the main conveying direction (T).
[0132] In order to be able to monitor the quality of printing of the image (I) on each segment (C) and in order to monitor the operation of each device and machine present in the system (A), the quality control system (13) is configured to analyze each piece or segment (C) output by the system (A) described in the preceding paragraph.
[0133] In practice, the quality control system (13) comprises a plurality of sensors configured to acquire information relating to each section (C).
[0134] A first example of control performed by the quality control system (13) concerns the printed image (I): a plurality of sensors, for example optical sensors, detect the image printed by the printing unit (3) on the section (C).
[0135] The comparison algorithm integrated with the quality control system (13) is able to compare the result of the printing operation detected on the section (C) by the optical sensors with the original image (I), taking into account any modifications introduced by the scaling unit (7) or the trimming unit (8) and the alignment unit (9) to adapt the actual dimensions (D"). The information obtained from such a comparison is sent to the classifier (14) which is configured to convert the data transmitted by the comparison algorithm into a classification of the printed piece obtained.
[0136] That is, after the comparison operation performed by the comparison algorithm integrated in the quality control system (13) and based on a preset tolerance threshold, the classifier (14) is configured to attribute a class to each product output by the system (A); an increasing class indicates a greater difference between the expected result and the result obtained.
[0137] That is, for example, but not exclusively, the classifier (14) attributes to each section (C) output by the system (A) a label defined by a class: an increasing class number indicates a worsening of the performance of the device, in this case the printing unit (3) with the associated matching unit (5), scaling unit (7) or trimming unit (8) and alignment unit (9).
[0138] For example, an increasing class therefore indicates the presence of an increasing number of defects at a qualitative level.
[0139] In a preferred, but not exclusive, embodiment, the classifier (13) attributes to each section (C) and, in turn, to each printing event performed by the printing unit (3) one of the following classes: 1 - the printing is correct, the product is in specification; 2 - the printing has defects, the product is in specification within a tolerance threshold; 3 - the printing has defects, the product is not in specification.
[0140] From class 1 to class 3, the number of defects detected increases and the impact on the quality of the final product increases.
[0141] Other intermediate classes can be intuitively identified depending on the specific requirements of each production process.
[0142] Moreover, the control system (13) and the classifier (14) can be programmed and adapted to evaluate the quality of each step of the processing of the board (L): appropriately selected sensors detect suitable quantities capable of characterizing the specific production step. Advantageously, based on the classification performed by the classifier (14), the quality control system (13) is configured to emit signals that can be intuitively interpreted by the line operators or by another production line management system.
[0143] Moreover, the quality control system (13) is configured to send traceability commands to the plurality of devices and units included in the production line of the system (A) in order to correct any operating errors that cause the quality of the final product to not comply with the desired specifications.
[0144] That is, the quality control system (13), by means of the sensor detection parameters, transmits the comparison values to the classifier (14) and, based on the assigned classification, communicates feedback to each device or unit of the processing line of the system (A) in order to improve the production process.
[0145] Advantageously, thanks to the introduction of the quality control system (13) and the classifier (14), it is possible to reduce the number of final products that do not comply with the requirements and therefore need to be discarded, or the number of final products that comply with the requirements but are not perfect.
[0146] It should be noted that the non-compliance can concern essential elements, which affect the performance of the final product, or marginal elements, which do not affect the performance of the final product but make the product imperfectly compliant with the specifications: the quality control system (13) is configured to identify the difference between these two types of non-compliance and to send operating commands with different priorities and ways based on the detected non-compliance.
[0147] The processing system according to the present application, as shown above in the preferred but not exclusive embodiment, advantageously enables to efficiently cut a plurality of sections (C) from the board (L), print the plurality of sections (C), reduce the amount of waste and scrap, improve the printing quality, thus ensuring a high level of precision, reduce the processing time and correct any errors and malfunctions present in the different steps of the production line, making the process more efficient.
Claims
1. A high-efficiency processing system for boards, comprising: The mobile station (P) has a transmission direction (T); The apparatus (1) is used to cut a segment (C) having a shape (F) and actual size (D") from a plate (L) having a surface (S), and includes an optimization algorithm integrated with the cutting tool according to claims 1 to 4; The machining apparatus (2) is configured to perform machining on the surface of each segment (C) of the shape (F) or through the thickness of each segment; and The printing unit (3) is configured to receive a set of images (I) of a desired size (D') as input and to distribute ink onto each segment (C) of the shape (F), wherein the printing unit (3) is located downstream of the cutting device (1) considering the conveying direction (T). The drying device (11) is configured to dry the ink dispensed onto each segment (C); The printing unit is characterized by comprising: The identification unit (4) includes multiple sensors configured to detect the shape (F) and actual size (D") of each segment (C); The matching unit (5) is configured to match an image (I) belonging to the set of images with the shape (F) of each segment (C) detected by the recognition unit (4); Alignment unit (9) is configured to detect a rotation angle (α) between the segment (C) and the main transport direction (T); and The control unit (10) is configured to receive the image (I) or the modified image (Ir), the expected size (D'), the actual size (D") and the angle (α) of each segment (C) as input, and to send an operation command to the printing unit (3); At least one of the following: The scaling unit (7) integrates a scaling algorithm and is configured to adapt the expected size (D') of the image (I) to the actual size (D") of each segment (C) detected by the recognition unit (4) and transmitted to the scaling unit (7). The trimming unit (8) integrates a trimming algorithm, operates alternately with the scaling algorithm of the scaling unit (7), and is configured to receive the actual size (D") of each segment (C) transmitted by the detection unit (4) as input, and calculate the trimmed image (Ir) based on the image (I).
2. The processing system according to claim 1, wherein, The printing unit (3) includes at least one printing strip (31) located above the moving stage (P), the at least one printing strip including a plurality of nozzles (33) configured to dispense ink toward the moving stage (P), and wherein the printing leading edge (H) perpendicular to the transport plane (T) is identified by the ink dispensed from top to bottom by the nozzles (33) belonging to the printing strip (31).
3. The processing system according to claim 2, wherein, The printing leading edge (H) extends a certain width, which is measured along a horizontal transverse direction (X) perpendicular to the transport direction (T) and is sufficient to be positioned above two or more segments (C) placed side by side along the transverse direction (X).
4. The processing system according to claim 1, wherein, The recognition unit (4) includes a plurality of image sensors configured to detect the shape (F) of each segment (C).
5. The processing system according to claim 4, wherein, The identification unit (4) converts the shape (F) of the segment (C) into a shape signal (S(f)).
6. The processing system according to claim 5, wherein, The identification unit (4) transmits the shape signal (S(f)) to the matching unit (5).
7. The processing system according to claim 1, wherein, The scaling unit (7) is configured to: transmit the expected size (D') of the image (I) to the control unit (10) if the expected size (D') of the image (I) and the actual size (D") of the segment (C) are consistent; or If the actual size (D") of the segment (C) and the expected size (D') of the image (I) are inconsistent, the actual size (D") of the new image (I') given by the adaptation of the image (I) to the actual size (D") is transmitted to the control unit (10).
8. The processing system according to claim 1, wherein, If the actual size (D") is smaller than the expected size (D'), the trimming unit (8) will trim the edges of the image (I) to obtain a trimmed image (Ir) with the actual size (D").
9. The processing system according to any one of claims 1 and 8, wherein, The trimming unit (8) transmits the trimmed image (Ir) to the control unit (10).
10. The processing system according to claim 1, comprising a quality control unit (13), the quality control unit including a plurality of sensors and integrating a classifier (14), the quality control unit (13) being configured to at least: Detect the parameters of interest for each segment (C) output by the processing system; The value of the parameter of interest detected for each segment (C) is compared with the preset optimal value of the parameter of interest; Based on the comparison between the detected value and the optimal value of the detected parameter of interest, each segment (C) output by the processing system is assigned a classification; Send a traceability operation command, which is distinguished according to the classification performed by the classifier (14), and the operation command points to one or more of the following: cutting device (1), machining device (2), printing unit (3), drying device (11), identification unit (4), matching unit (5), scaling unit (7) or trimming unit (8), alignment unit (9) and control unit (10).