Ceramic tile multi-process pattern virtual queue control method and system
By applying identification codes to the tiles to establish a virtual queue of patterns and comparing them in real time, the problem of order changes during tile transportation was solved. This enabled cross-process queue status synchronization and anomaly handling, ensuring the consistency of tile pattern order, reducing scrap and improving production efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- DEPU TECH (GUANGDONG) CO LTD
- Filing Date
- 2026-05-28
- Publication Date
- 2026-07-31
AI Technical Summary
Existing ceramic digital printing production lines lack full-process tracking capabilities during tile transport, resulting in the inability to detect changes in tile position in a timely manner. This makes it impossible to ensure that the physical order of tiles across processes matches the order of the design pattern, easily leading to pattern misalignment and jigsaw puzzle errors, resulting in the scrapping of the entire batch.
By applying a unique identification code to the tile, a virtual queue of patterns is established, and a physical queue is formed at the entrance of the printing process. The actual pattern ID is compared with the expected pattern ID in real time, triggering an exception handling strategy to dynamically update the virtual queue of patterns, ensuring sequence consistency, and synchronizing with the downstream process in real time.
It enables full tracking of the tile transfer process and synchronization of queue status across processes, reducing large-scale scrap due to incorrect printing, improving production continuity and pass rate, and enhancing the level of intelligent management.
Smart Images
Figure CN122492129A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of digital printing technology, and in particular to a virtual queue control method and system for multi-process patterns on ceramic tiles. Background Technology
[0002] In the production process of ceramic digital printing, it is usually necessary to accurately print the designed pattern onto the surface of each tile. For complex composite patterns made up of multiple tiles, the printing order between the tiles is strictly dependent. It is essential to ensure that the physical transfer order of the tiles is completely consistent with the order of the designed pattern in order to achieve complete pattern splicing.
[0003] Currently, most existing ceramic digital printing production lines use a single-point identification method to track tiles. Specifically, an identification device (such as a barcode reader) is usually installed at the entrance of the printing process to read the markings on the tile to confirm the pattern to be printed on the current tile. However, this method only performs identification once at the entrance of the printing process and lacks the ability to continuously track changes in the tile's position during long-distance transport. In actual production, tiles undergo multiple pre-processing steps and conveyor belt transport from the forming of the blank to entering the printing process. During this process, tiles may be manually removed due to breakage, their relative positions may be misaligned due to conveyor belt slippage, or the order of tiles may change due to accumulation and release of buffer zones between multiple processes. Because the existing system relies only on a single identification at the entrance and cannot detect changes in the actual position of the tiles during the above processes, it is very easy for the pattern to be printed on the wrong tile.
[0004] Furthermore, for complex patterns requiring the assembly of multiple tiles, the printing order of each tile is strictly dependent. Current technology, relying solely on single-point recognition, cannot guarantee the consistency between the physical order of the tiles and the design pattern order across different devices and processes. When an upstream process is missing or out of order, subsequent processes cannot detect the change, leading to serious consequences such as misaligned tiles and entire batch scrap. Moreover, existing production lines lack a cross-process queue status synchronization mechanism. Once a process experiences a change in queue status due to missing or out-of-order tiles, subsequent processes cannot promptly detect this change and make corresponding adjustments, causing errors to cascade along the production process and further amplifying production losses.
[0005] Therefore, there is an urgent need for a virtual queue control method and system for multi-process patterns of ceramic tiles, which can track the entire process of tile transmission, synchronize the queue status across processes, and handle exceptions according to the exception handling strategy. Summary of the Invention
[0006] Based on this, it is necessary to provide a virtual queue control method and system for multi-process patterns of ceramic tiles to address the existing problems. This method and system can track the entire process of ceramic tile transmission, synchronize the queue status across processes, and handle exceptions according to the exception handling strategy.
[0007] The first aspect of this application provides a virtual queue control method for multi-process patterns in ceramic tiles, comprising: Step S1: Apply a unique identification code to each tile that has undergone the inkjet printing process on the conveyor line. The identification code includes at least the batch serial number and pattern ID of the corresponding tile. At the same time as applying the identification code, establish a virtual pattern queue. The virtual pattern queue includes the batch serial number of each tile and the pattern ID bound to the corresponding batch serial number, which are recorded in the order of the batch serial number. Step S2: At the current printing process entrance of the conveyor line, read the identification code one by one according to the order of arrival of the tiles, record the identification code read each time and the timestamp of the reading time, and simultaneously extract the pattern ID from the identification code read each time, and form a physical queue of tiles according to the timestamp order. The physical queue includes the actual physical position of each tile formed according to the timestamp order. Step S3: Obtain the actual physical position of the currently arriving tile, and use the pattern ID in the identification code of the currently arriving tile as the actual pattern ID; use the actual physical position to index and search for the batch sequence number corresponding to the actual physical position in the pattern virtual queue and use it as the expected batch sequence number; determine the corresponding bound pattern ID based on the expected batch sequence number and use it as the expected pattern ID; compare the actual pattern ID with the expected pattern ID and obtain the comparison result. Step S4: Obtain and analyze the comparison results. If the comparison results are consistent, issue the printing instruction directly. If the comparison results are inconsistent, trigger the exception handling strategy. The exception handling strategy is used to determine the exception type. Update the pattern virtual queue according to the exception type to obtain the updated pattern virtual queue. Issue the printing instruction according to the updated pattern virtual queue to control the current tile to perform printing according to the actual pattern ID. Step S5: After the exception handling strategy, the updated pattern virtual queue is synchronized to each downstream process in real time. Each downstream process replaces the current pattern virtual queue with the received updated pattern virtual queue.
[0008] In some implementations, exception handling strategies include: Read a preset number of pattern IDs following the actual pattern ID in the physical queue. If the actual pattern ID of the current tile matches the expected pattern ID at a certain position in the reading window of the pattern virtual queue, and the preset number of pattern IDs following the actual pattern ID in the physical queue corresponds one-to-one with the preset number of pattern IDs following the expected pattern ID in the pattern virtual queue in the original order, then it is determined to be a missing abnormality and skipping compensation is performed. The reading window is used to read a preset number of pattern IDs, and the preset number is an integer not less than 3.
[0009] In some implementations, skip compensation is performed, including: Starting from the expected batch sequence number corresponding to the current actual physical position in the pattern virtual queue, up to the batch sequence number corresponding to the previous pattern ID of the expected pattern ID matched in the reading window of the pattern virtual queue, mark these pattern IDs and their corresponding batch sequence numbers as skipped. The expected pattern ID matched by the actual pattern ID in the reading window is moved forward to adjust the batch sequence number corresponding to the expected pattern ID to correspond to the current actual physical position; all pattern IDs after the expected pattern ID are moved forward synchronously, and the batch sequence number corresponding to each pattern ID after the expected pattern ID is updated synchronously to generate an updated pattern virtual queue. The printing command is issued based on the updated pattern virtual queue, controlling the current tile to perform printing according to the actual pattern ID.
[0010] In some implementations, exception handling strategies include: If the pattern IDs located in the reading window from the virtual pattern queue form the same set as the pattern IDs located in the reading window from the physical queue, but their order is inconsistent, it is determined to be an out-of-order anomaly, and out-of-order rearrangement correction is performed. The reading window is used to read a preset number of pattern IDs, and the preset number is an integer not less than 3.
[0011] In some implementations, out-of-order rearrangement correction is performed, including: Based on all pattern IDs in the physical queue located within the reading window, and the actual physical position corresponding to all pattern IDs in the physical queue located within the reading window, rearrange all pattern IDs in the virtual pattern queue located within the reading window to update the batch sequence number corresponding to all pattern IDs in the reading window, and obtain the updated virtual pattern queue; issue printing instructions based on the updated virtual pattern queue to control the current tile to perform printing according to the actual pattern ID.
[0012] In some implementations, all pattern IDs in the physical queue located within the reading window are directly replaced with all pattern IDs in the virtual pattern queue located within the reading window in the original order to obtain an updated virtual pattern queue; printing instructions are issued according to the updated virtual pattern queue to control the current tile to perform printing according to the actual pattern ID.
[0013] In some implementations, the preset quantity is 3.
[0014] In some implementations, reading the identification codes one by one in the order in which the tiles arrive includes reading a preset number of identification codes through a reading window in the order in which the tiles arrive.
[0015] In some implementations, exception handling strategies include: If the actual pattern ID is inconsistent with all the pattern IDs in the reading window, it is determined to be an unrecoverable exception, triggering a shutdown alarm and requiring manual updating of the pattern virtual queue.
[0016] In some implementations, triggering a shutdown alarm and manually updating the pattern virtual queue includes: Send a shutdown alarm signal to the operation terminal and display the abnormality type as unrecoverable abnormality, the process in which the abnormality occurred, the current actual physical position, and the actual batch sequence number on the operation terminal; After manually inputting the correction command, update the pattern virtual queue according to the correction command to obtain the updated pattern virtual queue; Printing instructions are issued based on the updated pattern virtual queue.
[0017] In some embodiments, the method of applying the identification code in step S1 includes at least one of the following: printing a visible code on the side of the tile, printing a visible code on the bottom of the tile, or printing an invisible code on the printed surface of the tile using invisible ink that can be read under a specific wavelength excitation.
[0018] In some implementations, the identification code also includes the batch number and check digit corresponding to the tile. The batch number and the serial number within the batch together ensure the uniqueness of the tile's identity throughout the entire factory.
[0019] A second aspect of this application provides a virtual queue control system for multi-process patterns in ceramic tiles, comprising: The identification code application module is used to apply an identification code containing a unique identifier to each tile that has undergone the inkjet printing process on the conveyor line. The identification code includes at least the batch serial number and pattern ID of the corresponding tile. At the same time as applying the identification code, a virtual pattern queue is established. The virtual pattern queue includes the batch serial number of each tile and the pattern ID bound to the corresponding batch serial number, which are recorded in the order of the batch serial number. The physical queue tracking module is used to read the identification code one by one at the entrance of the current printing process of the conveyor line according to the order of arrival of the tiles, record the identification code read each time and the timestamp of the reading time, and simultaneously extract the pattern ID from the identification code read each time, and form a physical queue of tiles according to the timestamp order. The physical queue includes the actual physical position of each tile formed according to the timestamp order. The comparison and verification module, connected to the identification code application module and the physical queue tracking module, is used to obtain the actual physical position of the currently arriving tile, and to use the pattern ID in the identification code of the currently arriving tile as the actual pattern ID; to use the actual physical position to index and find the batch sequence number corresponding to the actual physical position in the pattern virtual queue and use it as the expected batch sequence number; to determine the corresponding bound pattern ID based on the expected batch sequence number and use it as the expected pattern ID; and to compare the actual pattern ID with the expected pattern ID and obtain the comparison result. The exception handling and recovery module is connected to the comparison and verification module. It is used to obtain and analyze the comparison results. If the comparison results are consistent, the printing instruction is directly issued. If the comparison results are inconsistent, the exception handling strategy is triggered. The exception handling strategy is used to determine the exception type, update the pattern virtual queue according to the exception type to obtain the updated pattern virtual queue, and issue the printing instruction according to the updated pattern virtual queue. The virtual queue management module, connected to the identification code application module and the exception handling and recovery module, is used to obtain the pattern virtual queue generated by the identification code application module as the initial virtual queue, and dynamically update the pattern virtual queue of the current printing process according to the updated pattern virtual queue output by the exception handling and recovery module. The cross-process synchronization module, connected to the exception handling and recovery module, is used to synchronize the updated pattern virtual queue to each downstream process in real time after the exception handling strategy is implemented. Each downstream process replaces its current pattern virtual queue with the received updated pattern virtual queue.
[0020] The beneficial effects of this invention are: Step S1 establishes a virtual queue of patterns ordered by batch sequence number in the inkjet printing process. Step S2 then forms a physical queue at the current printing process entrance reflecting the actual arrival order of the tiles. Step S3 compares the actual pattern ID with the expected pattern ID in the virtual queue, enabling real-time detection of any positional changes in the tiles during transport. Compared to existing technologies that rely solely on single-entry identification, this method proactively verifies sequence consistency at each printing process entrance.
[0021] Step S4 does not simply halt production when the comparison results are inconsistent. Instead, it triggers an anomaly handling strategy, dynamically updating the virtual pattern queue based on the identified anomaly type and issuing printing instructions based on the updated queue. This "on-site correction, continued production" mechanism reduces manual intervention and line-wide downtime, significantly minimizing production capacity losses caused by anomalies and reducing large-scale scrap due to erroneous printing.
[0022] Step S5 synchronizes the updated pattern virtual queue to downstream processes in real time, requiring each downstream process to replace its original pattern virtual queue with the received updated one. This ensures that when an upstream anomaly occurs and the pattern virtual queue is corrected, all downstream printing processes can immediately detect the change and use the updated pattern virtual queue for subsequent comparison and printing. Compared to the isolated operation of each process in existing technologies, this method effectively prevents errors from cascading and amplifying along the production process, ensuring the consistency of pattern sequence during multi-process, multi-printing machine collaborative production.
[0023] Because this method uses decoupled control of the pattern virtual queue and the physical queue, it no longer requires the conveyor line to maintain the tile sequence with absolute precision; any change in physical position can be absorbed and corrected through real-time comparison at the entrance of the printing process and update of the pattern virtual queue.
[0024] The batch sequence number and pattern ID bound to the identification code, combined with the timestamp recorded in step S2 and the anomaly handling results in step S4, can completely reconstruct the actual position, expected position, whether an anomaly was triggered, and how the virtual pattern queue was updated for each tile in each printing process. This data provides a reliable digital foundation for subsequent quality analysis, defect attribution, and production optimization, improving the intelligent management level of the entire production line. Attached Figure Description
[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only one embodiment of the present invention. For those skilled in the art, other embodiments can be obtained based on these drawings without creative effort.
[0026] Figure 1 A flowchart illustrating a method for controlling a virtual queue of patterns in a multi-process ceramic tile, provided for an embodiment of the present invention; Figure 2 This is a flowchart comparing missing exceptions, out-of-order exceptions, and unrecoverable exceptions in the exception handling strategy. Figure 3 This is a schematic diagram of a virtual queue control system for multi-process patterns of ceramic tiles, provided for an embodiment of the present invention. Detailed Implementation
[0027] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.
[0028] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.
[0029] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.
[0030] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.
[0031] In this invention, unless otherwise explicitly specified and limited, a feature "above" or "below" the second feature may mean that the feature is in direct contact with the second feature or indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature may mean that the feature is directly above or diagonally above the second feature, or simply indicates that the feature is at a higher horizontal level than the second feature. Similarly, "below," "below," and "beneath" of the second feature may mean that the feature is directly below or diagonally below the second feature, or simply indicates that the feature is at a lower horizontal level than the second feature.
[0032] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.
[0033] refer to Figures 1-3 The embodiments of this application provide a virtual queue control method for multi-process patterns in ceramic tiles, which includes: Step S1: Apply a unique identification code to each tile that has undergone the inkjet printing process on the conveyor line. The identification code includes at least the batch serial number and pattern ID of the corresponding tile. At the same time as applying the identification code, establish a virtual pattern queue. The virtual pattern queue includes the batch serial number of each tile and the pattern ID bound to the corresponding batch serial number, which are recorded in the order of the batch serial number. Step S2: At the current printing process entrance of the conveyor line, read the identification code one by one according to the order of arrival of the tiles, record the identification code read each time and the timestamp of the reading time, and simultaneously extract the pattern ID from the identification code read each time, and form a physical queue of tiles according to the timestamp order. The physical queue includes the actual physical position of each tile formed according to the timestamp order. Step S3: Obtain the actual physical position of the currently arriving tile, and use the pattern ID in the identification code of the currently arriving tile as the actual pattern ID; use the actual physical position to index and search for the batch sequence number corresponding to the actual physical position in the pattern virtual queue and use it as the expected batch sequence number; determine the corresponding bound pattern ID based on the expected batch sequence number and use it as the expected pattern ID; compare the actual pattern ID with the expected pattern ID and obtain the comparison result. Step S4: Obtain and analyze the comparison results. If the comparison results are consistent, issue the printing instruction directly. If the comparison results are inconsistent, trigger the exception handling strategy. The exception handling strategy is used to determine the exception type. Update the pattern virtual queue according to the exception type to obtain the updated pattern virtual queue. Issue the printing instruction according to the updated pattern virtual queue to control the current tile to perform printing according to the actual pattern ID. Step S5: After the exception handling strategy, the updated pattern virtual queue is synchronized to each downstream process in real time. Each downstream process replaces the current pattern virtual queue with the received updated pattern virtual queue.
[0034] This application's method for controlling virtual queues of tile patterns across multiple processes establishes a virtual queue of patterns ordered by batch sequence number in the inkjet printing process (step S1). Then, in step S2, a physical queue reflecting the actual arrival order of the tiles is formed at the entrance of the current printing process. Step S3 compares the actual pattern ID with the expected pattern ID in the virtual queue, enabling real-time detection of any positional changes during tile transport. Compared to existing technologies that rely solely on single-entry identification, this method actively verifies sequence consistency at each printing process entrance. Step S4, when the comparison results are inconsistent, does not simply halt production but triggers an anomaly handling strategy. It dynamically updates the virtual queue based on the determined anomaly type and issues printing instructions based on the updated queue. This "on-site correction, continued production" mechanism reduces manual intervention and line-wide shutdowns, significantly minimizing production capacity losses caused by anomalies and reducing large-scale scrap due to erroneous printing. Step S5 synchronizes the updated virtual queue to downstream processes in real-time and requires downstream processes to replace their original virtual queues with the received updated ones. This allows all downstream printing processes to immediately detect changes and use the updated virtual pattern queue for subsequent comparisons and printing once an upstream anomaly occurs and the virtual pattern queue is corrected. Compared to the isolated operation of each process in existing technologies, this method effectively prevents errors from cascading and amplifying along the production process, ensuring the consistency of pattern sequence during multi-process, multi-printer collaborative production. Furthermore, by decoupling the virtual pattern queue from the physical queue, this method no longer requires the conveyor line to maintain an absolutely precise tile sequence; any change in physical position can be absorbed and corrected through real-time comparison and virtual pattern queue updates at the printing process entry point. In addition, the batch sequence number and pattern ID bound to the identification code, combined with the timestamp recorded in step S2 and the anomaly handling results in step S4, can completely reconstruct the actual position, expected position, whether an anomaly was triggered, and how the virtual pattern queue was updated for each tile in each printing process. This data provides a reliable digital foundation for subsequent quality analysis, defect attribution, and production optimization, improving the intelligent management level of the entire production line.
[0035] refer to Figures 1-3 In some implementations, the exception handling strategy includes: Read a preset number of pattern IDs following the actual pattern ID in the physical queue. If the actual pattern ID of the current tile matches the expected pattern ID at a certain position in the reading window of the pattern virtual queue, and the preset number of pattern IDs following the actual pattern ID in the physical queue corresponds one-to-one with the preset number of pattern IDs following the expected pattern ID in the pattern virtual queue in the original order, then it is determined to be a missing abnormality and skipping compensation is performed. The reading window is used to read a preset number of pattern IDs, and the preset number is an integer not less than 3.
[0036] This step describes the process for judging missing anomalies. By reading the pattern IDs of the subsequent preset number in the window to check the sequence consistency, it is possible to identify missing anomalies caused by tile removal or omission and perform skip printing compensation.
[0037] refer to Figures 1-3 In some implementations, skip compensation is performed, including: Starting from the expected batch sequence number corresponding to the current actual physical position in the pattern virtual queue, up to the batch sequence number corresponding to the previous pattern ID of the expected pattern ID matched in the reading window of the pattern virtual queue, mark these pattern IDs and their corresponding batch sequence numbers as skipped. The expected pattern ID matched by the actual pattern ID in the reading window is moved forward to adjust the batch sequence number corresponding to the expected pattern ID to correspond to the current actual physical position; all pattern IDs after the expected pattern ID are moved forward synchronously, and the batch sequence number corresponding to each pattern ID after the expected pattern ID is updated synchronously to generate an updated pattern virtual queue. The printing command is issued based on the updated pattern virtual queue, controlling the current tile to perform printing according to the actual pattern ID.
[0038] This step outlines the specific procedures for compensation of missing patterns and skipped prints. By explicitly marking all pattern IDs and their corresponding batch sequence numbers between the current physical position and the expected pattern ID (which should be matched) as "skipped," and synchronously moving the matched pattern ID and all subsequent pattern IDs forward and rebinding them to their batch sequence numbers, the virtual pattern queue accurately reflects the actual tile arrangement order. This operation eliminates the need to readjust the conveyor line or physically remove tiles. Through missing pattern compensation alone, it improves the errors caused by missing patterns, ensuring the accuracy of the comparison benchmark for each subsequent tile. This achieves closed-loop recovery of missing pattern anomalies without machine shutdown or manual intervention, minimizing the risk of batch printing offset due to missing patterns.
[0039] refer to Figures 1-3In some implementations, the exception handling strategy includes: If the pattern IDs located in the reading window from the virtual pattern queue form the same set as the pattern IDs located in the reading window from the physical queue, but their order is inconsistent, it is determined to be an out-of-order anomaly, and out-of-order rearrangement correction is performed. The reading window is used to read a preset number of pattern IDs, and the preset number is an integer not less than 3.
[0040] This step accurately identifies disordered patterns by comparing the sets of pattern IDs in the virtual and physical queues within the reading window to see if they are the same but in different orders. This method relies on a preset number of pattern IDs within the reading window, has low computational cost, and fast response. It can quickly identify disordered tile order without interrupting production, providing accurate triggering conditions for subsequent targeted disordered rearrangement correction, thereby effectively preventing puzzle errors caused by disordered order.
[0041] refer to Figures 1-3 In some implementations, out-of-order rearrangement correction is performed, including: Based on all pattern IDs in the physical queue located within the reading window, and the actual physical position corresponding to all pattern IDs in the physical queue located within the reading window, rearrange all pattern IDs in the virtual pattern queue located within the reading window to update the batch sequence number corresponding to all pattern IDs in the reading window, and obtain the updated virtual pattern queue; issue printing instructions based on the updated virtual pattern queue to control the current tile to perform printing according to the actual pattern ID.
[0042] This step provides specific steps for disordered rearrangement correction. Based on the actual pattern IDs and their actual physical order within the reading window of the physical queue, the pattern IDs within the corresponding window of the virtual pattern queue are directly rearranged, and the batch sequence number is updated synchronously. This allows for rapid realignment of the virtual pattern queue with the actual order of the physical queue with minimal computational overhead and queue adjustment range. This correction only affects the local queue within the reading window and does not change the mapping relationship of other tiles outside the reading window. Thus, without interrupting production or triggering a shutdown, it effectively solves the problem of disordered order caused by conveyor belt slippage or buffer release, ensuring the correct comparison benchmark for the pattern IDs of subsequent tiles and reducing the cascading occurrence of mosaic misalignment and multi-process printing errors.
[0043] In other implementations, all pattern IDs in the physical queue located within the reading window are directly replaced with all pattern IDs in the virtual pattern queue located within the reading window in the original order to obtain an updated virtual pattern queue; printing instructions are issued according to the updated virtual pattern queue to control the current tile to perform printing according to the actual pattern ID.
[0044] This method requires no matching or sorting calculations for pattern IDs. It simply replaces the corresponding pattern IDs in the virtual pattern queue with the pattern IDs in the physical queue reading window in their original order, thus completing the queue rearrangement. Its implementation logic is extremely simple, with near-zero computational overhead, enabling disorder correction within milliseconds. This makes it particularly suitable for high-speed printing production lines. Furthermore, since the replacement operation only alters a local queue within the window, it does not affect the mapping relationships of other tiles outside the window, ensuring the continuity and low intrusion of the correction process into the production flow. This effectively reduces subsequent printing errors caused by disordered sequences, significantly improving the system's real-time responsiveness and robustness.
[0045] refer to Figures 1-3 In some implementations, the preset quantity is 3.
[0046] Furthermore, in some embodiments, reading the identification codes one by one in the order the tiles arrive in step S2 includes reading a preset number of identification codes through a reading window in the order the tiles arrive. For example, reading the information of three tiles in the printing process.
[0047] refer to Figures 1-3 In some implementations, the exception handling strategy includes: If the actual pattern ID is inconsistent with all the pattern IDs in the reading window, it is determined to be an unrecoverable exception, triggering a shutdown alarm and requiring manual updating of the pattern virtual queue.
[0048] This step provides methods and strategies for handling severe exceptions that cannot be automatically matched.
[0049] In some implementations, triggering a shutdown alarm and manually updating the pattern virtual queue includes: Send a shutdown alarm signal to the operation terminal and display the abnormality type as unrecoverable abnormality, the process in which the abnormality occurred, the current actual physical position, and the actual batch sequence number on the operation terminal; After manually inputting the correction command, update the pattern virtual queue according to the correction command to obtain the updated pattern virtual queue; Printing instructions are issued based on the updated pattern virtual queue.
[0050] This step triggers a shutdown alarm when the actual pattern ID is inconsistent with all pattern IDs in the reading window. It can clearly distinguish between automatically recoverable anomalies (such as missing or out-of-order patterns mentioned above) and serious anomalies that cannot be automatically matched, avoiding blindly continuing production in a state of logical confusion that could lead to a larger batch of scrap. At the same time, the operation terminal displays detailed information on the anomaly type, the process in which it occurred, the actual physical sequence, and the actual batch sequence number, providing operators with accurate fault location information and significantly reducing manual troubleshooting and decision-making time. By manually inputting correction commands to update the virtual queue before resuming production, the correct and reliable queue benchmark for subsequent printing operations is ensured, guaranteeing the safety of the production line and providing a fallback recovery mechanism for extreme anomalies.
[0051] refer to Figures 1-3 In some implementations, the application of the identification code in step S1 includes at least one of the following methods: printing a visible code on the side of the tile, printing a visible code on the bottom of the tile, or printing an invisible code on the printed surface of the tile using invisible ink that can be read under specific wavelength excitation. By printing a visible code on the side or bottom of the tile, the reading failure caused by ink coverage or pattern obstruction during the printing process can be avoided, ensuring that the identification code can always be read across multiple processes. On the other hand, using invisible ink that is visible under specific wavelength excitation to print on the printed surface does not damage the decorative effect of the tile surface, meeting the requirements of high-end products for seamless appearance tracking. The combination of multiple methods can be flexibly selected or complemented according to different tile types and process requirements, significantly improving the robustness and adaptability of the identification code in long-process, multi-stage production environments, and providing a reliable data source foundation for the accurate establishment and continuous tracking of subsequent virtual queues.
[0052] refer to Figures 1-3 In some implementations, the identification code also includes the batch number and check digit of the corresponding tile. The batch number and the sequence number within the batch together ensure the uniqueness of the tile's identity throughout the entire factory. By adding the combination of batch number and sequence number as a unique identifier for the entire factory, tiles from different production batches can be effectively distinguished, reducing identity conflicts caused by the reuse of sequence numbers within the batch. This ensures accurate traceability of each tile in the virtual queue in large-scale, multi-batch parallel production scenarios. At the same time, the addition of the check digit allows for real-time verification of the integrity and correctness of the identification code during the reading process, effectively suppressing misreading or skipping caused by code surface damage, reading interference, etc., and significantly improving the data reliability and anti-interference capability of the system in multi-process, long-flow operation.
[0053] Explanatoryly, in this application, the pattern virtual queue is an initially determined pattern virtual queue during the inkjet printing stage. In the subsequent printing process, the pattern virtual queue will be updated synchronously in real time, and the updated pattern virtual queue will serve as the basis for subsequent comparison and judgment with the physical queue.
[0054] Furthermore, Figure 3A specific embodiment is provided, which includes a method for judging out-of-order anomalies, missing anomalies, and unrecoverable anomalies, as well as the process of updating and aligning the pattern virtual queue.
[0055] Taking out-of-order anomaly as an example, when the actual physical sequence of the conveyor line is: 1 corresponds to pattern ID: A; 2 corresponds to pattern ID: C; 3 corresponds to pattern ID: B; 4 corresponds to pattern ID: D; 5 corresponds to pattern ID: E; 6 corresponds to pattern ID: F; and the current virtual pattern queue is: 1 corresponds to pattern ID: A; 2 corresponds to pattern ID: B; 3 corresponds to pattern ID: C; 4 corresponds to pattern ID: D; 5 corresponds to pattern ID: E; 6 corresponds to pattern ID: F; at this time, the barcode reader corresponding to the current printing process reads the pattern IDs corresponding to the three consecutive sequences 2-4: C, B, and D; from the current virtual pattern queue... The pattern IDs for indexes 2-4 in the column are B, C, and D. Comparison reveals that the indexes can be found after three consecutive comparisons, but their order is disordered; this is identified as an out-of-order anomaly. The batch sequence number corresponding to all pattern IDs within the current pattern virtual queue's read window is updated, and the current pattern virtual queue is rearranged; alternatively, all pattern IDs in the physical queue located within the read window are directly replaced with their original order in the pattern virtual queue to obtain an updated pattern virtual queue. The updated pattern virtual queue is then aligned with the actual sorting on the conveyor line. For illustrative purposes, the gray area in the table in the figure represents the content read within the read window during the current printing process.
[0056] Similarly, Figure 3 The last two lines correspond to the process of judging missing anomalies and updating the virtual queue of patterns; the reading window can also be set to three. The specific recognition and analysis process is as described above, and can also be combined with... Figure 3 We will learn about the disordered anomaly before proceeding, but will not elaborate further here.
[0057] In summary, this application establishes and compares the virtual and physical pattern queues in real time. When inconsistencies are detected, the virtual pattern queue is automatically updated and synchronized to the downstream process. This achieves closed-loop correction of anomalies such as missing or disordered patterns, ensuring that the order of tile patterns in multi-process printing is strictly consistent with the design, and significantly improving production continuity and pass rate.
[0058] refer to Figures 1-3 Some embodiments of this application also provide a virtual queue control system for multi-process patterns of ceramic tiles, which includes an identification code application module, a physical queue tracking module, a comparison and verification module, an anomaly handling and recovery module, a virtual queue management module, and a cross-process synchronization module.
[0059] The system comprises several modules: an identification code application module and a pattern ID module. The identification code applies a unique identifier to each tile that has undergone the inkjet printing process on the conveyor line. The identification code includes at least the tile's batch serial number and pattern ID. Simultaneously, a virtual pattern queue is established, containing the batch serial number of each tile and the pattern ID associated with that number, recorded in order of batch serial number. A physical queue tracking module reads the identification codes one by one at the current printing process entrance on the conveyor line, recording each read code and its timestamp. It also extracts the pattern ID from each read code and forms a physical queue of tiles based on their timestamps. The physical queue includes the actual physical position of each tile in that order. A comparison and verification module, connected to the identification code application module and the physical queue tracking module, obtains the actual physical position of the currently arriving tile, using the pattern ID from the tile's identification code as the actual pattern ID. It then uses the actual physical position to search the virtual pattern queue for the corresponding batch serial number and sets it as the expected batch serial number. The expected pattern ID is determined based on the expected batch sequence number and used as the expected pattern ID. The actual pattern ID is compared with the expected pattern ID to obtain the comparison result. The exception handling and recovery module is connected to the comparison and verification module to obtain and analyze the comparison result. If the comparison result is consistent, the printing instruction is directly issued. If the comparison result is inconsistent, the exception handling strategy is triggered. The exception handling strategy is used to determine the exception type. The pattern virtual queue is updated according to the exception type to obtain the updated pattern virtual queue. The printing instruction is issued according to the updated pattern virtual queue. The virtual queue management module is connected to the identification code application module and the exception handling and recovery module. It is used to obtain the pattern virtual queue generated by the identification code application module as the initial virtual queue and dynamically update the pattern virtual queue of the current printing process according to the updated pattern virtual queue output by the exception handling and recovery module. The cross-process synchronization module is connected to the exception handling and recovery module. After the exception handling strategy, it is used to synchronize the updated pattern virtual queue to each downstream process in real time. Each downstream process replaces the current pattern virtual queue with the received updated pattern virtual queue.
[0060] Furthermore, in some embodiments, the multi-process pattern virtual queue control system for ceramic tiles is composed of hardware devices and software modules. The hardware devices include inkjet printers installed in the inkjet printing process, barcode readers (which may include a ring light source, photoelectric trigger sensor, and rotary encoder) configured at the entrance of each printing process, controllers (which can be distributed or centralized), printing machines installed in each printing process, industrial Ethernet switches, and fiber optic networks. Additionally, it may include audible and visual alarms, human-machine interface touchscreens, and optional central monitoring servers. The software modules are embedded in the controller and include a barcode application module and a physical queue tracking module, a comparison and verification module, an anomaly handling and recovery module (with built-in skip printing compensation, out-of-order reordering correction, and shutdown alarm logic), a virtual queue management module, and a cross-process synchronization module.
[0061] During operation, the system first executes step S1 of the multi-process pattern virtual queue control method for ceramic tiles using an inkjet printer. This step applies an identification code containing the batch sequence number and pattern ID to each tile and simultaneously establishes a virtual queue of patterns recorded in order of the batch sequence number, in conjunction with the virtual queue management module of the controller. At the entrance of each printing process, the system's barcode reader reads the identification code in step S2 and generates a physical queue with a timestamp in conjunction with the physical queue tracking module of the controller. The controller's comparison and verification module indexes the virtual queue with the actual physical position of the current tile in step S3 to obtain the expected pattern ID, compares it with the actual pattern ID, and obtains the comparison result. The controller's exception handling and recovery module executes step S4. If the comparison matches, a printing instruction is directly issued; otherwise, an exception handling strategy is executed. The anomaly handling strategy identifies anomalies such as missing, out-of-order, or unrecoverable errors and performs corresponding skip print compensation, out-of-order rearrangement, or manual correction by stopping the machine. The pattern virtual queue is dynamically updated before the printing command is issued. The cross-process synchronization module of the controller of the current process executes step S5, which synchronizes the updated pattern virtual queue to the controllers of each downstream process in real time via industrial Ethernet. The downstream process replaces the original pattern virtual queue with the received updated pattern virtual queue, thereby ensuring that the tile pattern order is strictly consistent with the design in multi-process, multi-printer scenarios.
[0062] Furthermore, in some implementations, if the controller's exception handling and recovery module determines that the actual pattern ID is inconsistent with all pattern IDs in the reading window, it is determined to be an unrecoverable exception, triggering a shutdown and an audible and visual alarm. Staff can manually update the virtual pattern queue through the human-machine interface touch screen and the optional central monitoring server.
[0063] In addition, the virtual queue management module can also be connected to the cross-process synchronization module. The cross-process synchronization module can directly obtain the updated pattern virtual queue through the virtual queue management module corresponding to the current process, so as to synchronize it to the virtual queue management module of the downstream corresponding process.
[0064] Finally, it should be noted that the technical features of the above embodiments can be combined arbitrarily. For the sake of brevity, not all possible combinations of the technical features in the above embodiments have been described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.
[0065] The above embodiments illustrate only one implementation of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of the present invention should be determined by the appended claims.
Claims
1. A method for controlling a virtual queue of patterns in multi-process ceramic tiles, characterized in that, include: Step S1: Apply a unique identification code to each tile that has undergone the inkjet printing process on the conveyor line. The identification code includes at least the batch serial number and pattern ID of the corresponding tile. At the same time as applying the identification code, establish a virtual pattern queue. The virtual pattern queue includes the batch serial number of each tile and the pattern ID bound to the corresponding batch serial number, which are recorded in the order of the batch serial number. Step S2: At the current printing process entrance of the conveyor line, read the identification code one by one according to the order of arrival of the tiles, record the identification code read each time and the timestamp of the reading time, and simultaneously extract the pattern ID from the identification code read each time, and form a physical queue of tiles according to the timestamp order. The physical queue includes the actual physical position of each tile formed according to the timestamp order. Step S3: Obtain the actual physical position of the currently arriving tile, and use the pattern ID in the identification code of the currently arriving tile as the actual pattern ID; use the actual physical position to index and search for the batch sequence number corresponding to the actual physical position in the pattern virtual queue and use it as the expected batch sequence number; determine the corresponding bound pattern ID based on the expected batch sequence number and use it as the expected pattern ID; compare the actual pattern ID with the expected pattern ID and obtain the comparison result. Step S4: Obtain and analyze the comparison results. If the comparison results are consistent, issue the printing instruction directly. If the comparison results are inconsistent, trigger the exception handling strategy. The exception handling strategy is used to determine the exception type. Update the pattern virtual queue according to the exception type to obtain the updated pattern virtual queue. Issue the printing instruction according to the updated pattern virtual queue to control the current tile to perform printing according to the actual pattern ID. Step S5: After the exception handling strategy, the updated pattern virtual queue is synchronized to each downstream process in real time. Each downstream process replaces the current pattern virtual queue with the received updated pattern virtual queue.
2. The method for controlling virtual queues of multi-process patterns in ceramic tiles according to claim 1, characterized in that, Exception handling strategies include: Read a preset number of pattern IDs following the actual pattern ID in the physical queue. If the actual pattern ID of the current tile matches the expected pattern ID at a certain position in the reading window of the pattern virtual queue, and the preset number of pattern IDs following the actual pattern ID in the physical queue corresponds one-to-one with the preset number of pattern IDs following the expected pattern ID in the pattern virtual queue in the original order, then it is determined to be a missing abnormality and skipping compensation is performed. The reading window is used to read a preset number of pattern IDs, and the preset number is an integer not less than 3.
3. The method for controlling virtual queues of multi-process patterns in ceramic tiles according to claim 2, characterized in that, Performing skipping compensation includes: Starting from the expected batch sequence number corresponding to the current actual physical position in the pattern virtual queue, up to the batch sequence number corresponding to the previous pattern ID of the expected pattern ID matched in the reading window of the pattern virtual queue, mark these pattern IDs and their corresponding batch sequence numbers as skipped. The expected pattern ID matched by the actual pattern ID in the reading window is moved forward to adjust the batch sequence number corresponding to the expected pattern ID to correspond to the current actual physical position; all pattern IDs after the expected pattern ID are moved forward synchronously, and the batch sequence number corresponding to each pattern ID after the expected pattern ID is updated synchronously to generate an updated pattern virtual queue. The printing command is issued based on the updated pattern virtual queue, controlling the current tile to perform printing according to the actual pattern ID.
4. The method for controlling virtual queues of multi-process patterns in ceramic tiles according to claim 1, characterized in that, Exception handling strategies include: If the pattern IDs located in the reading window from the virtual pattern queue form the same set as the pattern IDs located in the reading window from the physical queue, but their order is inconsistent, it is determined to be an out-of-order anomaly, and out-of-order rearrangement correction is performed. The reading window is used to read a preset number of pattern IDs, and the preset number is an integer not less than 3.
5. The method for controlling virtual queues of multi-process patterns in ceramic tiles according to claim 4, characterized in that, Perform out-of-order rearrangement correction, including: Based on all pattern IDs in the physical queue located within the reading window, and the actual physical position corresponding to all pattern IDs in the physical queue located within the reading window, rearrange all pattern IDs in the virtual pattern queue located within the reading window to update the batch sequence number corresponding to all pattern IDs in the reading window, and obtain the updated virtual pattern queue; issue printing instructions according to the updated virtual pattern queue to control the current tile to perform printing according to the actual pattern ID; or, Replace all pattern IDs in the virtual pattern queue with all pattern IDs in the reading window in the physical queue according to their original order to obtain an updated virtual pattern queue; issue printing instructions based on the updated virtual pattern queue to control the current tile to print according to the actual pattern ID.
6. The method for controlling virtual queues of multi-process patterns in ceramic tiles according to any one of claims 2-5, characterized in that, The preset quantity is 3; and / or, Step S2 involves reading the identification codes one by one according to the order in which the tiles arrive, including reading a preset number of identification codes through the reading window according to the order in which the tiles arrive.
7. The method for controlling virtual queues of multi-process patterns in ceramic tiles according to claim 1, characterized in that, Exception handling strategies include: If the actual pattern ID is inconsistent with all the pattern IDs in the reading window, it is determined to be an unrecoverable exception, triggering a shutdown alarm and requiring manual updating of the pattern virtual queue.
8. The method for controlling virtual queues of multi-process patterns in ceramic tiles according to claim 7, characterized in that, Trigger a shutdown alarm and manually update the pattern virtual queue, including: Send a shutdown alarm signal to the operation terminal and display the abnormality type as unrecoverable abnormality, the process in which the abnormality occurred, the current actual physical position, and the actual batch sequence number on the operation terminal; After manually inputting the correction command, update the pattern virtual queue according to the correction command to obtain the updated pattern virtual queue; Printing instructions are issued based on the updated pattern virtual queue.
9. The method for controlling virtual queues of multi-process patterns in ceramic tiles according to claim 1, characterized in that, The application of the identification code in step S1 includes at least one of the following methods: printing a visible code on the side of the tile, printing a visible code on the bottom of the tile, or printing an invisible code on the printed surface of the tile using invisible ink that is readable under a specific wavelength excitation; and / or, The identification code also includes the batch number and check digit of the corresponding tile. The batch number and the serial number within the batch together ensure the uniqueness of the tile's identity throughout the entire factory.
10. A virtual queue control system for multi-process patterns in ceramic tiles, characterized in that, include: The identification code application module is used to apply an identification code containing a unique identifier to each tile that has undergone the inkjet printing process on the conveyor line. The identification code includes at least the batch serial number and pattern ID of the corresponding tile. At the same time as applying the identification code, a virtual pattern queue is established. The virtual pattern queue includes the batch serial number of each tile and the pattern ID bound to the corresponding batch serial number, which are recorded in the order of the batch serial number. The physical queue tracking module is used to read the identification code one by one at the entrance of the current printing process of the conveyor line according to the order of arrival of the tiles, record the identification code read each time and the timestamp of the reading time, and simultaneously extract the pattern ID from the identification code read each time, and form a physical queue of tiles according to the timestamp order. The physical queue includes the actual physical position of each tile formed according to the timestamp order. The comparison and verification module, connected to the identification code application module and the physical queue tracking module, is used to obtain the actual physical position of the currently arriving tile, and to use the pattern ID in the identification code of the currently arriving tile as the actual pattern ID; to use the actual physical position to index and find the batch sequence number corresponding to the actual physical position in the pattern virtual queue and use it as the expected batch sequence number; to determine the corresponding bound pattern ID based on the expected batch sequence number and use it as the expected pattern ID; and to compare the actual pattern ID with the expected pattern ID and obtain the comparison result. The exception handling and recovery module is connected to the comparison and verification module. It is used to obtain and analyze the comparison results. If the comparison results are consistent, the printing instruction is directly issued. If the comparison results are inconsistent, the exception handling strategy is triggered. The exception handling strategy is used to determine the exception type, update the pattern virtual queue according to the exception type to obtain the updated pattern virtual queue, and issue the printing instruction according to the updated pattern virtual queue. The virtual queue management module, connected to the identification code application module and the exception handling and recovery module, is used to obtain the pattern virtual queue generated by the identification code application module as the initial virtual queue, and dynamically update the pattern virtual queue of the current printing process according to the updated pattern virtual queue output by the exception handling and recovery module. The cross-process synchronization module, connected to the exception handling and recovery module, is used to synchronize the updated pattern virtual queue to each downstream process in real time after the exception handling strategy is implemented. Each downstream process replaces its current pattern virtual queue with the received updated pattern virtual queue.