3D Camera Print Parameter Optimization for Flexographic Presses

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Solution Overview

Problem

Flexographic printing machines face challenges in determining optimized printing parameters due to deviations in digital print templates and production-related irregularities in printing forms, leading to inefficiencies and increased setup times.

Innovation Solution

A method using a 3D camera to record high-resolution images of the printing form's surface, calculate its height profile, and simulate print images based on initial parameters, allowing for iterative adjustments to determine optimized print settings without actual printing, thus reducing setup times and ink usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If test prints are performed on the flexographic printing press to assess print quality and determine optimal parameters, then printing parameter optimization is achieved, but setup time increases and machine run time is consumed without producing finished products

Engineering Contradiction:

Improveprint qualityVSAvoidsetup time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The invention performs preliminary measurements of the printing form's relief structure using a 3D sensor before actual printing. The system calculates expected print results based on the measured height profile and simulates print images to determine optimized printing parameters in advance, eliminating the need for time-consuming test prints on the production press

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention creates a digital copy of the printing form's surface topography through 3D scanning. This digital model is then used to simulate print images and predict print quality without physically printing test samples, replacing physical test prints with virtual simulations

Inventive Principle:

Principle #26Copying

2Manufacturing precision

If multiple test prints are performed to determine optimized printing parameters, then print quality is improved, but ink consumption and substrate usage increase

Engineering Contradiction:

Improveprint qualityVSAvoidink consumption

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The system uses a digital 3D model of the printing form to simulate print images instead of creating physical test prints. This virtual simulation approach eliminates ink and substrate consumption entirely while still enabling optimization of printing parameters for high print quality

Inventive Principle:

Principle #26Copying

3Manufacturing precision

If printing parameters are determined through iterative test prints, then optimal print settings are achieved, but productivity decreases due to extended setup times

Engineering Contradiction:

Improveprinting parameter optimizationVSAvoidoutput per unit time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system performs all necessary measurements and calculations to determine optimized printing parameters before the printing press is even set up. By measuring the printing form relief structure and simulating print results in advance, the invention eliminates iterative test printing and gets the production press ready for immediate high-quality output

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention replaces the mechanical trial-and-error process of physical test printing with a computational simulation system. The 3D scanning and virtual print image generation substitute for repeated mechanical printing operations, dramatically reducing setup time and increasing productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method enables precise determination of printing parameters before actual printing, reducing setup times and optimizing print quality without the need for test prints, making it suitable for flexographic and other printing methods.

Implementation Method 1

The 3D camera can capture images based on triangulation methods, time-of-flight measurements and/or interferometric measurement methods.

Methodology Applied

Scientific EffectTriangulation:

Implementation Method 2

The 3D camera can capture images based on triangulation methods, time-of-flight measurements and/or interferometric measurement methods.

Methodology Applied

Scientific EffectTime-of-flight measurement: Time of Flight

Implementation Method 3

The 3D camera can capture images based on triangulation methods, time-of-flight measurements and/or interferometric measurement methods.

Methodology Applied

Scientific EffectInterferometric measurement:

Data Source

PatentEP3822080B1Method for determining print parameters of a printing machine and test bench

Publication Date: 2023.04.26 BOBST BIELEFELD

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AI summary

A method for determining the printing parameters of a printing press, in particular a flexographic printing press, comprises the following steps: First, a printing form (12) is provided and mounted on a printing cylinder (14). Then, at least one high-resolution image of the surface of the printing form (12) is captured using a 3D camera (18). Based on this high-resolution image, a height profile of the printing form (12) is determined, and a simulated printed image is then calculated using the height profile and an initial set of printing parameters. Finally, optimized printing parameters are determined by checking and/or varying the printing parameters of the initial set. For this purpose, a simulated printed image is calculated again after varying the printing parameters. A test setup on which such a method can be carried out is also specified.