Adaptive Consumable Estimation for Printing Systems

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Solution Overview

Problem

Print shops face challenges in ensuring consistent consumable use estimates for recurring print jobs due to variations in printing device configurations and settings over time, particularly in distributed printing environments, which can lead to increased ink or toner usage and potential losses.

Innovation Solution

An adaptive consumable estimation method that determines dot count information from rendered images and applies current device settings to estimate consumable use, allowing for comparison with stored estimates and alerting operators to potential increases in ink or toner usage, enabling informed decision-making on setting adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If print jobs are printed using fixed price contracts on a long term basis, then print shop profitability is improved, but consumable use may increase due to device configuration changes over time

Engineering Contradiction:

Improveprofitability consistencyVSAvoidink or toner usage

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The system implements feedback by continuously monitoring current device settings and comparing them against original estimation settings. When deviations are detected that would increase consumable usage, the system provides feedback to operators through warnings and alerts, enabling corrective action to maintain profitability under fixed-price contracts.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary action by calculating and storing expected consumable usage based on original device settings before printing occurs. This allows the system to proactively identify potential consumable overuse scenarios and alert operators in advance, preventing profitability loss before it occurs.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If printing devices are replaced or reconfigured to improve productivity, then printing capacity is improved, but all previous consumable use estimates become invalid

Engineering Contradiction:

Improveprinting capacityVSAvoidconsumable use estimate validity

Core Design Contradiction:

ProductivityVSLoss of information

Solution Approach 1:

The system implements dynamics by creating an adaptive consumable estimation framework that can dynamically adjust to device changes. Instead of relying on static historical estimates, the system continuously compares current device settings against original estimates and recalculates consumable usage expectations, making the estimation system flexible and adaptable to device replacements or reconfigurations.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system applies parameter changes by monitoring deviations in device settings parameters (such as resolution, color modes, duplex printing) from original estimation parameters. When parameters change due to device replacement or reconfiguration, the system detects these changes and adjusts consumable usage estimates accordingly, maintaining estimate validity despite parameter variations.

Inventive Principle:

Principle #35Parameter changes

3Loss of energy

If distributed printing is implemented to reduce shipping and mailing costs, then operational costs are reduced, but it becomes infeasible to ensure consistent device configurations across locations

Engineering Contradiction:

Improveshipping and mailing costsVSAvoiddevice configuration consistency

Core Design Contradiction:

Loss of energyVSStability of the object's composition

Solution Approach 1:

The system achieves universality by creating a centralized consumable estimation framework that can universally apply across multiple distributed printing locations. The system stores original estimation settings centrally and compares them against local device settings at each distributed location, enabling consistent consumable monitoring and estimation across diverse device configurations without requiring identical device setups.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Productivity

If device settings are adjusted to improve printing quality or speed, then printing performance is improved, but consumable use increases beyond original estimates

Engineering Contradiction:

Improveprinting performanceVSAvoidink or toner consumption

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The system provides feedback by monitoring device setting changes that affect consumable usage (such as resolution adjustments, color mode changes, or duplex printing modifications). When settings are adjusted to improve printing performance, the system calculates the impact on consumable usage and provides feedback to operators, enabling informed decisions about performance versus consumable trade-offs.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS12019929B2Methods and printing system using adaptive consumable estimation in printing operations

Publication Date: 2024.06.25 KYOCERA DOCUMENT SOLUTIONS INC

AI summary

A printing system includes an estimation system that stores the dot count value and a stored consumable use value for a recurring print job. The dot count value relates to the dot count of a rendered image for the print job for use in printing operations using estimate settings of the printing device. For a later instance of the print job, the estimation system retrieves the dot count value. It also obtains the current settings for the printing device and applies these settings to the dot count value to determine a current consumable use value. Based on the current consumable use value, the estimation system determines whether use of the current settings will result in an increase of ink or toner use.