Calibrated Optical Inspection for Custom Printed Articles
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Solution Overview
Problem
Optical printing process verification for freely configurable articles is hindered by the lack of image data and learning data, making it difficult to ensure quality standards, especially for custom-configured articles without prior production records.
Innovation Solution
An apparatus comprising a data providing device, camera device, and computer device that uses calibration data to perform automatic optical inspection by comparing printing data with image data, generating synthetic learning data, and employing machine learning for quality control, allowing for accurate alignment and quality estimation without requiring prior printing operations or reference images.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional optical inspection systems with image databases are used, then quality verification can be performed for standard articles, but they fail for freely configurable articles without prior production records
Solution Approach 1:
The system performs preliminary calibration by capturing images of calibration objects with known geometric properties and storing calibration data before actual inspection. This preliminary action creates a reference framework that enables subsequent inspection of freely configurable articles without requiring pre-existing image databases for each specific article type.
Solution Approach 2:
The system changes the approach from comparing against fixed image databases to dynamically adjusting inspection parameters based on calibration data. By modifying the inspection methodology to incorporate calibration-based geometric reconstruction, the system adapts to various article configurations while maintaining reliable quality verification.
2Ease of manufacture
If manual learning processes or conventional optical systems are used, then inspection can be performed with existing data, but they are not possible for articles without learning data or image databases
Solution Approach 1:
The inspection system performs self-calibration by automatically capturing images of calibration objects and generating its own reference data. This self-service capability eliminates the need for manual setup of article-specific image databases while enabling the system to adapt to any article configuration, combining ease of manufacture with high versatility.
3Measurement precision
If image databases with multitude of correctly performed printing images are used, then conventional optical inspection can be performed, but learning data is not available for newly created custom articles
Solution Approach 1:
The system introduces calibration objects as an intermediary element that bridges the gap between the inspection system and diverse article configurations. By using calibration objects with known properties as a mediator, the system can establish accurate measurement references without requiring article-specific image databases, thereby maintaining measurement precision while avoiding information loss for new articles.
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
Enables reliable monitoring and quality control of printing processes for newly created, custom-configured articles, increasing process reliability and eliminating the need for manual teach-in or prototype reference images, thus facilitating the inspection of freely configurable products.
Implementation Method 1
The image of the printed article is digitized by means of an electronic image converter or image sensor and provided in the form of the image data
Data Source
AI summary
The present invention relates to an apparatus for calibrated testing of a printing of an article. The apparatus includes a data providing device adapted to provide printing data for the article from product data of the article and a camera device adapted to capture an image of an article printed by a printing process and to provide it as image data. The apparatus also includes a database device adapted to provide calibration data for the camera device and a computer device adapted to perform a quality check of the printing process based on a comparison of the printing data with the image data taking into account the calibration data.