Carton Former Register Correction via Image Pattern Matching
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Solution Overview
Problem
Existing box producing apparatuses require skilled operators to make precise adjustments for print, slotting, cutting, and gluing positions, which is burdensome and time-consuming, especially for new orders, as multiple test feeds are needed to match the initial deviation, leading to inefficiencies in production.
Innovation Solution
A box producing apparatus equipped with a printing section, image obtaining unit, and register correction control unit that compares images of printed faces against master images to determine register displacement, automatically correcting print unit positions, slotting, cutting, and gluing positions using pattern matching methods, reducing operator burden and improving precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment by skilled operators is used for print, slotting, cutting, and gluing positions, then adjustment precision can be achieved, but the process becomes burdensome and time-consuming, especially for new orders requiring multiple test feeds
Solution Approach 1:
The patent replaces manual mechanical adjustment operations with an automated image processing system. The inspection unit captures images of printed faces, and the control unit automatically calculates position deviations by comparing captured images with master images, then sends correction amounts to the register adjustment mechanisms. This substitution eliminates the need for skilled operators to perform multiple test feeds and manual adjustments, significantly reducing setup time while maintaining precision.
Solution Approach 2:
The system enables self-service adjustment by automatically detecting position deviations and calculating correction amounts without human intervention. The control unit autonomously processes images, determines deviation amounts for each color print unit, and controls register adjustment mechanisms based on calculated corrections. This self-service capability allows the apparatus to automatically adapt to new orders without requiring skilled operators or multiple test feeds.
2Manufacturing precision
If multiple test feeds are performed to match initial deviation for new orders, then position accuracy is improved, but productivity decreases due to repeated adjustments
Solution Approach 1:
The system performs preliminary action by capturing an image of the printed face immediately after a single test feed and automatically calculating position deviations before mass production begins. The control unit processes the captured image, determines correction amounts for all color print units, and pre-adjusts register positions. This preliminary automatic adjustment eliminates the need for multiple test feeds during setup, significantly improving productivity while maintaining position accuracy.
Solution Approach 2:
The system implements feedback by using the inspection unit to capture images of printed faces and the control unit to automatically analyze position deviations. The calculated deviation amounts are fed back to control the register adjustment mechanisms, creating a closed-loop system that automatically corrects positioning errors. This feedback mechanism eliminates the need for repeated test feeds and manual adjustments, thereby improving production efficiency.
3Ease of operation
If automated image comparison is used to determine register displacement, then operator skill requirements are reduced and setup time decreases, but device complexity increases
Solution Approach 1:
The system achieves universality by using a single inspection unit with an image sensor to perform multiple functions: capturing printed face images, determining position deviations for multiple color print units, and providing feedback for register adjustments. The control unit integrates image processing, deviation calculation, and adjustment control in one system. This multi-functional approach reduces operator skill requirements while managing device complexity through consolidation rather than proliferation of separate systems.
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
Facilitates pre-adjustment of the box producing apparatus, allowing for precise and efficient production of boxes with reduced operator skill requirements, enabling faster setup and improved quality by automatically correcting register positions and detecting deviations in slotting, cutting, and gluing positions.
Implementation Method 1
an image obtaining unit that obtains an image of a printed face which is printed on a box material sheet by the printing section
Implementation Method 2
a register correction control unit that compares a specific picture in a master image (master pattern) of a sample for the print, and the specific picture in the image of the printed face obtained by the image obtaining unit to determine an amount of register displacement
Data Source
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AI summary
An box producing apparatus is disclosed, including a camera that obtains an image of a printed face which is printed on a box material sheet by the printing section; and a register correction control unit that compares a specific picture in a master image of a sample for the print, and a picture in a region specified according to the specific picture in the image of the printed face obtained by the camera to determine an amount of register displacement in each of the print units, and controls a register adjustment mechanism provided in each of the print units based on the amount of register displacement to correct a register of the print.