Ceramic Tile Printing Alignment Using Post-Press Keypoints
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Solution Overview
Problem
The non-correspondence or non-perfect superimposition of decorations on ceramic tiles or slabs occurs due to deformations during the pressing step, causing discrepancies between the digital graphic design and the actual image after firing, especially when using digital inkjet printing and mass decoration before and after pressing.
Innovation Solution
An image identification method and system that involves acquiring a real image of the compacted layer post-pressing, detecting keypoints, comparing them with the digital graphic design, and applying a transformation function to align and print the image correctly on the substrate, ensuring correspondence between the structure and decoration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If digital inkjet printing and mass decoration are applied before and after pressing, then decorative effects are improved, but non-correspondence between decorations occurs due to deformation during pressing
Solution Approach 1:
The system performs preliminary actions by capturing the substrate structure before pressing occurs, then uses this captured structure as a reference to guide subsequent printing operations after pressing, ensuring alignment despite deformation
Solution Approach 2:
The system employs feedback mechanisms by continuously monitoring and comparing the actual substrate structure against the reference structure, using this information to dynamically adjust printing parameters and maintain alignment accuracy throughout the pressing process
2Productivity
If pressing step is applied to compact the layer, then manufacturing efficiency is improved, but deformation of the mass decoration occurs causing non-correspondence
Solution Approach 1:
The system captures the substrate structure before pressing as a reference, enabling subsequent printing operations to compensate for pressing-induced deformations and maintain alignment accuracy
Solution Approach 2:
The system dynamically adjusts printing parameters based on the comparison between reference and actual substrate structures, compensating for deformations caused by pressing and maintaining decoration correspondence
3Manufacturing precision
If the structure changes during pressing, then compacting is achieved, but the digital image no longer coincides with the compacted layer structure
Solution Approach 1:
The system creates a digital copy (reference image) of the substrate structure before pressing, which is then used as a template to guide subsequent printing operations, ensuring the digital image remains synchronized with the physical structure despite deformation
Solution Approach 2:
The system adjusts printing parameters based on the transformation between the reference image and actual substrate structure, compensating for changes in position, orientation, and scale caused by pressing
Data Source
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AI summary
The invention describes an image identification method for printing on rigid substrates comprising the steps of: defining a digital graphic design (P_G_DGT) representative of a rigid substrate to be produced;_spreading a soft layer (SL) of granular or powder ceramic material on a deposition surface (Repressing the soft layer (SL) to obtain a compacted layer (CL); acquiring a real image (I REAL) of the compacted layer (CL) after the pressing step; detecting keypoints (KPI_REAL) of the real image (I REAL); comparing the keypoints (KPI_REAL) of the real image (I REAL) with keypoints (KPi_pred) of an image (l_G_DGT) obtained/derived from said predefined digital graphic design (P_G_DGT); and calculating a portion (l_P_G_DGT) of said digital graphic design (P_G_DGT) corresponding to a portion (P_I REAL) of said acquired real image (I REAL). The invention further comprises an image identification system for printing for the implementation of the described method and a corresponding printing method/system.