Contactless Area-Scan Measurement for Rotary Body Elevations

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Solution Overview

Problem

Existing systems for measuring elevated areas on rotary bodies in printing presses, such as flexographic printing plates, are not able to achieve high precision and speed while avoiding contact, which can damage delicate print dots and result in suboptimal print quality and increased downtime.

Innovation Solution

A device using an area scan camera with a radiation source and a reference object for contactless measurement of rotary bodies, allowing precise and rapid detection of elevated areas, such as flexographic print dots, by employing a two-dimensional light-sensitive area sensor and a motor-adjustable reference object.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If contactless measurement is used, then the risk of damage to delicate print dots is reduced, but measurement precision and speed are insufficient

Engineering Contradiction:

Improvedamage to print dotsVSAvoidmeasurement precision

Core Design Contradiction:

Object-affected harmful factorsVSMeasurement precision

Solution Approach 1:

The patent replaces mechanical contact-based measurement systems with an optical measurement system using a radiation source and area scan camera. This substitution eliminates physical contact that could damage delicate print dots while achieving high measurement precision through optical detection of surface elevations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the measurement parameters by using optical radiation properties (light reflection, absorption) instead of mechanical contact properties. The area scan camera captures optical signals that correspond to surface topography, enabling non-contact measurement with high precision by detecting variations in reflected or emitted radiation.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If contactless measurement is used, then the risk of damage to delicate print dots is reduced, but measurement speed is insufficient

Engineering Contradiction:

Improvedamage to print dotsVSAvoidmeasurement speed

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The optical measurement system replaces slow mechanical scanning with rapid optical capture. The area scan camera can capture the entire measurement field simultaneously in a single frame or through fast sequential scanning, achieving high measurement speed without mechanical contact that would slow down the process or risk damage.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent transitions from one-dimensional line scanning to two-dimensional area scanning, enabling parallel measurement of multiple points across the surface simultaneously. This dimensional change dramatically increases measurement speed while maintaining non-contact operation, allowing the entire printing plate surface to be measured rapidly without mechanical wear or damage risk.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Difficulty of detecting and measuring

If a moving laser head is used for scanning, then measurement capability is achieved, but measurement speed and precision are compromised

Engineering Contradiction:

Improvemeasurement capabilityVSAvoidmeasurement precision

Core Design Contradiction:

Difficulty of detecting and measuringVSMeasurement precision

Solution Approach 1:

The patent replaces the moving laser head mechanical scanning system with a stationary area scan camera-based optical system. This eliminates mechanical movement errors, vibrations, and alignment issues that compromise precision, while achieving full surface measurement capability through the camera's wide field of view and high-resolution sensor array.

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

Enables high-precision, contactless measurement of rotary body surfaces, reducing the risk of damage and enabling optimal working pressure settings for improved print quality and reduced downtime.

Implementation Method 1

a measuring unit, in which the measuring unit for the contactless measurement includes at least one radiation source and at least one area scan camera

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS12409646B2Device for measuring elevated areas of the surface of a rotary body and system having the device

Publication Date: 2025.09.09 HEIDELBERGER DRUCKMASCHINEN AG

AI summary

A device for measuring elevated areas of the surface of a rotary body in the form of a cylinder, a roller, a sleeve or a plate of a printing press, for example a flexographic printing plate, includes a first motor for rotating the rotary body about a rotational axis and a measuring unit for contactless measurement. The measuring unit for contactless measurement includes at least one radiation source and at least one area scan camera. The measuring unit for contactless measurement preferably includes a reference object, for example a wire tensioned in an axially parallel manner, a second motor and optionally a further second motor, for adjusting the measuring unit and/or the reference object perpendicularly to the rotational axis. The device makes it possible to measure elevated areas, for example flexographic print dots, quickly and with high precision. A system having the device is also provided.