Digital Print Color Calibration Without Iterative Proofing
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Solution Overview
Problem
Existing methods for ensuring consistent print quality in digital printing are time-consuming, leading to significant downtime and high costs due to the iterative production of proof prints, which is particularly unfavorable for small print jobs.
Innovation Solution
A method involving printing multiple copies of a section of the print motif with varying color settings, capturing digital images of these copies, and using an electrical control system to determine optimal color settings based on similarity with a master pattern, eliminating the need for iterative proof prints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If iterative proof prints are produced to ensure print quality consistency, then manufacturing precision is improved, but productivity deteriorates due to significant downtime
Solution Approach 1:
The patent applies preliminary action by printing multiple test copies with different color settings before actual production begins. These test copies are printed on a first paper web that is later removed, allowing color optimization to be completed in advance. The electrical control system automatically determines the optimal color settings by comparing test copies with the master pattern, so that when production starts on the second paper web, the correct color settings are already established, eliminating iterative proofing during production.
Solution Approach 2:
The patent segments the paper web into two separate portions: a first paper web used for printing test copies with different color settings, and a second paper web used for actual production printing. This segmentation allows the testing and production processes to be separated in space, enabling simultaneous preparation and production activities, thereby reducing downtime while maintaining print quality consistency.
2Manufacturing precision
If multiple proof prints are produced to determine optimal color settings, then manufacturing precision is improved, but loss of time increases due to repeated printing cycles
Solution Approach 1:
The patent maintains continuity of useful action by ensuring that while the first paper web is being processed for test copies, preparations for the second paper web can proceed simultaneously. The electrical control system continuously processes and compares digital images of test copies with the master pattern, automatically determining optimal color settings without interruption. This continuous processing minimizes idle time and keeps the production flow uninterrupted.
Solution Approach 2:
The patent replaces manual iterative proofing with an automated electrical control system that uses optical sensors to capture digital images and algorithms to determine color settings. This substitution eliminates the need for human operators to manually produce multiple proof prints and visually compare them, significantly reducing the time required for color optimization while maintaining or improving accuracy through objective digital measurement.
3Measurement precision
If the digital printing system remains idle during comparison processes, then measurement precision is improved, but productivity deteriorates due to system shutdown
Solution Approach 1:
The patent segments the printing system's operation into two parallel streams: the first paper web is dedicated to printing test copies that are then removed and processed for color setting determination, while the second paper web is prepared for and enters production printing. This spatial segmentation allows the measurement and comparison processes to occur on the first paper web without preventing the second paper web from being utilized for productive printing, thereby maintaining system utilization during analysis.
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
Significantly reduces downtime by allowing immediate production start with optimal color settings, ensuring high-quality print consistency without repeated proof prints.
Implementation Method 1
creating digital images of the printed copies using an optical sensor
Data Source
Figure 1~3
AI summary
The invention relates to a method for printing at least one print motif on a paper web (2) by means of a digital printing system, the method including the following steps: providing a digital image of a master sample of the print motif, printing a plurality of copies of a section (6) of the at least one print motif with different color settings, creating digital images of the printed copies, comparing the digital images of the printed copies with the digital images of the master sample, a degree of similarity being determined in each case, choosing color settings on the basis of the determined degrees of similarity and printing the print motif onto the paper web (2) using the chosen color settings.