Digital Substrate Alignment via Image Processing
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Solution Overview
Problem
Existing digital printing technologies face challenges with substrate deformation and imperfect transport, leading to issues like shifts and misalignment during the printing process, which are not adequately addressed by sophisticated transport systems that require constant technical expertise and rely on registration marks, limiting production capacity and image quality.
Innovation Solution
A digital transformation method and device that uses a control station with parallelizable calculation units, such as GPGPUs or quantum computers, to analyze substrates, record digital files, and generate correction files (FN3-CORR) for optimizing substrate transformation, allowing for real-time adjustments without the need for registration marks, enabling efficient and precise printing across various substrate types and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sophisticated substrate transport devices with numerous mechanical systems and sensors are used to improve substrate alignment, then manufacturing precision is improved, but device complexity increases and productivity decreases
Solution Approach 1:
The patent replaces complex mechanical alignment systems with a digital image processing approach. A camera captures substrate images, and software algorithms automatically detect and correct misalignments by comparing captured images with reference patterns, eliminating the need for numerous mechanical adjustment systems and sensors.
Solution Approach 2:
The patent creates digital copies of substrate images using a camera and uses these copies for alignment analysis. By working with digital image data rather than physical substrate manipulation, the system achieves precise alignment without complex mechanical transport devices.
2Manufacturing precision
If registration marks and pre-printed features are used for substrate positioning, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent utilizes color or pattern differences between the substrate and registration marks to enable automatic detection. The image processing system identifies registration marks based on their distinct visual characteristics, allowing for automated positioning without complex mechanical positioning systems.
3Manufacturing precision
If the entire pre-printed substrate is digitized before overprinting begins, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent performs preliminary capture of substrate images and prepares alignment data before overprinting begins. By pre-processing the image data and calculating correction factors in advance, the system ensures accurate positioning while minimizing interruptions to the production flow.
Solution Approach 2:
The patent enables continuous overprinting operations by preparing alignment corrections in advance. The system captures substrate images, processes alignment data, and applies corrections seamlessly during the printing process, maintaining continuous production without stopping for complete substrate digitization.
4Manufacturing precision
If sophisticated substrate transport devices are used to improve alignment, then manufacturing precision is improved, but operating costs increase due to requiring near-constant presence of technical experts
Solution Approach 1:
The patent implements self-service alignment through automated image capture and processing. The system automatically detects substrate misalignments, calculates correction factors, and applies adjustments without requiring technical experts to manually operate complex transport devices, significantly reducing operational complexity and costs.
Solution Approach 2:
The patent uses feedback from captured substrate images to automatically adjust alignment parameters. The system continuously monitors substrate position through imaging, compares it with reference data, and applies real-time corrections, creating a closed-loop system that maintains precision without human intervention.
Data Source
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AI summary
The present invention relates to a device for transforming by digital processing a substrate and preferably a pre-processed substrate. The present invention also relates to a method for transforming by digital processing a substrate, preferably a preprocessed substrate.