Dynamic Sampling Frequency for In-Line Case Printing Quality Control
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Solution Overview
Problem
Existing quality control systems for printing on packaging face challenges such as variations in line speed, misalignment, clogging of nozzles, and inefficiencies in printing diagnostic checkmarks, leading to unsightly marks, waste, and increased manufacturing costs.
Innovation Solution
A dynamic quality control system that adjusts the frequency and placement of checkmarks and indicia using a printer and analyzer feedback loop, allowing for selective printing based on predetermined criteria, with the option of using the same or different printers for checkmarks and indicia, and incorporating a conveyor system to optimize print quality and reduce waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If checkmarks are printed on every case for quality control, then print quality monitoring is improved, but manufacturing cost and waste increase
Solution Approach 1:
The patent implements a dynamic sampling frequency system that automatically adjusts the checkmark printing frequency based on real-time print quality metrics. When print quality is stable and within specifications, the system reduces or eliminates checkmark printing. When quality deviations are detected, the system increases sampling frequency to monitor and maintain quality standards. This dynamic adjustment resolves the contradiction by making quality monitoring effective only when necessary, reducing waste while maintaining reliability.
Solution Approach 2:
The system incorporates a feedback loop where print quality is continuously monitored and the sampling frequency is adjusted based on the feedback. The analyzer evaluates print quality metrics and provides feedback to the controller, which then modifies the checkmark printing frequency accordingly. This feedback mechanism ensures that quality monitoring is intensified when problems arise and reduced when quality is stable, resolving the contradiction between monitoring reliability and waste reduction.
2Measurement precision
If checkmarks are printed at a high frequency to ensure quality control, then print quality detection is improved, but production efficiency deteriorates
Solution Approach 1:
The system dynamically adjusts the sampling frequency based on actual print quality conditions rather than using a fixed high frequency. When print quality metrics indicate stable operation within specifications, the system automatically reduces or pauses checkmark printing. When quality deviations are detected, the system increases sampling frequency to ensure proper detection. This dynamic approach maintains measurement precision when needed while maximizing production efficiency during stable operation.
Solution Approach 2:
The system changes the sampling frequency parameter based on print quality metrics. The controller monitors print quality parameters and adjusts the sampling frequency parameter accordingly - increasing it when quality deviations are detected and decreasing it when quality is stable. This parameter adjustment resolves the contradiction by optimizing the balance between detection precision and production efficiency based on actual operating conditions.
3Reliability
If the printing line is stopped frequently to check for quality issues, then print quality control is improved, but manufacturing cost increases
Solution Approach 1:
The system performs preliminary quality assessment continuously during production using the dynamic sampling approach. By monitoring print quality metrics in real-time and adjusting sampling frequency proactively, the system can detect and address quality issues before they result in defective products. This preliminary action eliminates the need for frequent production stoppages and manual quality checks, maintaining quality control while avoiding the energy loss and cost associated with repeated line stoppages.
Solution Approach 2:
The system maintains continuous quality monitoring through dynamic sampling without interrupting production flow. The automated adjustment of checkmark printing frequency and real-time analysis ensures continuous quality control while the production line operates continuously. This continuity of useful action - both in quality monitoring and production - resolves the contradiction by eliminating the need to stop the line for quality checks while maintaining reliable quality control.
Data Source
AI summary
A dynamic and adaptive control system for printing cases for and individual packages of consumer products. The system prints one or more checkmarks at a predetermined frequency. As the quality parameters of the checkmark[s] drift from the target criteria towards unacceptable range[s] sampling frequency is autonomously increased proportionately. This system enables one to monitor and act upon a greater range of process parameters than conventional systems, as different checkmarks may be printed in limited space therefor on different packages. This arrangement also reduces unacceptable production, by sampling each case/package if necessary, notifying the operator when corrective action is needed.