Fold Position Adjustment Using Optical Pattern Distortion
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Solution Overview
Problem
Existing image processing devices face challenges in accurately adjusting the fold position of recording paper due to variations in paper characteristics, leading to inconsistent fold quality.
Innovation Solution
An image processing device that includes a fold unit, an image reader, a position identifying unit, and a fold position adjusting unit. The device uses an adjustment sheet with a printed pattern to identify the distortion of line segments, allowing for precise adjustment of the fold position based on the difference between the actual and reference fold positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement and adjustment of fold position is used, then device complexity is reduced, but measurement precision and manufacturing precision deteriorate due to operator dependency and inconsistency
Solution Approach 1:
The patent replaces manual mechanical measurement with an optical measurement system using an image reader to capture images of adjustment patterns. The position identifying unit automatically determines fold line positions by analyzing distortion in the captured images, eliminating manual measurement operations and improving precision while reducing operator dependency.
Solution Approach 2:
The system uses an adjustment sheet with predetermined adjustment patterns that automatically provides reference information for measurement. The image reader and position identifying unit work together to self-determine fold positions without requiring external measurement tools or manual intervention, enabling the system to self-adjust.
2Manufacturing precision
If automatic fold position adjustment is implemented, then manufacturing precision improves, but device complexity increases due to additional components
Solution Approach 1:
The image reader serves multiple functions: it reads adjustment patterns from the adjustment sheet, captures images for position analysis, and provides data for fold position calculation. This multi-functionality reduces the need for separate dedicated components, thereby limiting the increase in device complexity while achieving automatic precise adjustment.
Solution Approach 2:
The adjustment sheet acts as an intermediary carrier with predetermined adjustment patterns that bridge the fold unit and the image reader. These patterns serve as reference markers that enable the system to automatically determine fold positions without requiring complex sensors or measurement systems directly on the fold unit.
3Manufacturing precision
If fold position adjustment is performed without considering paper characteristics, then ease of operation is maintained, but manufacturing precision deteriorates due to variations in paper properties
Solution Approach 1:
The system captures images of adjustment patterns after folding and uses the position identifying unit to analyze the actual fold position. This feedback loop allows the system to detect deviations caused by paper characteristics and adjust the fold position accordingly, achieving consistent results across different paper types without requiring manual adaptation.
Data Source
AI summary
An image processing device includes: a fold unit that folds an adjustment sheet, in which an adjustment pattern including at least one line segment is formed, over the at least one line segment based on a predetermined reference fold position; an image reader that reads an image of the adjustment pattern of the adjustment sheet with the adjustment sheet folded by the fold unit unfolded; a position identifying unit that identifies, as a position of a fold line, a position of distortion of the at least one line segment or a predetermined position of an area which appears in the image of the adjustment pattern read by the image reader; and a fold position adjusting unit that adjusts a fold position of the fold unit based on a difference between the position of the fold line identified by the position identifying unit and the reference fold position.