Hybrid Consumable Estimation in Printing Systems
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Solution Overview
Problem
Existing consumable use estimation systems in printing operations are either resource-intensive and delay job quoting by requiring press operator time, or they are less accurate as standalone offline applications that cannot consider printing device configuration.
Innovation Solution
A hybrid consumable use estimation method that involves sending print jobs to a digital front end (DFE) of a printing device for estimation, with the option to use a raster image processor (RIP) if the DFE cannot provide an estimate, and allowing for processing in a separate queue to minimize resource usage and prioritize production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If consumable use estimation is performed using the same RIP that processes print jobs, then measurement precision is improved, but productivity deteriorates due to delayed job quoting and press operator time consumption
Solution Approach 1:
The system divides consumable estimation into separate functional modules: an estimation RIP for accurate calculation, a production RIP for actual print processing, and a server for coordinating between them. This segmentation allows accurate estimation without blocking production workflows.
Solution Approach 2:
A server acts as an intermediary between the estimation RIP and production RIP. It receives print jobs, routes them to appropriate RIPs based on their function, and manages the flow of estimation results back to customers, eliminating the need for press operators to manually perform estimations.
2Productivity
If consumable use estimation is performed using offline standalone applications, then productivity is improved by not taking press operator time, but measurement precision deteriorates due to generic estimation without printing device configuration knowledge
Solution Approach 1:
The server serves as an intermediary that connects offline estimation capability with online device configuration data. It automatically retrieves current printing device settings (calibration, color profiles, etc.) and transmits them to the estimation RIP, enabling accurate estimation without manual press operator involvement.
Solution Approach 2:
The system enables self-service consumable estimation by automatically fetching device configuration data and performing calculations without requiring press operator intervention. Customer service representatives can access estimates independently, improving both productivity and consistency.
3Measurement precision
If DFE resources are allocated for consumable estimation, then measurement precision is improved, but loss of energy increases due to additional processing load
Solution Approach 1:
The system segments estimation processing from production processing. The estimation RIP handles consumable calculations separately from the production RIP that performs actual print rendering, preventing estimation tasks from consuming DFE resources needed for production.
Solution Approach 2:
Instead of using the production DFE for estimation, the system creates a separate estimation RIP instance that copies only the necessary color conversion and calculation functionality. This lightweight copy performs estimation without requiring full production-grade DFE resources.
Data Source
AI summary
A printing system provides consumable use estimation for print jobs using an estimation system and the digital front end (DFE) of a printing device. A hybrid consumable use estimation process is enabled that minimizes impact to the production printing at the printing device. The DFE of the printing device generates a consumable use estimate using an estimate job queue and raster image processor (RIP) separate from the normal job queues. The estimate job queue does not generate print data. Using the rendered data, the DFE generates the consumable use estimate and returns it to the estimation system. The printing device then prints the document for the print job and provides the actual consumable use to the estimation system for monitoring and tracking of consumable use. In some instances, the estimation system performs the consumable use estimation when a condition exists at the DFE at the printing device.