Image Forming Error Detection for Automatic Print Interruption
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Solution Overview
Problem
Existing image forming systems continue to produce defective prints despite inspection errors, leading to wasted resources and inefficiencies due to inconsistent inspection results caused by sensor contamination or defects, and lack the ability to autonomously halt production when errors persist.
Innovation Solution
An information processing apparatus that communicates with an image forming apparatus and a reader, capable of determining errors in image data and automatically halting image forming and reading operations when a predetermined number of consecutive errors occur, with user intervention for confirmation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If automatic inspection is implemented to detect defects, then inspection accuracy is improved, but production stops when sensor contamination occurs
Solution Approach 1:
The system continuously monitors inspection results and feeds back to the control unit. When a predetermined number of consecutive inspection failures occur, the feedback mechanism triggers automatic suspension of the inspection process, preventing further production stoppages while maintaining high inspection accuracy through continuous quality monitoring.
Solution Approach 2:
The system performs preliminary actions by automatically suspending the inspection process before sensor contamination severely impacts production. The control unit proactively identifies patterns of consecutive failures and initiates suspension in advance, preventing the need for manual intervention and minimizing production loss.
2Productivity
If inspection process continues despite errors, then productivity is maintained, but defective products are output
Solution Approach 1:
The control unit receives continuous feedback on inspection results and automatically adjusts production based on this feedback. When consecutive inspection failures are detected, the system suspends production automatically, ensuring that defective products are not output while maintaining high productivity through automated quality control.
Solution Approach 2:
The inspection system performs self-service by automatically suspending production when quality issues are detected, without requiring manual intervention. The control unit independently monitors inspection results, identifies patterns of failure, and initiates suspension autonomously, ensuring both high productivity and reliable product quality.
3Device complexity
If manual visual inspection is used, then device complexity is reduced, but inspection efficiency decreases at high speed
Solution Approach 1:
The system replaces manual visual inspection with an automated optical inspection system that uses sensors and image processing. This substitution eliminates the need for human workers while significantly improving inspection efficiency at high production speeds, though it increases device complexity through automation technology.
Solution Approach 2:
The automated inspection system performs self-service by continuously monitoring product quality without human intervention. The control unit automatically analyzes inspection data, identifies defects, and manages production suspension, providing high-efficiency inspection that operates independently of manual labor constraints.
Data Source
AI summary
An information processing apparatus, which communicates with an image forming apparatus and a reader, including: a display; and a controller configured to: obtain read image data output from the reader; determine an error of the read image data based on the read image data and reference data; cancel image forming operation of the image forming apparatus in a case where the error is determined in succession a predetermined number of times; cancel reading operation of the reader in the case where the error is determined in succession the predetermined number of times; notify, on the display, the cancellation of the image forming operation and the reading operation in the case where the error is determined in succession the predetermined number of times; and receive a user's instruction information about the predetermined number of times.