Label Gap Detection Using Moving Average Voltage Filtering
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Solution Overview
Problem
Existing printing systems face challenges in accurately detecting the gap portions between label portions on label paper due to small reflectance differences and potential errors from paper fluttering, leading to erroneous detections.
Innovation Solution
A printing system that calculates moving averages of voltage values from a sensor's output to determine gap portions, using a threshold value based on the maximum value of previous gap portions to differentiate between label and gap areas, reducing false detections from paper fluttering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor optically detects the mark on the paper surface to determine gap portions, then the detection function is achieved, but erroneous detections occur due to small reflectance differences and paper fluttering
Solution Approach 1:
The system performs preliminary actions by acquiring detection signals at predetermined intervals during paper conveyance and calculating integrated values before final determination. This preliminary data collection and processing enables the system to distinguish genuine gap portions from false detections caused by fluttering, thereby improving detection reliability without sacrificing precision
Solution Approach 2:
The system uses feedback mechanisms by continuously monitoring detection signals and comparing integrated values against threshold criteria. The feedback loop allows the system to adjust and refine its detection logic based on real-time signal patterns, reducing erroneous detections while maintaining accurate gap portion identification
2Device complexity
If the mark is detected based on reflectance difference between label portions and gap portions, then the detection method is simple, but the detection accuracy deteriorates due to very small reflectance differences
Solution Approach 1:
The system performs preliminary signal acquisition at predetermined intervals and calculates integrated values before making final detection determinations. This preliminary processing amplifies the subtle reflectance differences through cumulative integration, transforming them into detectable signals that maintain accuracy while keeping the overall method simple
Solution Approach 2:
The system changes the detection parameter from instantaneous reflectance difference to integrated value of detection signals over time. This parameter transformation converts subtle, hard-to-detect reflectance variations into more prominent integrated signal patterns, improving accuracy without significantly increasing methodological complexity
3Productivity
If detection signals are acquired at predetermined intervals during paper conveyance, then the detection process is efficient, but false detections occur when paper fluttering causes similar signal patterns
Solution Approach 1:
The system performs preliminary signal acquisition at predetermined intervals during efficient paper conveyance, then applies integrated value calculation and threshold comparison to filter out false detections. This maintains detection efficiency while the preliminary integrated analysis ensures reliability by distinguishing genuine gap portions from fluttering artifacts
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively reduces erroneous detections of gap portions by using moving averages and threshold calculations, improving accuracy in identifying gap and label areas without increasing sensor size, thus enhancing printing precision.
Implementation Method 1
a sensor which optically detects the mark on the paper surface conveyed by the conveyor
Implementation Method 2
an acquisition device acquires detection signals from a sensor which optically detects the mark
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A printing system (1) includes: a conveyance controller (5-6) configured to control a conveyor (51), the conveyor (51) being configured to convey paper (P) having a printing surface in which label portions (P1) are formed at predetermined intervals; a sensor (81) configured to irradiate light on the paper (P) conveyed by the conveyor (51) to detect reflected light of the irradiated light; a detector (5-7) configured to detect an output of the sensor (81); a moving average calculator (5-8) configured to calculate moving averages of voltage values based on the output of the sensor (81) detected by the detector (5-7); and a determiner (5-9) configured to determine that a portion between an adjacent pair of the label portions (P1) has been detected based on the moving averages of the voltage values calculated by the moving average calculator (5-8), and the output of the sensor (81).