Lane Bitmap Image Processing for Substrate Shrinkage Compensation
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Solution Overview
Problem
Existing image processing systems face alignment issues during finishing operations, such as cutting or folding, due to substrate shrinkage or stretching during printing, which affects the alignment of small images on printed substrates.
Innovation Solution
An image processing system that converts source image data into lane-specific bitmap elements, allowing independent adjustment of image positions using a streaming processor, which generates control signals based on position data to align images accurately within the printing direction, and includes measurement means for automatic correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single ready-to-print file is generated for the full width of the printing apparatus, then the printing process can handle various image sizes, but alignment problems occur during finishing operations due to substrate shrinkage or stretching
Solution Approach 1:
The patent divides the printing system into multiple independent streaming processors, each handling a specific lane (e.g., first lane, second lane). Each streaming processor receives and processes image data for its designated lane independently, allowing separate position adjustment for each lane. This segmentation enables precise control over image positioning in each lane, compensating for substrate shrinkage or stretching without affecting other lanes, thus resolving the alignment precision problem while maintaining versatility.
2Productivity
If small images are grouped into a single image file for printing, then printing efficiency is improved, but the substrate material shrinkage or stretching causes misalignment for finishing operations
Solution Approach 1:
Instead of grouping all small images into a single file processed by one streaming processor, the patent segments the images into multiple lanes, with each lane processed by a dedicated streaming processor. This allows each processor to independently adjust positions within its lane based on substrate deformation, maintaining both high printing efficiency (through parallel processing) and alignment precision (through independent position control in each lane).
Solution Approach 2:
The system dynamically adjusts the position of images within each lane based on detected substrate shrinkage or stretching. Each streaming processor can independently modify image positions in real-time, allowing the system to adapt to varying substrate conditions while maintaining alignment precision for finishing operations.
3Manufacturing precision
If position adjustment is applied to the entire printed image, then alignment can be corrected, but adjacent small images cannot be positioned independently
Solution Approach 1:
The patent divides the printing system into multiple independent streaming processors, each handling a specific lane. Each streaming processor can independently adjust image positions within its designated lane without affecting other lanes. This segmentation provides both overall alignment precision (through coordinated position adjustments across lanes) and independent position adjustment capability (through lane-specific control), resolving the contradiction between these two requirements.
Data Source
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AI summary
Image processing system for generating control signals for printing means, from source image data from an image source, comprising a raster image processing and layout module configured to convert said source image data into a first lane bitmap element and a second lane bitmap element; a streaming processor arranged to receive said first lane bitmap element and said second lane bitmap element, and position signals comprising position data for said first and/or said second lane image in the printed image; said streaming processor being configured to generate control signals for the printing means based on said first lane bitmap element, said second lane bitmap element, and said position signals in order to be able to adjust the position of said first lane image and/or the position of the second lane image in the printed image.