NIR Spectroscopy for Continuous Color Deviation Detection
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Solution Overview
Problem
Current methods for detecting color deviations in print decorations applied to carrier materials are complex, costly, and disrupt production, as they require stopping production to compare current prints with master templates.
Innovation Solution
A method using Near-Infrared (NIR) spectroscopy to record and compare NIR spectra of printed samples with reference spectra from a master template, allowing for continuous and rapid detection of color deviations without the need for production stops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional visual inspection methods are used to check colour uniformity, then colour deviation can be detected, but production must be stopped and inspection time is required
Solution Approach 1:
The patent replaces the mechanical/visual inspection system with an optical measurement system using a spectrophotometer. The device automatically measures colour deviations by recording spectral reflectance data and comparing it against reference values, eliminating the need for manual visual inspection and production interruptions.
Solution Approach 2:
The inspection system performs automatic self-measurement and self-evaluation of colour uniformity. The spectrophotometer autonomously records spectral data, compares it with stored reference values, and evaluates colour deviations without requiring human intervention or stopping the printing process.
2Productivity
If scanners are used to constantly compare current print with master pattern, then continuous monitoring is achieved, but the system becomes technically complex and costly
Solution Approach 1:
The patent extracts and focuses on a specific measurement parameter (colour/reflectance spectrum) rather than using a complete complex scanning system. By isolating the essential spectral measurement function, the system achieves continuous monitoring with simplified equipment - a spectrophotometer rather than a complex scanner.
Solution Approach 2:
The system changes the measurement approach by using spectral reflectance parameters instead of image-based scanning. This parameter transformation simplifies the measurement system while enabling continuous monitoring, as spectral data can be quickly compared against reference values without complex image processing.
3Productivity
If production speed is increased to meet demand, then productivity improves, but colour deviations become more difficult to detect and assess
Solution Approach 1:
The patent implements continuous colour measurement during the printing process. The spectrophotometer continuously records spectral data as the print is produced, allowing immediate detection of colour deviations without interrupting the printing stream. This continuous monitoring enables real-time quality control at high production speeds.
Solution Approach 2:
The system establishes a feedback loop where measured spectral data is immediately compared with reference values, and colour deviations are evaluated in real-time. This feedback mechanism allows for immediate detection and assessment of colour deviations even at high production speeds, enabling timely corrections.
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
Enables quick and continuous monitoring of color deviations, reducing production losses and costs, while allowing for immediate color correction measures to be initiated, thus maintaining high production efficiency.
Implementation Method 1
Recording of at least one NIR spectrum of several reference samples with the print template using at least one NIR measuring head
Data Source
AI summary
Provided is a method for determining the colour deviation of at least one print decoration applied to at least one carrier material from a print template using only NIR spectroscopy including the steps of recording of at least one NIR spectrum of several reference samples with the print template using at least one NIR measuring head in a wavelength range between 700 nm and 2500 nm, applying the at least one printed decoration to the at least one carrier material by means of printing, recording at least one NIR spectrum of the carrier material printed with the print decoration using the at least one NIR measuring head in a wavelength range between 700 nm and 2500 nm, and determining the colour deviation of the print decor by comparing with the at least one NIR spectrum recorded for the print template.