Nozzle Malfunction Detection in Digital Printing Presses
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Solution Overview
Problem
Digital printing presses face challenges in detecting and classifying malfunctioning nozzles, which can result in noticeable defects in printed images, leading to substrate waste and reduced quality.
Innovation Solution
A method and system that utilize a nozzle pattern and/or a uniformity pattern to identify and classify malfunctioning nozzles by analyzing images acquired from an imager, determining the location and type of malfunction through nozzle locators and strength scores, enabling the detection of missing, deviated, inconsistent, and redundant nozzles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a digital printing press operates continuously to maximize productivity, then output increases, but malfunctioning nozzles may go undetected causing substrate waste and quality issues
Solution Approach 1:
The system performs preliminary nozzle detection by printing test patterns before production printing. The imager captures images of these patterns to identify malfunctioning nozzles in advance, allowing the system to rectify issues through software compensation before they affect production quality or cause substrate waste.
Solution Approach 2:
The system establishes a feedback loop where the imager continuously monitors printed test patterns, detects nozzle malfunctions, and provides information to the controller. The controller then adjusts print data in real-time to compensate for detected issues, enabling continuous operation without quality degradation.
2Manufacturing precision
If the printing press stops to detect and repair malfunctioning nozzles, then print quality is maintained, but productivity decreases due to interruptions
Solution Approach 1:
The system performs self-diagnosis by automatically detecting malfunctioning nozzles through test pattern imaging and analysis. The controller automatically generates compensation data without human intervention, allowing the press to maintain quality while minimizing stops. Only when compensation is insufficient does the system require manual nozzle maintenance.
3Productivity
If malfunctioning nozzles are not detected, then productivity is maintained, but substrate waste increases due to unprintable material
Solution Approach 1:
The system identifies malfunctioning nozzles before production printing begins through test pattern analysis. By detecting issues in advance and applying software compensation, the system prevents defective printing that would otherwise result in substrate waste, allowing continuous production of quality material.
4Measurement precision
If a detailed test pattern is printed to detect all nozzle malfunctions, then detection precision improves, but the time required for detection increases
Solution Approach 1:
The test pattern is segmented into multiple sections, each targeting specific nozzle groups or malfunction types. The imager captures and analyzes these segments systematically, allowing comprehensive detection without requiring a single excessively large test pattern, thus balancing detection completeness with time efficiency.
Data Source
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AI summary
A method of identifying at least one malfunctioning nozzle in a digital printing press, the digital printing press including a plurality of nozzles. The method includes the procedures of printing a design on a substrate, acquiring at least one image of the printed design and identifying at least one artifact in the acquired image. The method further includes the procedure of identifying the malfunctioning nozzle and classifying the at least one malfunction nozzle according to at least a portion of a combined pattern.