Print Inspection Image Grouping for Real-Time Defect Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing digital printers face challenges in achieving real-time inspection of print quality during production, particularly in roll label printing, due to the need for resource-intensive image comparisons across multiple pages, leading to prolonged inspection times and inefficiencies.
Innovation Solution
An inspection apparatus and system that groups pages into inspection units, generates sample images, and performs collective inspections using a GPU to reduce the number of resource-intensive comparisons, enabling real-time defect detection before the print is completed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If inspection time is reduced to achieve real-time inspection, then productivity is improved, but measurement precision may deteriorate
Solution Approach 1:
The patent generates sample images in advance from RIP data before actual printing occurs. These pre-generated sample images are stored and ready for immediate comparison with inspection images during printing, eliminating the need to generate sample images in real-time and thus reducing inspection time while maintaining comparison accuracy
Solution Approach 2:
The patent replaces traditional CPU-based image processing with GPU-based parallel processing. The GPU accelerates the computationally intensive image comparison operations between sample images and inspection images, enabling real-time inspection without compromising measurement precision
2Manufacturing precision
If multiple copies are inspected with defect inspection program, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
Sample images for multiple copies are generated in advance from the RIP data before printing begins. This preliminary generation allows the inspection system to have all reference images ready simultaneously, enabling parallel or rapid sequential comparison with inspection images from multiple copies without delaying the inspection process
Solution Approach 2:
The inspection system continuously compares inspection images against pre-generated sample images as prints are produced. The GPU maintains continuous processing operations, ensuring that inspection of multiple copies occurs without interruption or idle time, thereby reducing total inspection time while maintaining defect detection accuracy
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 significantly reduces inspection time by optimizing resource usage and enabling real-time detection of defects, ensuring high-quality print production without delays.
Implementation Method 1
an image produced by scanning a print in advance or a raster image processor (RIP) image during printing is generated as a sample image
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
In inspection of a minimum size in a feeding direction in inspection, the inspection of the previous page is not finished before the inspection of the next page is started due to ensuring of resources, initial setup, and so on for the inspection. An inspection apparatus (200) includes receiving means (221) that receives a first image, registration means (223) that generates a second image in which multiple first images are continuously arranged based on the first image if the received first image meets a predetermined condition to register the second image as a sample image, a reader (225) that reads a read image, and inspection means (223) that inspects a print based on the sample image and the read image read by the reader from the print resulting from formation of an image on a sheet by image formation means.