Print Quality Control via Visual Grey Tone Reference
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Solution Overview
Problem
The printing industry faces challenges in achieving precise and consistent color printing due to the reliance on operator judgment and the inefficiency of existing color management systems, which result in high costs, extensive setup times, and wastage, as current methods can only provide partial ink density data, leading to inaccurate ink adjustments and imbalanced color outputs.
Innovation Solution
A print quality control method that uses visual referring targets on the printing substrate, including a specific halftone of black 'K' and accurately registered cyan, magenta, and yellow colors to create a neutral grey tone, allowing for continuous monitoring and fine color correction, thereby enabling precise color balance adjustments across the full machine width without the need for expensive equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional color management systems and ink density readers are used, then measurement precision can be achieved, but device complexity and cost increase significantly
Solution Approach 1:
The patent creates a visual copy of the printing process by printing test patterns (color bars and neutral grey tones) on the same substrate as the actual print job. This visual copy allows operators to assess ink density and color balance without requiring complex electronic measurement devices, thereby achieving measurement precision through a simple visual reference system rather than sophisticated equipment
Solution Approach 2:
The patent introduces a visual intermediary system consisting of printed test patterns and neutral grey tone references that mediate between the printing process and quality assessment. Instead of directly measuring ink density with complex devices, the visual reference patterns serve as an intermediary that translates physical ink properties into visible comparisons, enabling operators to make accurate assessments without specialized equipment
2Manufacturing precision
If trial and error adjustment method is used, then manufacturing precision can be achieved, but loss of time and loss of substance increase significantly
Solution Approach 1:
The patent performs preliminary action by printing test patterns and neutral grey tone references before the actual production run. These pre-printed references establish the expected ink density and color balance conditions in advance, allowing operators to immediately compare against actual production results and make targeted adjustments without time-consuming trial and error during the main production process
Solution Approach 2:
The patent implements feedback by providing visual reference patterns that show the expected ink density and color balance outcomes. Operators can immediately compare these references with actual print results, receiving instant feedback on ink placement accuracy. This feedback loop enables rapid identification and correction of issues without repeated trial and error cycles, significantly reducing setup time while maintaining precision
3Measurement precision
If conventional color bars are used, then measurement precision for single color can be achieved, but loss of information occurs regarding multi-color overprinting conditions
Solution Approach 1:
The patent merges multiple color measurement functions into a single integrated visual reference system. By combining CMYK color bars with neutral grey tone patterns and overprinting test patterns on the same substrate, the system simultaneously provides reference data for individual color densities and their interactions when overprinted. This merged reference structure eliminates information loss by capturing multi-color relationship data that conventional separate color bars cannot provide
4Ease of operation
If operator judgment is used for color balance control, then ease of operation is maintained, but manufacturing precision deteriorates due to subjectivity
Solution Approach 1:
The patent utilizes color changes and visual tone variations in the printed reference patterns to provide objective visual cues for color balance assessment. By incorporating neutral grey tones and controlled color variations in the test patterns, the system transforms subjective operator judgment into objective visual comparisons. Operators can reliably assess ink density and color balance by comparing these standardized visual references, thereby improving precision while maintaining ease of operation through simple visual inspection
Data Source
AI summary
A print quality control method, including the steps of: providing a visual referring target on the printing substrate, setting a specific halftone of black âKâ; creating a neutral grey tone i.e. NGT; placing tightly both MGT and NGT next to each other across the printing surface; and comparing both printed tones result. By adopting the grey balance theory and visual matching technique, the resultant can provide accurate ink balance information for the production personnel to immediate execute the correction on the imbalance inking condition during production.