Automated Print Quality Inspection for Absorbent Articles
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Solution Overview
Problem
Current print quality inspection systems for absorbent articles rely on human subjectivity, leading to inconsistent evaluations and the need for objective assessment methods to ensure consistent quality across all printed graphics on substrates intended for final article assemblies.
Innovation Solution
A method involving a communication network connecting cameras and spectrophotometers with an analyzer to inspect printed regions, calculate visual and quality scores based on parameters like grayscale, color, shape, mismatch size, and location, and execute control actions to maintain print quality, eliminating human involvement and ensuring comprehensive evaluation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If human beings are used to inspect print quality, then subjective evaluation can be performed, but consistency and objectivity of quality assessment deteriorate
Solution Approach 1:
The patent replaces the human visual inspection system with an automated optical inspection system comprising a camera, light source, and image processing unit. The system captures images of printed regions, processes them through algorithms that compare against reference images, and automatically determines print quality without human intervention, thereby eliminating subjectivity while maintaining ease of operation.
Solution Approach 2:
The patent introduces an image processing algorithm as an intermediary between the printed substrate and the quality assessment. This intermediary processes the visual information captured by the camera, extracts relevant features, compares them against reference standards, and generates objective quality metrics, serving as a mediator that translates physical print characteristics into quantifiable quality data.
2Measurement precision
If automated inspection devices are used, then objectivity of evaluation is improved, but the ability to account for consumer perception and acceptance deteriorates
Solution Approach 1:
The patent performs preliminary action by collecting consumer feedback and perception data about print quality attributes before implementing the inspection system. This pre-collected data is used to train and calibrate the image processing algorithms, ensuring that the automated system evaluates print characteristics that consumers actually value, thereby aligning objectivity with consumer acceptance from the outset.
Solution Approach 2:
The patent implements a feedback mechanism where consumer acceptance data and quality metrics from the automated inspection system are continuously analyzed and used to refine and update the inspection algorithms. This closed-loop feedback ensures that the system remains adaptable to changing consumer preferences while maintaining its objective assessment capabilities.
3Productivity
If random spot checks are used for inspection, then resource consumption is reduced, but the quantity of inspected graphics deteriorates
Solution Approach 1:
The patent enables continuous inspection by integrating the camera and image processing system into the production line, allowing every printed region to be inspected as it passes through, rather than relying on intermittent spot checks. The automated system operates continuously without fatigue or resource constraints, inspecting 100% of graphics while maintaining high productivity through efficient real-time processing.
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 provides an objective evaluation of print quality, reducing human error and ensuring consistent print quality across all printed regions, thereby enhancing consumer acceptance and product reliability.
Implementation Method 1
a camera (310a) configured to inspect the printed region (400) and generate an image
Implementation Method 2
a spectrophotometer (310b) configured to inspect the printed region (400) and measure a delta E and a dot area
Data Source
AI summary
The present disclosure relates to systems and processes for inspecting and evaluating qualities of printed regions on substrates, wherein the systems and methods may be configured to eliminate subjective aspects relating to human involvement in performing visual checks when evaluating print quality. The systems may include one or more communication networks connecting one or more sensors with an analyzer. In operation, ink is applied to a substrate to create at least one printed region, and the sensors are configured to inspect the printed region. The sensors may be configured to communicate measurements and/or images to the analyzer. And the analyzer may then calculate one or more quality subscores based on respective measurements and/or images. In turn, a full print quality score may be calculated based on one or more of the quality subscores. The analyzer may then execute a control action based on the full print quality score.