Automated Template Matching for Print Production Control

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Solution Overview

Problem

Current methods in the graphics industry for producing printed products are time-consuming and require extensive operator expertise due to the need for manual setting adjustments between print jobs, leading to inefficiencies and potential quality issues with untested settings combinations.

Innovation Solution

A method that stores multiple templates with predefined parameter sets for production steps in a computer, allowing task information to identify the most similar template for automated settings, ensuring reproducible high-quality output by using only tested and proven settings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual setting adjustments are made between print jobs, then operator control and adaptability are maintained, but production time increases and expertise requirements rise

Engineering Contradiction:

Improveoperator controlVSAvoidproduction time

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The system pre-calculates and stores optimal machine settings for different print jobs before production begins. When a print job is initiated, the system automatically retrieves and applies the pre-determined settings, eliminating the need for manual adjustment during production and reducing both time and expertise requirements

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system performs self-configuration by automatically selecting and applying appropriate machine settings based on the print job parameters. The automated production control system independently manages the setting adjustments without requiring operator intervention, thereby maintaining control while improving productivity

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If multiple templates with different settings are stored and manually selected, then production flexibility is improved, but operator expertise and time consumption increase

Engineering Contradiction:

Improveproduction flexibilityVSAvoidtime consumption

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system automatically compares the current print job parameters with stored templates, selects the most appropriate template based on the best match, and applies its settings. This automated feedback loop eliminates manual template selection while maintaining production flexibility through the template library

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The manual mechanical process of selecting and adjusting settings is replaced by an automated computer-based system that electronically retrieves and applies template settings, significantly reducing time consumption while preserving adaptability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If untested settings combinations are used, then production speed increases, but product quality and reliability decrease

Engineering Contradiction:

Improveproduction speedVSAvoidproduct quality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Optimal settings templates are pre-calculated and validated for different print job scenarios before production begins. This preliminary preparation ensures that only proven, reliable settings are available for automated application, maintaining both speed and quality

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system manages discrete parameter sets within templates that define machine settings. By changing between pre-defined parameter sets rather than creating new combinations, the system maintains reliability through tested configurations while achieving production speed through automated selection

Inventive Principle:

Principle #35Parameter changes

4Productivity

If automated production control is implemented, then productivity and consistency are improved, but system complexity increases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system uses template copies of proven settings configurations rather than requiring complex real-time calculations. Each template is a replicated set of parameters that can be automatically applied, simplifying the automated control system while maintaining productivity and consistency

Inventive Principle:

Principle #26Copying

Data Source

PatentUS8045213B2Automated production control method

Publication Date: 2011.10.25 HEIDELBERGER DRUCKMASCHINEN AG

AI summary

In a method for operating at least one machine with a computer, it is possible for at least one task for the production of a printed product to be stored in the computer, which task is processed on the machine. Parameters for setting the machine are stored as parameter sets in templates and relate to one or more production steps. For the purpose of job-specific adaptation, the settings in the templates must be modified. On account of settings which have not been tried and tested and not proven worthwhile, costs arise in terms of quality; in addition the settings can be made only by specialized personnel. To increase quality and to allow less qualified personnel to operate the machines, a parameter set based on rough entered data is compared with templates and that a most similar template be used to set the production step or steps.