Printed Image Inspection for Separating Print and Sensor Defects
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Solution Overview
Problem
Existing image forming systems lack the ability to accurately distinguish between image defects caused by the printing process and those resulting from sensor malfunctions in the reading sensor, leading to inefficient maintenance and potential misdiagnosis of issues.
Innovation Solution
An image forming apparatus equipped with a reading sensor, a display, and circuitry that compares printed images with a master image to identify defects, determines if they are sensor-related, calculates the defect's position, and displays this information for user intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the inspection device reads the printed material to detect image defects, then the ability to identify printing quality issues is improved, but the inability to distinguish sensor defects from actual image defects reduces measurement precision
Solution Approach 1:
The patent segments the defect detection process into two distinct analysis stages: first detecting image defects through normal inspection, then separately analyzing whether defects are caused by printing issues or sensor problems by comparing multiple read images. This segmentation allows each stage to focus on its specific function, improving overall measurement precision.
Solution Approach 2:
The patent introduces an intermediary analysis process that uses the master image and multiple read images as mediators to determine the cause of defects. By comparing the read image with the master image and analyzing defect patterns across multiple readings, the system can identify whether defects originate from the printing process or the sensor, thereby improving measurement precision.
2Reliability
If the system performs comprehensive image inspection to detect all defects, then the defect detection coverage is improved, but the time required for inspection increases
Solution Approach 1:
The patent applies partial action by performing comprehensive defect detection only when necessary. The system first performs a quick initial inspection, and only when defects are detected does it proceed to the more time-consuming sensor defect analysis process. This approach maintains high defect detection coverage while minimizing unnecessary inspection time for normal prints.
Solution Approach 2:
The system performs preliminary actions by pre-processing images to identify potential defect areas before conducting full analysis. The comparison with the master image allows the system to quickly identify regions of interest, reducing the overall inspection time while maintaining comprehensive defect detection coverage.
3Speed
If the reading sensor continuously monitors the printed material, then the real-time detection capability is improved, but the potential for sensor defects affecting accuracy increases
Solution Approach 1:
The patent implements feedback mechanisms by continuously comparing read images with the master image and using the comparison results to adjust the inspection process. When sensor defects are detected through pattern analysis, the system can provide feedback to flag potential sensor issues, allowing for real-time detection while monitoring and maintaining reading accuracy through continuous validation.
Data Source
AI summary
An image forming apparatus includes a printer, a reading sensor, a display, and circuitry. The printer produces a printed material. The reading sensor reads the printed material. The circuitry controls the reading sensor to read the printed material and generate a read image, compares the read image and a master image of the printed material, determines whether an image defect exists in the read image based on a comparison between the read image and the master image, determines whether the image defect is generated by a sensor defect in the reading sensor based on the comparison when the image defect exists in the read image, calculates a position of the sensor defect on the reading sensor, and controls the display to display the position and the read image on the display.