Printed Material Inspection With Multi-Level Defect Thresholds
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Solution Overview
Problem
Existing printed material inspection systems lack the ability to easily determine if the initial inspection level is appropriate and to flexibly change the inspection level based on the specific requirements of each print job, leading to potential over-inspection or under-inspection.
Innovation Solution
A printed material inspection system that includes a processor to perform inspections at multiple levels, automatically comparing scanned images with reference images and displaying defects at different inspection levels, allowing users to easily adjust the inspection level based on the results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single inspection level is used for all print jobs, then the inspection system is simple to operate, but it cannot flexibly adapt to different job requirements leading to over-inspection or under-inspection
Solution Approach 1:
The patent segments the inspection process by implementing multiple inspection levels (first inspection level and second inspection level) with different defect detection thresholds. Each level can be independently selected and applied to different print jobs, allowing the system to adapt to varying quality requirements without increasing overall system complexity.
Solution Approach 2:
The patent introduces dynamic adjustability by allowing the inspection level to be changed based on job requirements. The system can switch between a first inspection level (stricter) and a second inspection level (more lenient), making the inspection criteria flexible rather than fixed, thereby improving adaptability while maintaining operational simplicity.
2Measurement precision
If a strict inspection level is applied, then defect detection accuracy is improved, but the number of false positives increases leading to unnecessary reprints
Solution Approach 1:
The patent changes the inspection parameter (inspection level) to optimize the balance between defect detection accuracy and material waste. By adjusting the defect detection threshold according to the inspection level, the system can achieve high detection accuracy when needed while reducing false positives in other cases, thereby minimizing unnecessary reprints and material waste.
Solution Approach 2:
The patent applies partial inspection strictness by using a stricter first inspection level only when necessary (for high-priority jobs or critical defects) and a more lenient second inspection level for routine jobs. This partial application of strict inspection criteria reduces false positives and material waste while maintaining adequate quality control.
3Adaptability or versatility
If inspection level is adjusted after printing, then flexibility is improved, but the process time is extended due to re-inspection
Solution Approach 1:
The patent performs preliminary action by conducting the inspection at the appropriate level from the beginning. The system determines the suitable inspection level before or during the inspection process and applies it immediately, avoiding the need for re-inspection after printing. This eliminates additional process time while maintaining the flexibility to choose the appropriate inspection level for each job.
4Adaptability or versatility
If multiple inspection levels are implemented, then inspection flexibility is improved, but the device complexity increases
Solution Approach 1:
The patent implements multi-functionality by designing the inspection system to handle multiple inspection levels through a unified control mechanism. The same inspection apparatus can operate at different levels (first and second inspection levels) depending on the selected criteria, eliminating the need for separate inspection systems for each level and thereby reducing overall device complexity while maintaining flexibility.
Data Source
AI summary
A printed material inspection system includes a processor configured to inspect a quality of a printed material; and a display that displays a result of the inspection. The processor is configured to: by reading and executing a program, compare a scanned image obtained by scanning an inspection target page of the printed material, out of pages forming a job, with a reference image created based on rasterize data of the inspection target page and perform an inspection of whether or not a first defect is present in the scanned image at a first inspection level, which is a preset initial level or a level set by a user; automatically perform an inspection of whether or not a second defect is present in the scanned image at a second inspection level that is different from the first inspection level; and display the first defect and the second defect on the display in such a manner that the first defect and the second defect are able to be distinguished from each other.