Printer Defect Subtraction for Continuous High-Quality Printing
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Solution Overview
Problem
Existing printing technologies fail to continue printing operations effectively when printer defects occur, leading to reduced productivity due to the need to interrupt printing for adjustments and maintenance.
Innovation Solution
An image processing apparatus that acquires defect image data, extracts and subtracts defect similar components from print target image data, allowing for continued printing with minimal defect impact by replacing defect components with printer defect information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If printing operations are interrupted to perform adjustment and maintenance when defects are detected, then printing quality is improved, but productivity deteriorates
Solution Approach 1:
The system performs preliminary defect detection by printing test charts and acquiring defect image data before actual printing operations. This allows the printing conditions to be adjusted in advance, so that when actual printing occurs, the printer is already optimized and fewer interruptions are needed during production printing.
Solution Approach 2:
The system creates a defect image model that copies the characteristics of printer defects. This model is then used to identify and correct similar defects in actual printed materials without needing to physically inspect each printed piece, thereby maintaining quality while improving productivity.
2Manufacturing precision
If strict quality determination is performed to ensure printing quality, then manufacturing precision is improved, but productivity deteriorates due to frequent interruptions
Solution Approach 1:
The system enables the printing process to self-correct defects by automatically comparing actual print images with the defect image model and performing necessary adjustments without human intervention. This automated quality control maintains high printing quality while minimizing interruptions to productivity.
Solution Approach 2:
The system implements a feedback mechanism where print images are continuously monitored and compared against the defect model. When defects are detected, the system automatically adjusts printing parameters and notifies operators, creating a closed-loop quality control system that maintains precision without requiring constant manual inspection.
3Manufacturing precision
If defect detection is performed to maintain printing quality, then manufacturing precision is improved, but the complexity of the system increases
Solution Approach 1:
The defect detection system is designed to be universal and can detect various types of printer defects (streaks, spots, density variations) using a single integrated approach. The same defect image model and comparison algorithm handle multiple defect types, reducing the need for separate detection systems for each defect type and thereby limiting the increase in system complexity.
Data Source
AI summary
An image processing apparatus configured to correct image data for printing includes: a defect image data acquisition unit configured to acquire defect image data indicating image information of a printer defect appearing on a printed material due to a printer; a print target image data input unit configured to acquire print target image data to be printed by the printer; a defect similar component extraction unit configured to extract a defect similar component, which is similar to the defect image data, from the print target image data; and a defect similar component subtraction unit configured to subtract the defect similar component from the print target image data.