Automated Error Management in Printing Machines
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Solution Overview
Problem
Existing inspection systems and error recognition algorithms in printing machines do not effectively enable automatic error management, failing to support operators in all phases of error detection, diagnosis, and elimination during the printing process.
Innovation Solution
The implementation of a method that utilizes a control unit with integrated error recognition algorithms, line scan cameras, area scan cameras, and optical spectrometers to create a cluster image for error diagnosis, allowing for automatic identification and localization of print errors, and enabling the system to take corrective actions such as stopping defective rollers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If inspection systems use line scan cameras to acquire print images, then resolution and readout speed are improved, but the system complexity increases due to the need for feed synchronization via encoders
Solution Approach 1:
The patent replaces the mechanical encoder-based synchronization system with an optical reference system. A reference mark on the material web is detected by the line scan camera, and the feed synchronization is achieved through optical measurement of the mark's position across multiple images, eliminating the need for mechanical encoders and reducing system complexity while maintaining high resolution.
2Ease of operation
If area scan cameras are used to acquire print images, then the ability to display stationary images is improved, but the readout speed and resolution are reduced compared to line scan cameras
Solution Approach 1:
The patent segments the image acquisition process by using line scan cameras to capture individual lines of the print image sequentially as the material web moves. This segmentation allows the system to maintain high readout speed and resolution while still being able to reconstruct the complete image, and the stationary image display is achieved through software processing of the sequential line data rather than requiring a single high-speed area scan.
3Measurement precision
If optical spectrometers are added to monitor color components, then color error detection is improved, but the device complexity and cost increase
Solution Approach 1:
The patent makes the line scan camera multi-functional by using it for both the primary function of acquiring print images and the secondary function of detecting reference marks for synchronization. This eliminates the need for separate dedicated spectrometer devices, reducing overall system complexity while still enabling color component monitoring through the optical measurement capabilities of the existing camera system.
4Extent of automation
If error recognition algorithms compare current images with reference images, then automatic error detection is improved, but the processing time and computational complexity increase
Solution Approach 1:
The patent performs preliminary action by capturing and storing reference images of the material web at specific locations before the actual printing process. These reference images are used as baselines for comparison during automated error detection. By preparing the reference data in advance, the system can quickly compare current print images against the pre-stored references, reducing real-time processing time while maintaining high automation capability.
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
This approach enhances the capability for automatic error management by providing comprehensive error detection, diagnosis, and elimination, reducing operator intervention and improving print quality by identifying and addressing recurring errors caused by defective rollers.
Implementation Method 1
An optical spectrometer breaks the light absorbed by a light point into its spectral components and evaluates the result in a computer system
Implementation Method 2
The grating is located behind the aperture and scatters the spectral components of the incident light at slightly varying angles
Implementation Method 3
the line scan camera only acquires a single image line at a time since this allows for achieving a higher resolution and a higher readout speed
Implementation Method 4
the area scan camera (also called matrix camera) that acquires a section of the print image on the moving material web
Data Source
AI summary
The invention relates to a method for automated error management in a printing machine, wherein a recurring print image is imprinted on a moving material web. To improve automated error management for existing inspection systems, the invention provides a method wherein the print image is acquired by a line scan camera and forwarded to a control unit, in which a print error is recognized in the acquired print image, using an error recognition algorithm, and is saved by the control unit together with a position information and a status information. The position includes at least the margin position of the print error on the material web, and a plurality of recognized print errors are entered by the control unit in a cluster image depending on the position information and the status information, wherein the control unit recognizes an error cluster and error cluster information is output via the error cluster.