Printing Press Roller Setup Using Optical No-Print Threshold Detection
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Solution Overview
Problem
Existing methods for setting up printing presses are inefficient as they require manual adjustments or complex automated systems to achieve optimal ink transfer between rollers, lacking a straightforward method to determine the minimal distance for effective ink transfer.
Innovation Solution
A system and method that uses a camera and processor to determine the no-print threshold, where ink is not transferred to the substrate, and then adjusts the distance between rollers based on this threshold to set up the printing press effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual adjustment methods are used to set up the printing press, then the operator can inspect and adjust pressure between rollers, but the process is time-consuming and labor-intensive
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated optical measurement system. A camera captures images of the printed pattern, and image processing algorithms automatically determine the pattern width and calculate the required pressure adjustment, eliminating the need for manual inspection and adjustment operations.
Solution Approach 2:
The system implements a closed-loop feedback mechanism where the actual printed pattern is measured and compared with the desired pattern. The image processing system calculates the deviation and automatically adjusts the roller pressure to achieve the target pattern dimensions, continuously improving precision without manual intervention.
2Productivity
If automated optical sensing methods are used to sense the printed image, then the pressure can be adjusted according to the image width, but the system complexity increases with multiple sensors and controllers
Solution Approach 1:
The patent employs a single camera that serves multiple functions: capturing the printed pattern, measuring pattern width, and providing feedback for pressure adjustment. This multi-functional approach replaces multiple specialized sensors and controllers with one versatile imaging device, reducing system complexity while maintaining automation.
Solution Approach 2:
The system creates an optical copy (image) of the printed pattern and analyzes this digital representation to determine pattern dimensions and adjust pressure. This indirect measurement through image copying simplifies the system compared to direct mechanical measurement methods, as it eliminates the need for complex mechanical sensors and measurement mechanisms.
3Manufacturing precision
If the distance between rollers is varied to adjust pressure, then the printed image quality can be improved, but the setup process becomes more complex and time-consuming
Solution Approach 1:
The system performs self-adjustment by automatically measuring the printed pattern and calculating the required roller distance adjustment. The image processing algorithm determines the optimal pressure setting based on the captured image data, eliminating the need for operator expertise and manual trial-and-error adjustments.
Solution Approach 2:
The patent systematically varies the roller distance parameter to optimize printing quality. The image processing system analyzes how changes in roller distance affect pattern width and density, automatically identifying the optimal parameter setting that produces the desired image quality without manual intervention.
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 allows for precise adjustment of roller distances to ensure optimal ink transfer, improving the setup process by determining the minimal distance for ink transfer, thus enhancing the quality and efficiency of the printing process.
Implementation Method 1
The processor determines this no-print threshold according to the output respective of the absence or presence of the representative impression, in a setup pattern printing zone of the print material
Data Source
AI summary
A system for setting up a printing station (136), the printing station (136) includes printing rollers (110, 114, 116), the printing rollers (110, 114, 116) including at least one ink transferring roller (110, 114) and an impression roller (116). The system includes a camera (104), an actuator interface (106) and a processor (102), the actuator interface (106) being coupled with at least one actuator (108, 112), the processor (102) being coupled with the camera (104) and with the actuator interface (106), the actuator interface (106) directing the at least one actuator (108, 112) to move at least one printing roller (110, 114, 116) of the printing press (1OO). The processor (102) receives an output from the camera (104), the processor (102) determining at least one no print threshold respective of each adjacent pair of the printing rollers, according to the output respective of the absence or presence of the representative impression (132). In a setup pattern printing zone (134) of the print material (118), the at least one no print threshold is defined as the minimal distance between the rotation axes (122, 128, 130) of each adjacent pair of the printing rollers, at which no print liquid is transferred to the print material (118).