Printing System Sheet Quality Rerouting
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Solution Overview
Problem
In printing systems, the presence of defective sheets with different media types disrupts the sequence of images to be printed, leading to increased waste and reduced productivity, as the entire batch of sheets must be discarded when a single defective sheet is detected.
Innovation Solution
A sensor monitors the quality of sheets at the transport path, and a controller reroutes images to compatible sheets, allowing only the defective sheet to be discarded while maintaining the print sequence and order, thus minimizing waste and ensuring high productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire batch of sheets is discarded when a defective sheet is detected, then the quality of printed images is ensured, but productivity is reduced and material waste increases
Solution Approach 1:
The patent segments the batch of sheets into individual sheets, allowing defective sheets to be identified and removed independently rather than discarding the entire batch. The controller tracks each sheet's status and routes defective sheets separately, enabling continuous processing of non-defective sheets and maintaining high productivity while ensuring quality.
Solution Approach 2:
The patent implements selective discarding of only the defective sheet while recovering and continuing to use the remaining non-defective sheets in the batch. The system reroutes the image intended for the defective sheet to another suitable sheet, thereby recovering the print job and avoiding complete batch rejection, which maintains both quality and productivity.
2Reliability
If the entire batch of sheets is discarded when a defective sheet is detected, then the quality of printed images is ensured, but material waste increases
Solution Approach 1:
The patent segments the batch of sheets into individual sheets, allowing defective sheets to be identified and removed independently rather than discarding the entire batch. The controller tracks each sheet's status and routes defective sheets separately, enabling continuous processing of non-defective sheets and maintaining high productivity while ensuring quality.
Solution Approach 2:
The patent implements selective discarding of only the defective sheet while recovering and continuing to use the remaining non-defective sheets in the batch. The system reroutes the image intended for the defective sheet to another suitable sheet, thereby recovering the print job and avoiding complete batch rejection, which maintains both quality and productivity.
3Reliability
If a defective sheet is skipped in the print sequence, then the quality of printed images is maintained, but the sequence of sheets and images becomes mismatched
Solution Approach 1:
The patent implements a dynamic rescheduling mechanism where the controller continuously adjusts the print sequence in real-time based on detected defective sheets. When a defective sheet is identified, the controller dynamically reroutes the corresponding image to another suitable sheet and reorders the remaining images to maintain proper sequence matching, ensuring both quality and sequence integrity.
Solution Approach 2:
The patent employs a feedback mechanism where the sensor detects defective sheets and provides information to the controller, which then adjusts the print sequence accordingly. The controller monitors the entire batch and makes real-time corrections to the scheduling, ensuring that images are always matched with the correct non-defective sheets while maintaining the overall sequence integrity.
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 the printing process to continue uninterrupted, utilizing existing sheets and reducing material waste by rerouting images to compatible sheets, ensuring high-quality prints and maintaining productivity.
Implementation Method 1
a sensor is arranged at the transport path for detecting a quality condition of sheets being fed to the print station
Data Source
AI summary
A printing system includes a print station disposed at a sheet transport path, a feed section arranged to feed media sheets of different media types into the transport path so as to be fed sequentially to the print station, and a controller arranged to receive print instructions concerning images to be printed, to schedule a sequence of the media sheets, and to control the feed section and the print station such that each image is printed on a sheet of a media type that has been specified for that image in the print instructions. A sensor is arranged at the transport path for detecting a quality condition of the sheets being fed to the print station, and the controller is adapted to receive a quality signal from the sensor and, when the quality of a sheet is found to be insufficient, to skip that sheet and to reroute the corresponding image to another scheduled sheet that is compatible with the print instructions.