Registration and Skew Correction Using 2D Grid Patterns
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for measuring print registration and skew in high-speed, high-volume printing operations are imprecise and subjective, leading to alignment degradation due to factors like frictional slippage, heat, and mechanical vibrations, which can result in misaligned images, especially in precision printing applications.
Innovation Solution
A system and method utilizing a two-dimensional pattern with a grid enclosed within a geometric shape, such as concentric circular rings, to determine registration and skew errors, where the positional data points define a directional displacement vector for correcting alignment issues, allowing for precise and automatic correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional manual alignment practices using grid templates and magnifying glasses are used, then registration and skew measurement can be performed, but measurement precision deteriorates due to subjectivity and imprecision of visual measurement
Solution Approach 1:
The patent replaces manual visual measurement with automated optical scanning and digital image processing. A scanner or camera captures the printed marker's position on the grid, and software automatically calculates registration and skew values, eliminating subjective human measurement errors while maintaining ease of operation through automated end-of-line checking.
Solution Approach 2:
The patent creates a digital copy of the physical measurement process by scanning the printed marker and grid pattern. The digital image is then processed to extract precise positional data, allowing for accurate measurement without direct human intervention and enabling automated correction calculations.
2Manufacturing precision
If frequent registration and skew checks are performed during high-speed printing operations, then alignment precision can be maintained, but productivity deteriorates due to production interruptions
Solution Approach 1:
The patent incorporates registration and skew checking into the normal printing workflow by placing test grids and markers on the print medium before actual production printing. This preliminary action allows alignment verification to occur without interrupting the main production process, maintaining both precision and productivity.
Solution Approach 2:
The system enables continuous registration and skew monitoring during high-speed printing operations by integrating the measurement process into the printing flow. The scanner checks alignment on test lines without stopping the printer, allowing useful action (printing) to continue while measurement occurs in parallel.
3Measurement precision
If automated measurement systems are implemented, then measurement precision and objectivity improve, but device complexity increases
Solution Approach 1:
The patent uses a scanner or camera, which are multi-functional devices already present in modern printing environments, for registration and skew measurement. This universal approach leverages existing equipment to perform measurement tasks without requiring specialized complex measurement instruments, reducing overall system complexity while maintaining automated precision.
Data Source
AI summary
System, method, article for determining registration and/or skew errors in a print medium with respect to a printing element includes a print medium including a two-dimensional pattern including a grid within a geometric shape. The grid has a plurality of vertical and horizontal lines, the intersection of each forming a cross-hair defining an X-Y positional data point; the collection of data points defining a data set. The geometric shape is in the form of a two-dimensional target having a plurality of concentric rings; an innermost one enclosing at least one of the X-Y positional data points in the data set. The printing element provides a marker onto the print medium. The positional location of the marker with respect to the one of the at least one enclosed X-Y positional data point defines a directional displacement vector for correcting registration and/or skew error between the print medium and the printing element.