Reverse Simulation for Print Resource Optimization
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Solution Overview
Problem
Current production lines for print products often result in significant waste due to inefficient selection of input resources, such as paper size and ink usage, leading to trimmed sections and increased production time, despite using sufficiently large medium sheets.
Innovation Solution
A method that simulates the production process in reverse to determine optimal input resource parameters, such as paper format and ink usage, by tracking waste and duration, and generates a recommendation signal for the printer controller to suggest the most suitable resources, which may include standardized or next-best available sizes, to minimize waste and optimize production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a sufficiently large type of medium is selected to produce the desired print product, then the print product can be produced, but significant waste is generated due to large sections of the medium sheets having to be trimmed off
Solution Approach 1:
The patent applies reverse simulation by starting from the desired print product specifications and working backwards to determine the optimal medium parameters. Instead of selecting a medium and then determining what product can be made, the system simulates the production process in reverse to identify the precise medium dimensions and properties needed, thereby minimizing waste while ensuring the print product can be produced.
Solution Approach 2:
The system performs preliminary simulation and calculation of optimal medium parameters before the actual production process. By pre-determining the optimal medium size, format, and properties through reverse simulation, the system avoids trial-and-error production and directly selects the most efficient medium, reducing both waste and production time.
2Loss of substance
If standardized medium sizes are used, then the production process is simplified, but waste increases due to trimming requirements
Solution Approach 1:
The patent changes the approach from selecting from fixed standardized medium sizes to determining optimal medium parameters (dimensions, format, properties) based on the specific print product requirements. The reverse simulation calculates the precise medium parameters needed, allowing the system to specify custom-optimal medium dimensions rather than forcing adaptation to standardized sizes, thereby minimizing trimming waste.
3Loss of substance
If reverse simulation is performed to determine optimal input resource parameters, then waste is minimized, but additional computational processing is required
Solution Approach 1:
The system performs self-service by automatically executing the reverse simulation and determining optimal medium parameters without requiring external intervention or complex manual calculations. The printer controller or production management system autonomously runs the simulation, processes the results, and generates recommendations, making the computational complexity self-contained and eliminating the need for additional external processing resources.
Data Source
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AI summary
The invention provides a method for determining an optimal input resource parameter for a print product as well as a corresponding production line, printer, printer controller, computer program product, and data storage medium. A simulation of a sequence of actions required for forming a desired print product from input resources is performed in reverse order to determine an optimal input resource parameter.