Roll-to-Roll Printing Queue Management for Media Switching
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Solution Overview
Problem
Roll-to-roll printing systems face productivity drops due to the need for frequent roll changes when moving digital images in the printing queue, especially when the media for a moved image is different from the current input roll, leading to increased operator actions such as cutting, unloading, and reloading.
Innovation Solution
The method involves registering and displaying second and third digital items in the digital image queue, which identify the input and output rolls for each image, allowing users to manipulate the queue through a user interface, enabling repositioning of images without additional roll changes by indicating the correct input and output rolls for printing and winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If digital images are moved in the printing queue to change printing order, then the printing sequence can be adjusted to meet user requirements, but productivity drops dramatically due to frequent roll changes and additional operator actions
Solution Approach 1:
The system performs preliminary actions by pre-loading multiple input rolls into the printing system before printing begins. The queue management system is configured in advance to automatically switch between pre-loaded rolls based on the printing sequence, eliminating the need for operator interventions during the printing process.
Solution Approach 2:
The queue management system implements self-service by automatically handling roll changes and media switching based on the configured printing sequence. The system monitors media levels and roll availability, and autonomously performs roll changes without operator intervention, allowing users to simply define the desired printing order.
2Adaptability or versatility
If the digital image queue is configured to print images on different media types, then user requirements for diverse media output can be met, but additional operator actions are required for cutting, unloading, and reloading rolls
Solution Approach 1:
Multiple input rolls with different media types are pre-loaded into the system before printing begins. The queue management system is configured in advance with the complete printing sequence including media type transitions, so that all necessary rolls are ready and the system can automatically switch between them without operator intervention.
Solution Approach 2:
The queue management system performs self-service by automatically detecting when media type changes are required and executing the appropriate roll changes. The system monitors the printing queue configuration and autonomously manages media transitions, eliminating the need for operators to manually intervene for cutting, unloading, and reloading rolls.
3Adaptability or versatility
If frequent roll changes are performed to accommodate moved entries in the queue, then the printing order can be adjusted, but the time required for cutting, unloading, and reloading increases the total printing time
Solution Approach 1:
All necessary input rolls are pre-loaded into the system before printing begins, and the queue management system is configured with the complete printing sequence. This preliminary configuration ensures that when roll changes are needed, the system can quickly switch between already-loaded rolls without time-consuming operator interventions for unloading and reloading.
Solution Approach 2:
The queue management system automatically executes roll changes based on the configured printing sequence, performing these changes during normal printing operations without stopping the process. This self-service approach minimizes idle time and ensures that roll changes do not significantly impact the total printing time.
Data Source
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AI summary
The present invention relates to a method for printing digital images on at least one input roll of media in order to form at least one output roll by means of a roll-to-roll printing system. The roll-to-roll printing system comprises a digital image queue comprising an entry for each digital image to be printed. The method comprises the steps of registering in an entry of the digital image queue a first digital item identifying the digital image and digital items of print properties of the digital image, printing the digital image according to the order of the entry in the digital image queue, and registering in the entry a second digital item identifying an input roll on which the digital image is going to be printed and a third digital item identifying an output roll on which the printed digital image is going to be wound. The present invention also relates to a roll-to-roll printing system configured to apply the method.