Automated Web Break Cause Identification in Printing Presses

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Solution Overview

Problem

Manual analysis of web breaks in web-fed printing presses is tedious, time-consuming, and prone to errors, and existing systems fail to identify causes not related to paper web faults.

Innovation Solution

A system and method that utilize a database of predetermined web break causes, real cause probability calculation algorithms, and a processor to rank and identify the most likely cause of a web break based on sensing device outputs, allowing for quicker and more accurate determination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual analysis of video data from multiple video cameras is used to determine web break causes, then the system can identify web break causes, but the process becomes tedious, time-consuming and error prone

Engineering Contradiction:

Improveweb break cause identification accuracyVSAvoidtime to determine web break cause

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces the mechanical/manual process of watching video data with an automated electronic system. The cause determining processor automatically analyzes data from multiple sensing devices (video cameras, web tension sensors, web speed sensors, web position sensors) and executes algorithms to identify web break causes, eliminating the need for manual video review while improving both speed and accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs self-diagnosis by automatically collecting data from multiple sensing devices, processing the data through algorithms, and generating cause identification without requiring human intervention. The processor independently determines web break causes by evaluating data from web tension sensors, web speed sensors, and video cameras

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If only video camera data is used for web break analysis, then the system is simple to operate, but it cannot identify web break causes not due to faults in the paper web

Engineering Contradiction:

Improveweb break cause detection scopeVSAvoidsystem configuration

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system integrates multiple sensing devices with different functions into a single unified web break analysis system. Video cameras detect visual faults, web tension sensors measure tension variations, web speed sensors monitor speed changes, and web position sensors track web location. This multi-functional approach enables detection of various web break causes including mechanical issues, tension problems, and splicing errors

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system divides the web break detection function into multiple specialized sensing devices, each responsible for detecting specific parameters. The cause determining processor then integrates data from these segmented sensors to provide comprehensive cause identification, allowing the system to handle diverse web break scenarios

Inventive Principle:

Principle #1Segmentation

3Reliability

If multiple sensing devices are integrated to provide comprehensive data for web break analysis, then the accuracy of cause determination improves, but the device complexity increases

Engineering Contradiction:

Improveweb break cause determination reliabilityVSAvoidnumber of sensing devices and algorithms

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cause determining processor acts as an intermediary that receives data from multiple sensing devices and processes it through algorithms to produce cause identification. This intermediary component manages the complexity by centralizing data processing and providing a unified interface, reducing the burden on operators while maintaining high reliability through comprehensive data analysis

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP2826626B1Web break analysis system

Publication Date: 2016.01.20 GOSS CONTIWEB

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AI summary

A system (10) for analysing web breaks in a printing press, comprising sensing devices (12, 14) for monitoring the web and the printing press and detecting a web break, characterised by a database (24) with predetermined web break causes, for each of the predetermined web break causes, a real cause probability calculation algorithm for calculating the probability that the corresponding predetermined web break cause is the real cause of a detected web break as a function of said sensing devices' (12, 14) outputs, and a real web break cause determining processor (20) for executing each real cause probability calculation algorithm, ranking the predetermined web break causes according to their calculated real cause probabilities, and identifying the web break cause amongst the predetermined web break causes with the highest real cause probability as the cause for said detected web break.