Web Printing Imposition with Dynamic Frame Rewind
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Solution Overview
Problem
In frame by frame printing on a web of print medium, different pattern lengths in various lanes lead to uneven spacing and waste due to inconsistent gaps at the end of frames, making it difficult to achieve even spacing and automatic handling of printed products.
Innovation Solution
The method involves determining starting points for each lane based on the end points of the previous frame and calculating a frame rewind distance to ensure that the starting points of each lane align with the end points of the previous frame, allowing for the imposition and printing of patterns with different lengths in parallel lanes while maintaining even spacing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If print jobs with different pattern lengths are imposed in parallel lanes on a web of print medium, then the productivity and utilization of the web are improved, but the spacing between patterns becomes uneven and automatic handling becomes difficult
Solution Approach 1:
The patent applies dynamics by making the frame rewind distance variable rather than fixed. The system calculates and adjusts the rewind distance dynamically based on the actual pattern lengths in each lane, allowing the spacing to be corrected automatically. This dynamic adjustment enables uniform spacing even when patterns have different lengths, resolving the contradiction between high web utilization and spacing precision.
2Ease of manufacture
If frames are printed with fixed maximum length, then the printing process is simplified, but waste occurs due to inconsistent gaps at the end of frames
Solution Approach 1:
The patent changes the parameter of frame rewind distance from a fixed value to a variable value that is calculated based on actual pattern dimensions. By adjusting this parameter dynamically, the system minimizes waste material while maintaining the simplicity of the frame-by-frame printing process. The calculation ensures that frames are rewound by the precise amount needed, eliminating inconsistent gaps and reducing waste.
3Ease of operation
If patterns are imposed starting from the leading edge of each frame, then the imposition process is straightforward, but uneven gaps remain at the end of frames
Solution Approach 1:
The patent implements feedback by calculating the actual end positions of patterns in each lane and using this information to determine the appropriate frame rewind distance. This feedback loop ensures that the rewind operation compensates for variations in pattern lengths, achieving uniform gaps without complicating the imposition process. The system automatically adjusts based on measured or calculated pattern dimensions.
Data Source
AI summary
An example method is provided in accordance with the present disclosure, which may be used for example for aggregating print jobs on a web of print medium for frame by frame printing. The example method comprises imposing several print jobs, each comprising patterns to be printed, on the web of print medium, in at least two parallel lanes in the longitudinal direction of the web of print medium, wherein the patterns imposed in each frame are whole patterns, a starting point for the imposition of patterns in each lane and each frame depends on an end point of the imposed patterns in the same lane in the previous frame, and a frame rewind distance is determined for each frame whereby, when printing on the web of print medium, the starting point of each lane in one frame comes to be adjacent to the end point of the lane in the previous frame.