Workpiece Printing Alignment With Real-Time Deviation Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing printing systems for workpieces, particularly in large batches, suffer from print displacement over time due to imprecise positioning, leading to costly recalibrations and system shutdowns, despite self-adjustable systems with cameras and control systems.
Innovation Solution
A method and system that utilize a first and second camera to capture images of workpieces before and after printing, adjusting the printing head's position based on actual and desired positions, and compensating for deviations in real-time to ensure precise printing, with a control system controlling the conveyer, loading, and ejection devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a self-adjustable printing system with camera and control system is used, then printing position accuracy is improved, but print displacement over time still occurs requiring recalibration
Solution Approach 1:
The system captures a second image of the printed workpiece after it passes the printing station, determines the actual print position, calculates deviation from the desired position, and uses this feedback to compensate for deviations in subsequent printing operations. This closed-loop feedback mechanism continuously corrects positioning errors without requiring system shutdown or recalibration.
Solution Approach 2:
The printing system automatically detects and corrects its own positioning errors through the image capture and deviation calculation process, performing self-adjustment without external intervention. The system monitors its own performance and autonomously compensates for drift, making the recalibration process self-service rather than requiring operator intervention.
2Manufacturing precision
If precise positioning of workpieces in holders is maintained, then print positioning accuracy is improved, but system complexity and monitoring requirements increase
Solution Approach 1:
The system replaces complex mechanical positioning and monitoring mechanisms with an optical measurement system. Instead of using sophisticated mechanical devices to ensure precise workpiece placement and continuously monitor positions, the invention uses image capture and digital image processing to detect actual positions and calculate deviations, substituting mechanical complexity with optical and computational simplicity.
3Manufacturing precision
If recalibration is performed to correct print displacement, then printing accuracy is restored, but production downtime and costs increase
Solution Approach 1:
The system maintains continuous printing operation without shutdown by implementing real-time deviation detection and compensation. The second image is captured after the workpiece passes the printing station, allowing the system to continue producing while simultaneously measuring and correcting positioning errors, ensuring uninterrupted useful action.
Solution Approach 2:
The system performs preliminary compensation for positioning errors by calculating deviations from the second image and applying corrections to subsequent printing operations before new errors accumulate. This proactive correction approach prevents print displacement from affecting production quality rather than reacting after problems occur.
Data Source
Figure 1
AI summary
A method of printing on workpieces (30), comprising • placing a workpiece in one of a plurality of holders (20) provided spaced apart on a conveyer (10); • moving the holders (20) forward; • obtaining a first image of the workpiece (30) in the holder (20) as the holder is moved towards a first printing station (50), the first printing station (50) comprising a printing head (55) adjustable relative to the conveyer (10); • determining, based on the first image, the actual position of the workpiece (30) in the holder (20); • calculating a printing position of the printing head (55) relative to the holder (20) for positioning the print in a predetermined desired position on the workpiece (30), based on the predetermined desired position of the print on the workpiece (30) and the determined actual position of the workpiece in the holder (20); • adjusting the position of the printing head (55) to the calculated printing position; and • printing a print on the workpiece; wherein that the method further comprises • obtaining a second image of the printed workpiece in the holder (20) after the conveyer has moved the holder (20) downstream of the first printing station (50), • determining, in said second image, the actual position of the print on the workpiece (30); • calculating any deviance of the actual position of the print on the workpiece (30) relative to the predetermined desired position of the print on the workpiece; • if a deviance is detected, compensating for the deviance in the calculation of the printing position of the head (55) for a workpiece (30) in the next holder (20) upstream of the printing station (50).