EP3085536A1 - Method for detecting multiple print nozzles failing in ink jet print systems - Google Patents

Abstract

Method for the automated detection of failed printing nozzles in an inkjet printing machine using a control computer, comprising the following steps: €¢ Implementation of a printing process to produce a first print image with print image data €¢ Capture and digitization of the first print image produced in the printing process by at least one image sensor €¢ Digital displacement of the first print image by at least one print nozzle transverse to the print direction in the control computer €¢ Implementation of a further printing process to produce a second print image based on the digitally shifted first print image €¢ Capture and digitization of the second printed image by the at least one image sensor €¢ Comparison between the first and second recorded print image in the control computer €¢ Determination of failed pressure nozzles from the adjustment result by the control computer.

Description

The present invention relates to a method for detecting failed nozzles in inkjet printing systems having the features of claim 1 and a device for implementing such a method having the features of the preamble of claim 9.

The invention lies in the technical field of digital printing.

Generally, inkjet printing machines include one or more printheads and each printhead includes a plurality of printing nozzles. The inkjet printing machines use the nozzles for printing by emitting ink. These printing machines have nozzle plates with specific arrangements of the individual nozzles, which allow a resolution of up to 1200 dpi. This requires nozzle spacings of approx. 20μm. Failure of a single pressure nozzle creates areas that can not be imaged by the designated nozzle in the single color separation, according to BCMY. This results in color-free areas, which can show up as white lines. If it is a multicolor print, the corresponding color is missing at this point and the color values are distorted. It should also be noted that the beam path of a single nozzle is not ideal but may deviate more or less, and the size of a jetted point must also be taken into account. Thus, a malfunctioning nozzle affects the print quality of each printed document. The reasons for the failure of individual nozzles are diverse, it may be a temporary failure or a permanent failure.

In order to reduce the effects on the printed image, especially in solid areas, several approaches to compensation are known from the prior art. One approach attempts to cover the error with other nozzles in the same color and inkjet unit. That is, it will be to compensate for individual failed inkjet printing nozzles after determining which individual nozzle, the adjacent nozzles are controlled so that the dot sizes of these nozzles are increased so that the location of the failed nozzle is covered with. The neighboring nozzles thus write the picture of the failed nozzle. White lines, which result from the non-printing of individual nozzles, can thus be prevented.

Another known approach is to replace the failed pressure nozzle through the nozzles of the other used inks in the same place. An attempt is made, by targeted and controlled overprinting of the remaining available colors, to come as close as possible to the failed printing ink. This eliminates the need for redundant nozzles or heads, nor does the failure of adjacent nozzles cause problems. The main drawback of this compensation method, however, is that it can only be used for multicolor printing. In addition, an increased computing and taxation needs by the computer of the printing press required to determine the necessary color combinations. In addition, depending on the color difference of the color that has fallen out of the still printable color space of the residual colors, the resulting print result may deviate significantly from the desired values.

Other approaches to compensate failed nozzles include dual nozzle units in the same color to compensate for redundancy in individual nozzle failure. Or, multiple positionable printheads are used to print an image. If print nozzles fail, the print heads are repositioned to replace the failed nozzle as well as possible. In both approaches, a de facto redundancy of printing heads of the same color is required, which brings about the problems already mentioned.

However, the prerequisite for such compensation is the correct detection of a failed pressure nozzle. That is, not only does it need to be recognized that such a failure has occurred, but it also has to be recognized which pressure nozzle is exactly as most known compensation methods require the exact knowledge of the non-functioning pressure nozzles.

For detection, various approaches are known from the prior art:

1. Test print images are printed.

These print images are then assessed by a machine operator, ie counted, and the information of any missing nozzles is communicated to the machine by manual input. Based on this information, we created a new print image so that the failed nozzles are compensated. This process can not be performed concurrently. An error in the print image must first be recognized in order to then initiate the described manual process. An inspection is required, resulting in a loss of production time. In addition, it is not an automatic detection, which may possibly cause a waste of waste. Examples of such test patterns are from the patent application US 2011/227988 A1 , as well as the patent US 8322814 B2 known.

2. Print and automatically evaluate a specific test form

Option A: The test form is printed as a separate job on the press. Option B: The test form is between the benefits of printing from the roll or unused paper edge when printing sheets.

This test form allows a relatively simple automated detection of failed inkjet nozzles. Disadvantage is that a paper edge or gap between the benefits not desired in each type of printing, or can be implemented. It creates a lot of waste when the test pattern is created as a separate print job. A narrow paper edge allows only limited test shapes - so only the inspection of a part of the nozzles, so that an immediate detection and compensation of failed nozzles is not guaranteed. That is, there is production of rejects or, alternatively, inadequate use of full paper size.

Third

• Option A: The entire print image is read in real time using cameras or sensors. The recognized data must then be electronically with the original print image be matched. The adjustment of the data, however, requires a very high computing power and comparisons of the data in real time. When variable data is used, the target print image must also be made available again for comparison with each printout or adjusted according to the variable data. The solution requires high costs for the use of powerful hardware or causes downtime of the machine during data processing. The system is susceptible to errors because it is not automatically clear which nozzle row has failed exactly to then make the compensation. An electronic measurement would require very precise equipment and a high cost.
  An example of this is the patent application US 2013/187970 A1 to call. Here, the digital target image is compared with the scan of the printed image. Transformations are described which make the scanned image (resolution transformation, transformation of the scanner characteristic) comparable to the digital target image. Furthermore, a difference is described, which is used for deviations above defined thresholds for the detection of a malfunctioning nozzle. Also, the pressure of a reference mark is called, based on the determination of a position or identification of the non-functioning pressure nozzle can be achieved.
• Option B: Again, the entire print image is read in real time using cameras or sensors. The data are then summed up in the printing direction digitally with respect to the gray values / intensities or similar quantities and a profile is created transversely to the printing direction. If this profile has pixel width "break-ins", it is concluded that a malfunction has occurred. The big disadvantage here is that a nominal burglary, eg when printing a barcode, can not be distinguished from a nozzle malfunction. Known examples from the prior art are the patent US 8531743 B2 , It describes a failed nozzle detection system in which an image taken with an optical sensor is searched for intensity difference stripes along the printing direction. In this case, an integrated profile is generated, whereby after burglaries which are below a threshold value are sought. It explains methods that the assignment of the scans or recorded lines of the sensor to individual Allow printing process colors, so as to recognize the respective emergent nozzles in the ink.

Another example is the patent application EP 2626209 A1 , where also a detection of intensity difference stripes along the printing direction is made. In this case, one image per process color is generated by a changing illumination, ie different wavelengths, which can be searched directly for stripes in this scanned color separation. In this case, an integrated profile is generated, which is searched for burglaries that fall below a threshold.

The object of the present invention is therefore to disclose a method and a device for detecting failed nozzles in inkjet printing machines, which overcomes the disadvantages of the known methods with respect to the need for a test pattern or a lack of performance.

The inventive solution to this problem is a method having the features of main claim 1.

1. 1. Durchführung eines Druckprozesses zur Produktion eines ersten Druckbildes mit Druckbilddaten
2. 2. Erfassung und Digitalisierung des ersten, im Druckprozess produzierten, Druckbildes durch mindestens einen Bildsensor
3. 3. Digitale Verschiebung des ersten Druckbildes um mindestens eine Druckdüse quer zur Druckrichtung im Steuerungsrechner
4. 4. Durchführung eines weiteren Druckprozesses zur Produktion eines zweiten Druckbildes auf Basis des digital verschobenen ersten Druckbildes
5. 5. Erfassung und Digitalisierung des zweiten Druckbildes durch den mindestens einen Bildsensor
6. 6. Abgleich zwischen erstem und zweitem erfassten Druckbild im Steuerungsrechner
7. 7. Ermittlung ausgefallener Druckdüsen aus dem Abgleichergebnis durch den Steuerungsrechner.

It is a method for the automated detection of failed printing nozzles in an inkjet printing machine by means of a control computer, comprising the following steps:

1. 1. Carrying out a printing process for producing a first print image with print image data
2. 2. Detection and digitization of the first, produced in the printing process, print image by at least one image sensor
3. 3. Digital displacement of the first print image by at least one pressure nozzle transversely to the printing direction in the control computer
4. 4. Implementation of a further printing process for the production of a second print image on the basis of the digitally shifted first print image
5. 5. Detection and digitization of the second printed image by the at least one image sensor
6. 6. Matching between the first and second recorded print image in the control computer
7. 7. Determination of failed pressure nozzles from the calibration result by the control computer.

The basis of the method according to the invention is the detection of failed printing nozzles by a displacement of the printed image. For this purpose, the first printed benefit is detected by a camera and moved in the control computer by at least one pressure nozzle transversely to the printing direction. Whether the shift to the left or to the right happens is irrelevant. The only condition is that in the direction of displacement enough to date unused printing nozzles are present, so that continue and despite the shift of the entire benefit can be printed. After the shift of the print image, the next benefit is printed, digitized again and compared in the control computer with the old, non-shifted image. Unusual pressure nozzles can be determined by the fact that in the printing direction vertical free surfaces in the second use have "moved" around the shift width. If they were part of the printed image, they would have to appear again in the same image location in the shifted print image.

The advantage of this method is that, compared to the method known from the prior art, no special test pattern for detecting a nozzle failure is needed, since the detection is based on the actual printed image.
In contrast to the known methods, which realize the detection of a nozzle failure in the printed image, no knowledge of a desired print image is required. Compared to known methods, which identify missing nozzles in the print image without knowledge of the target print image, no complex analyzes of the printed lines over many prints are necessary. It is according to the invention a real, recognizable for the image sensor by subtraction between two copies of the printed image discernible difference, which can have as cause only a faulty pressure nozzle. As a result, the detection achieved a much higher reliability; In addition, it comes to a much shorter inspection period, or a smaller number of required hardcopies. Advantageous and therefore preferred developments of the method will become apparent from the accompanying dependent claims and from the description with the accompanying drawings.

A preferred development is that, in addition to the displacement of the first digital print image by at least one print nozzle transversely to the printing direction, a displacement of the print head by the same amount takes place in the opposite direction.
Since the control computer in the method according to the invention before the comparison between the first and second digitized benefits, the calculation of the print image out again - the image sensor is indeed still in the same place - it makes sense, the purely digital shift of the printed image by an equal mechanical Offset the print head in the opposite direction again. As a result, the benefit for the image sensor is back to the old location, while the shift of the printed image is still maintained on adjacent printing nozzles. The work of the control computer for the detection is thus facilitated. Alternatively, the image sensor can also be moved by the same amount and the same direction of the digital shift of the printed image.

A further preferred development is that the comparison between the first and second recorded digital print image is done by subtraction.
The simplest and most efficient way of comparing the two recorded benefits is achieved by subtraction. Only at points of a defective pressure nozzle may a relevant color value be present after the difference.

A preferred development is that the detection result is output by the control computer via a display to a user.
Although detection and compensation preferably take place automatically within the scope of a workflow process for the printing process, an optional feedback of the detection result to the human user via a graphical display is a necessary component of the method according to the invention.

A further preferred development is that the detection result is used as a trigger for the start of a compensation mode of the inkjet printing press for the at least one failed printing nozzle.
As already mentioned, the detection result is used in the context of the workflow process as a trigger for the activation of a compensation mode.

A preferred development is that the image sensor detects only one image section of the respective print image.
The detection process does not have to be performed over the entire printed benefit. It also reaches a detected strip, which detects all active pressure nozzles. Further reductions in the surveillance area are possible, but of course lead to a corresponding loss of information.

A further preferred development is that the captured image section is added up to a brightness profile during the current printing process and the difference between the brightness profiles of the captured image sections of the respective first and second digital print image occurs.
Since the image artifacts caused by failed print nozzles naturally appear strip-shaped in the print direction, instead of a comparison over the entire recorded benefit or monitoring area, this can also be added up to a brightness profile, whereby the adjustment then takes place between the two brightness profiles. This reduces the computational effort for the control computer massively.

A preferred development is that the displacement of the first digital print image by at least two printing nozzles transversely to the printing direction in steps of at least one pressure nozzle happens.
The shift of the digital print image by the total shift can also happen in several steps. For this, of course, a total shift by the distance of at least two pressure nozzles is required. This results in an "optical flow" in the direction of displacement with the exception of the points where there are defective pressure nozzles. For example, this approach may be beneficial when used in print Picture elements are present which resemble the strip-like image artifacts or if larger, completely unprinted areas are present in the printing direction.

An implementation of the method according to the invention to achieve the object is also achieved by an inkjet printing press, wherein the printing press for implementing a method according to at least one of claims 1 to 8 is set up. To implement the method according to the invention, the invention also includes a printing machine which is set up in accordance with the previous method claims.

• Fig. 1: ein Beispiel einer Inkjet-Rollendruckmaschine
• Fig. 2: ein Beispiel eines Fehlerbildes verursacht durch einen Druckdüsenausfall
• Fig. 3: Aufbau des verwendeten Druckmaschinensystems
• Fig. 4: schematische Darstellung des Detektionsvorgangs
• Fig. 5: den Ablauf des erfindungsgemäßen Verfahrens

The inventive method and functionally advantageous developments of the method will be described below with reference to the accompanying drawings with reference to at least one preferred embodiment. In the drawings, corresponding elements are provided with the same reference numerals.
The drawings show:

• Fig. 1 : an example of an inkjet web press
• Fig. 2 : an example of a fault caused by a pressure nozzle failure
• Fig. 3 : Construction of the used printing machine system
• Fig. 4 : schematic representation of the detection process
• Fig. 5 : the course of the method according to the invention

Field of application is in the preferred embodiment, an inkjet printing machine 1. An example of the structure of such a machine 1 is in FIG. 1 shown. During operation of this printing machine 1, as already described in the introduction, individual print nozzles may fail in the print heads 7 in the printing unit 6. The result is white lines 13, or in the case of multi-color printing, distorted color values. An example of such a White Line 13 is in FIG. 2 shown.

Since a manual implementation of the method described by a user would be inefficient, the implementation is carried out automatically by the control computer 15 of the inkjet printing press 1. FIG. 3 shows the exemplary structure of a such system. The automated method is integrated into the workflow of the printing machine 1. The configuration of the control computer 15 with regard to individual method steps can be manually corrected by the user if necessary. The control computer 15 is part of the printing press controller 14.

The functional principle of the detection method is in FIG. 4 shown in detail in the form of a preferred embodiment. Each printed image, or even the portion of an image 20, is detected by an image sensor. Prior to printing the next copy or portion 20 of the image, the print image is electronically shifted transversely to the print direction by one or more print nozzles so that other nozzles print the image information. A mechanical adjustment simultaneously displaces the printheads by the same amount across the print direction, counter to the electronic shift, so that the next copy of the print image is printed at the same position from the perspective of the image sensor. The opposite shift of the digital print image and the physical position of the head cancel each other out from the perspective of the image sensor. The lines / columns of the image change their nozzle assignment by the amount of digital shift in this process. A line-shaped artifact, which is caused by a pressure column without pressure data, that is intended, remains in the resulting, twice counter-shifted image, in its original position. On the other hand, a linear artifact 13 in the form of a pressure column 21, which is generated by defective nozzles, will only follow the physical displacement and thus be displaced in the resulting printed image 17. Thus, a simple difference formation of the images read by the image sensor with and without digital displacement, in which a difference as a line / column longitudinal in the printing direction, can be used as a safe detection criterion for a failed nozzle.

A further embodiment variant of the difference formation is the integration of the image data recorded in the image sensor over a specific period of a short image section to be defined into a brightness profile. In this case, an error in the print image is immediately visible: The brightness profile of the image data, possibly divided into individual channels, in the case of functioning nozzles with the brightness profile of the previous image section 20 match. Moving distinctive highs or lows in the accumulated brightness profile simultaneously with the displacement of the print image 16 relative to the nozzles, so it is an error 13, which is caused by a defective or failed nozzle.

The digital shift of the print image is possible even without mechanical counter-correction. In this case, the print image is shifted transversely to the printing direction by one or more printing nozzles, so that other nozzles print the image information. However, no simultaneous mechanical counter-displacement is performed. In order to enable a correct adjustment 18, the image acquisition of the camera is shifted by the necessary amount in the required direction. Alternatively, the control computer during image evaluation, i. before subtraction, move the scanned image 16 by the appropriate amount. After this operation, the differences of the successive images are just as possible again. However, there is the disadvantage that the absolute position shifts on the substrate. For most print jobs, this minimum absolute displacement can be tolerated. Analysis and subtraction are not affected anyway.

Another variant is the digital shift without mechanical counter-correction in several smaller steps: The total shift width is unknown, or unimportant - as long as the print image is not moved out of the range of existing print nozzles. The image analysis in the control computer recognizes the "optical flow" of the moving pixels and can distinguish this from the stationary lines 13, which are created by failed pressure nozzle. This has the disadvantage that an "optical flow" is created only by repeated shifting in small steps and thus some prints are needed. Furthermore, there is also the disadvantage here that the absolute position shifts on the substrate.

LIST OF REFERENCE NUMBERS

1

Inkjet press

2

liquidator

3

Prepress stage

4

Flexo-Werk for white / solid surface

5

Flexo plant for primers

6

Inkjet printing unit

7

Inkjet printhead

8th

Flexo plant for paint

9

Processing stage

10

rewinder

11

printing substrate

12

Use

13

Image defect caused by failed print nozzle

14

Press control

15

control computer

16

shifted, digital print image

17

resulting print image

18

match score

19

detection result

20

monitored image section

21

Pressure column with defective pressure nozzle

Claims (9)

Method for the automated detection of failed printing nozzles in an inkjet printing press (1) by means of a control computer (15), comprising the following steps: • Carrying out a printing process for producing a first print image (12) with print image data • Detection and digitization of the first printed image (12) produced in the printing process by at least one image sensor Digital displacement of the first printed image (12) around at least one printing nozzle transversely to the printing direction in the control computer (15) Carrying out a further printing process for producing a second printed image (16) on the basis of the digitally shifted first printed image (12) • Detection and digitization of the second print image (16) by the at least one image sensor • Comparison between the first and second recorded print image in the control computer (15) • Determination of failed pressure nozzles from the calibration result (18) by the control computer (15). Method according to claim 1,
characterized,
in that, in addition to shifting the first digital print image (12) about at least one printing nozzle transversely to the printing direction, a displacement of the print head (7) takes place by the same amount in the opposite direction. Method according to one of the preceding claims,
characterized,
in that the comparison between the first and the second acquired digital print image (12, 16) takes place by forming a difference. Method according to one of the preceding claims,
characterized,
in that the detection result (19) is output by the control computer (15) via a display to a user. Method according to one of the preceding claims,
characterized,
in that the detection result (19) is used as a trigger for the start of a compensation mode of the inkjet printing press (1) for the at least one failed printing nozzle. Method according to one of the preceding claims,
characterized,
that the image sensor only detects one image section (20) of the respective print image. Method according to claim 6,
characterized,
in that the captured image section (20) is added up to a brightness profile during the current printing process, and the difference between the brightness profiles of the acquired image sections (20) of the respectively first and second digital print image occurs. Method according to one of the preceding claims,
characterized,
in that the displacement of the first digital print image (12) takes place at least two printing nozzles transversely to the printing direction in steps of at least one printing nozzle. Inkjet printing machine with a control computer
characterized,
that the printing press (1) is adapted for implementing a method according to any one of claims 1 to. 8

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