Method and apparatus for detection of a print mark
10628669 ยท 2020-04-21
Assignee
Inventors
Cpc classification
G06F2218/00
PHYSICS
B41F33/0081
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A method for detection of print marks by evaluation of a cyclical sensor signal (S) from at least one contrast sensor, which senses an area of printed material containing a print mark that passes below the contrast sensor. The method includes forming a first derivation (S) of the cyclical sensor signal (S); determining a first edge region in a region where the first derivation (S) falls below a lower threshold value; determining a second edge region in a region where the first derivation (S) exceeds an upper threshold value; determining characteristic values for the first edge region and the second edge region; associating a print mark detection between the first edge region and the second edge region based on the determined characteristic values; and generating at least one output value which is representative of the print marks.
Claims
1. A method for detection of print marks by evaluation of a cyclical sensor signal (S) from at least one contrast sensor, which senses an area of printed material containing a print mark that passes below the contrast sensor, the method comprising: converting the cyclical sensor signal (S) into a discrete-path sensor signal with time steps synchronized with a feeding speed of the print mark so that each time step corresponds to a constant stretch of path traveled by the print mark; forming a first derivation (S) of the cyclical sensor signal (S); determining a first edge region in a region where the first derivation (S) falls below a lower threshold value; determining a second edge region in a region where the first derivation (S) exceeds an upper threshold value; determining characteristic values for the first edge region and the second edge region; associating a print mark detection between the first edge region and the second edge region based on the determined characteristic values; and generating at least one output value, which is representative of the detected print mark, wherein the at least one output value, which is representative of the print mark, is selected from a print mark position, a print mark width, a print mark contrast value, and/or a quality value.
2. The method according to claim 1, wherein the lower threshold value and/or the upper threshold value are dynamic threshold values which are determined on the basis of the first derivation (S).
3. The method according to claim 1, wherein the method further comprises: forming a second derivation (S) of the cyclical sensor signal (S); determining the zero crossing of the second derivation (S) of the cyclical sensor signal (S) in the first edge region; determining the zero crossing of the second derivation (S) of the cyclical sensor signal (S) in the second edge region; and associating a print mark detection between the first zero crossing and the second zero crossing.
4. The method according to claim 1, wherein the evaluation of the cyclical sensor signal (S) takes place in a measuring window.
5. The method according to claim 4, wherein the measuring window is determined by evaluation of at least one first cycle of the cyclical sensor signal.
6. The method according to claim 4, wherein a size and/or position of the measuring window is automatically adapted to a detected print mark signal.
7. The method according to claim 1, wherein a sampling rate (f, f) used for digitization of the cyclical sensor signal (S) is synchronized with a speed (v) at which the printed material is conveyed.
8. The method according to claim 1, wherein a measurement resolution is in a range between 2 and 100 m.
9. The method according to claim 1, wherein the at least one output value comprises a first output value and a second output value, and the method further comprises forming a difference value, which is a difference between the first output value, which is determined from the cyclical sensor signal from a first contrast sensor and is representative of a first print mark, and the second output value, which is determined from the cyclical sensor signal from a second contrast sensor and is representative of a second print mark.
10. The method according to claim 1, wherein the quality value comprises at least one of a value for the base quality, a value for symmetry quality and a combined quality value.
11. The method according to claim 8, wherein the measurement resolution is in a range between approximately 3 to 4 m.
12. The method according to claim 4, wherein the measuring window is defined by a user.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The present invention is explained in greater detail below with reference to
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DETAILED DESCRIPTION OF THE EMBODIMENTS
(9) The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.
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(11) The extent of the actual reduction of the sensor signal S is dependent upon many factors, inter alia the construction and the sensitivity of the contrast sensor, the relative speed between the print mark 2 and the contrast sensor 1, the environmental conditions, the printed material, and the type and the properties of the print mark 2 itself. In the event of changed environmental conditions, e.g. if the contrast sensor 1 has been replaced, the position or the type of print marks have changed, or if the illumination situation has changed, the type of print mark detection according to the prior art shown in
(12) For example, in the case of a low-contrast print mark 2 it may happen that the sensor signal S does not fall below the switching threshold G for long enough, or even does not fall below it at all, in order to be able to recognize this print mark 2 reliably. One such sensor signal of a weak print mark 2 is illustrated by way of example in
(13) A similar problem can occur if the switching threshold is selected to be too low or too high. In the first case of a switching threshold G which is selected to be too low, in the region of the print mark 2 the sensor signal S also does not fall below the switching threshold G, and in the second case of the switching threshold G which is selected to be too high the sensor signal S would continuously remain below the switching threshold G, and would therefore supply no usable result.
(14) A further possible problem can arise in the case of noisy or wavy sensor signals, as is illustrated by way of example in the sensor signal S. Although with the switching threshold G the print mark 2 can be correctly recognized, since the sensor signal S falls below the switching threshold G for a sufficiently long time, in another region F the sensor signal S also falls below the switching threshold G for a sufficiently long time, so that a print mark would be detected there too, but this is not actually present (thus this is an interfering mark). Such interfering marks can occur not only in the event of an unsuitable choice of the switching threshold, but also because of different interfering influences, such as for instance dirt or interfering light influences.
(15) In each of these cases an apparatus according to the prior art must be recalibrated and a suitable new switching threshold must be determined and set. Also after a replacement of the contrast sensor 1 a recalibration is necessary. For calibration it is sometimes sufficient to reset the switching threshold, but this is sometimes difficult and time-consuming, and cannot be carried out during the running time of the machine, so that in this case high costs can result. Also the calibration is generally not carried out by a specialist in the field of sensor technology, but by the operator of the respective printing or processing machine, for which the solution of sensor-specific problems involves additional and undesirable expenditure.
(16) The objective of the method and apparatus according to the invention is to simplify the calibration so much that it can be carried out by an operator quickly, simply and potentially even while the machine is in operation. The solution according to the invention is based on the idea of not using the absolute values for the evaluation of the sensor signal S, but the values of the first or second derivation S, S of the sensor signal S. The method according to the invention for evaluation of an analogue sensor signal S for the determination of print marks is explained with reference to
(17) For the method according to the invention no predefined switching threshold is necessary, but the geometric characteristics of the sensor signal S are evaluated. In this connection a first derivation S and a second derivation S are formed for example with the aid of signal filters which are known per se. The falling edge A can be detected by a pronounced negative value peak W.sub.A of the first derivation S, whereas the second, rising edge B produces a positive value peak W.sub.B in the first derivation S.
(18) In order to be able to detect the borders of the print mark 2 as accurately as possible, a lower threshold value U and an upper threshold value O are defined for the first derivation S, wherein the threshold values U, O in each case correspond to a specific (positive or negative) slope of the sensor signal. In contrast to the switching threshold of the prior art these threshold values U, O are independent of the (absolute) signal strength, since they only reflect the geometric characteristics of the sensor signal S. A preset value previously determined in advance by tests by the supplier can be used for the threshold values U, O, the threshold values U, O can preferably be determined dynamically on the basis of the sensor signal, for example as a percentage of the maximum or minimum of the first derivation S of the sensor signal S. As a result it will only be necessary in special cases to adjust these threshold values U, O at a later stage. In the case of a very noisy sensor signal the threshold values U, O could for example have a greater spacing, whereas they can be very close together in the case of a very smooth and interference-free pattern of the sensor signal. Furthermore a smoothing of the sensor signal and/or of the first derivation S and/or of the second derivation S can take place before these signals are evaluated for the detection of print marks. A smoothing of the sensor signal ensures that only sufficiently pronounced edges lead to the first derivation S falling below the threshold value U of exceeding the upper threshold value O for a sufficiently long time in order to trigger a detection of print marks.
(19) The characteristic shapes of the first derivation S of the sensor signal are used for evaluation of the sensor signal, wherein in particular a negative value peak followed by a positive value peak is characteristic of a print mark 2 (the edge direction towards a lower light density may usually be regarded as negative, but the reverse situation is also conceivable, for instance if a dark material is processed on which a light print mark is applied for better recognition). The principal difference between the upper and lower threshold values for the first derivation S of the sensor signal S, and the switching thresholds for the sensor signal S, such as are defined in the prior art, is that according to the invention the occurrence of a print mark 2 is determined on the basis of the slope and the length of the edges A, B and not by the (absolute) deflection of the sensor signal itself.
(20) The region in which the first derivation S falls below the lower threshold value U defines a first edge region FL.sub.A which extends over the steepest region of the edge A. In the same way the region in which the first derivation S exceeds the upper threshold value O defines a second edge region FL.sub.B which extends over the steepest region of the edge B. In these regions characteristic values can be determined which are characteristic of a print mark 2, and from which conclusions can be drawn concerning the quality or the presence of a corresponding print mark 2. In the simplest embodiment in order to distinguish the print mark 2 the turning points WP.sub.A and WP.sub.B of the two edges A, are determined B by determination of the respective zero crossing N.sub.A or N.sub.B of the second derivation S. In the event of a clear pronounced edge A, B there are in general precisely one turning point WP.sub.A, WP.sub.B and therefore also only precisely one zero crossing N.sub.A, N.sub.B of the second derivation S. Since only the turning points WP.sub.A, WP.sub.B within the edge regions FL.sub.A, FL.sub.B are determined, zero crossings which can occur away from the edges A, B due to signal ripples do not lead to false detection of a print mark.
(21) The point at which the first derivation S falls below the lower threshold value U for the first time may be regarded as the start of the region of the sensor signal S which is characteristic of the print mark 2, and in the context of the present description this point is designated as the lower base point BP.sub.A. Accordingly the base point BP.sub.B, which is located at the point at which the first derivation after the positive value peak falls again below the upper threshold value O, of the second edge B can be designated as the end of the region which is characteristic of the print mark 2.
(22) In an analogous manner the head points KP.sub.A and KP.sub.B are determined, wherein the first head point KP.sub.A designates the end of the first edge A, and the second head point KP.sub.B designates the start of the second edge B. A substantially horizontal region H, which corresponds to the darker detection region in the interior of the print mark 2 (i.e. the base of the trough-like pattern of the sensor signal in the region of the print mark 2), extends between the first and the second head point KP.sub.A, KP.sub.B. A value for the contrast K of the print mark 2 can be determined from the difference between the signal strength m outside a print mark 2 and the signal strength n in the horizontal region H of the sensor signal. If the two base points BP.sub.A, BP.sub.B or the two head points KP.sub.A and KP.sub.B have different values, they can be averaged in each case for the calculation of the contrast value K.
(23) Before the sensor signal is evaluated it can be digitized in an advantageous manner, wherein the length of the time steps used for the digitization is preferably adapted to the current speed of the print mark 2.
(24) The determined characteristic values can be used for evaluation of the quality and the symmetry of a print mark detection. A value for the base quality and a value for the symmetry quality can be determined for example for each detected print mark 2.
(25) A value which is characteristic of the difference between the two base points BP.sub.A and BP.sub.B is designated as the base quality. For calculation of such a value the two base points are determined and the difference between them is correlated with the contrast K. A poor base quality can indicate either an interfering mark or a print mark 2 of poorer quality, on the other hand the value for the base quality also diminishes very quickly if the print mark 2 migrates onto the edge of the measuring window ROI. This is because in the smoothing of signals (such as the sensor signal S, or the derivations S, S thereof) mean value filters are used which carry out the smoothed values for the sensor signal S on the basis of a plurality of consecutive measurement points of the digital sensor signal. Thus the value of the sensor signal in each time step is based on a plurality of signal values of the unsmoothed sensor signal which are located before and after the corresponding time step. If for example the measurement resolution (that is to say the step size of the digitization) is 4 m, the length of a print mark 2 corresponds for instance to 650 steps, and the mean value filter 25 takes account of measurement points before and after the respective time step, then the value for the base quality already changes when the region taken into account for the mean value formation moves out of the measuring window ROI, since several of the signal values used for the calculation of the smoothed value are cut off. This already has an effect on the pattern of the digitized sensor signal used for the evaluation before the edge of the print mark 2 itself leaves the measuring window ROI. Thus after the detection of a diminishing value for the base quality there is still time left for the operator to react before the changed conditions actually affect the product quality.
(26) A value for the symmetry of the two opposing edges A, B (that is to say the regions in which the first derivation S of the sensor signal S is located outside the region defined by the threshold values O, U) of a pattern of a sensor signal which is characteristic of a print mark 2 is designated as the symmetry quality. For determination of such a value an edge (for example the edge A) is mirrored by means of the other edge (for example the edge B) and the differential signal thereof is determined in relation to the contrast. In this case the symmetry quality reflects the sum of the differences between edge A or B, i.e. in the case of very pronounced marks with a high signal amplitude a higher differential signal is produced than in weak marks. If the calculated differential signal is correlated with the signal amplitude (contrast), this produces a standardized differential signal and thus a quality value which is independent of the signal strength.
(27) A value of zero indicates a perfect symmetry with identical edge shapes. The symmetry quality is even poorer the more the value differs from zero. Printing problems or other signal disruptions are frequently revealed in an asymmetry of the sensor signal in the region of the print mark detection, so that the value for the symmetry quality is suitable for monitoring these qualities. In addition the value can be used for the recognition of interfering marks.
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(34) By means of the base quality it is possible for example to detect whether the print mark 2 moves out of the measuring window ROI. If one of the mark edges is located too close to the edge of the measuring window, this quality value falls. Such a case is shown in
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(36) In practice the specifications for the respective measuring window ROI can be defined by the user, in order to coordinate it optimally with the expected position and width of the print mark 2. Depending upon the application, strategies or methods can be defined by the user which select the correct mark in the case of multiple detection. If a plurality of print marks are located in a measuring window ROI, initially all marks in the current measuring window are detected and subsequently with the aid of the defined selection method the correct mark is selected and taken into consideration in the detection of the print mark.
(37) In
(38) The signals from the first contrast sensor 1 and the second contrast sensor 1 are transmitted to the signal conditioning unit 5 which has a first analogue-digital converter 10 and a second analogue-digital converter 10 in which in each case a signal from one of the contrast sensors is converted into a digital signal. In this case the analogue sensor signals are converted with the aid of a predetermined sampling rate f, f into a discrete-path digital sensor signal. A discrete-path digital sensor signal is a discrete-time digital sensor signal of which the time steps are synchronized with the feeding speed of the print mark so that each (variable) time step corresponds to a constant stretch of path (which is traveled by the print mark 2).
(39) The sampling rate is determined by a computer unit 9 on the basis of a path signal x and a time signal t. For the digital sensor signal this produces a measurement resolution which can be specified in a unit of length (in the direction of movement of the print mark 2). In this case the measurement resolution may advantageously be chosen appropriately according to the application in a range from approximately 2 to approximately 100 m, preferably in a range between approximately 3 and approximately 4 m. This measurement resolution makes it possible to find an optimal compromise between the required high processing speeds of the machine and the maximum signal clocking which can be processed by digital filters.
(40) The signal conditioning unit 5 also has a plurality of filter units 11, wherein in the case of
(41) An internal communication connection 13 is provided in order to transmit the digitized sensor signals from the analogue-digital converters 10 and 10 to the individual filter units 11, 11, 11 and 11. Thus according to the respective configuration each of the filter units 11, 11, 11 and 11 can access the correspondingly required sensor signal.
(42) The functioning of the filter units 11, 11, 11 and 11 will be described in detail with reference to an example of a configuration in relation to the first filter unit 11. The first filter unit 11 accesses the signal from the first contrast sensor 1 which is digitized by the first analogue-digital converter 10. A measuring window ROI is defined for the first filter unit 10, so that this filter only evaluates signal values which lie between a first threshold value delimiting the measuring window ROI and a second threshold value, wherein the first and the second threshold value may be specified as an indication of position, for example specified in m. The indication of the position of the print mark may for example relate to the length of a machine part, for example the length of the circumference of a printing roller, given in m.
(43) The filter unit 11 has a first filter F.sub.1 which smooths the signal in the measuring window ROI. Then in a second filter F.sub.2 a first derivation S of the sensor signal S is formed from the signal and in a third filter F.sub.3 the second derivation S of the sensor signal S is formed. These derivations are evaluated in further filters and according to the method according to the invention print marks are detected and the position and width of these marls are determined. Further filters may be defined in order to determine the upper threshold value O and the lower threshold value U dynamically from the first derivation, in order to determine a contrast value for a detected print mark, and/or in order to determine one or more quality values for the detected print mark.
(44) From the sensor signal S from the first contrast sensor 1 the first filter unit 11 calculates the following output values and outputs them continuously by means of the industrial network 12: output value O.sub.1: position of the first print mark 2 [m] output value O.sub.2: width of the first print mark 2 [m] output value O.sub.3: contrast of the first print mark 2 [V] output value O.sub.4: combined quality value of the first print mark 2 [%] output value O.sub.5: sensor signal from the first contrast sensor [V]
(45) The combined quality value is a potentially weighted mean value of base quality and symmetry quality. All analyses of the first filter unit 11 are limited to the measuring window ROI.
(46) In order to enable a complete evaluation of the sensor signals S of the first contrast sensor 1 and of the second contrast sensor 1, the second filter unit 11 is configured similarly to the first filter unit 11, but for evaluation of the sensor signal of the second contrast sensor 1.
(47) Thus the second filter unit 11 calculates the following output values and outputs them by means of the industrial network 12: output value O.sub.1: position of the second print mark 2 [m] output value O.sub.2: width of the second print mark 2 [m] output value O.sub.3: contrast of the second print mark 2 [V] output value O.sub.4: combined quality value of the second print mark 2 [%] output value O.sub.5: sensor signal from the second contrast sensor [V]
(48) The evaluations of the second filter unit 11 are limited to the same measuring window ROI as those of the first filter unit 11.
(49) The output values of the first and the second filter unit 11, 11 can be used by the control unit 6 or potentially by another regulating device for the controlling the machine. Furthermore the control unit 6 can present the sensor signals in the selected measuring window ROI as well as a characteristic of the quality values to the user interface 7 in a clear manner.
(50) The third and fourth filter unit 11, 11 can be configured similarly to the first and the second filter unit 11, 11, but without being limited by a measuring window ROI, wherein they evaluate the respective sensor signal over the entire range of the cyclical signal. Also this characteristic can be presented by the control unit 6 to the user interface 7 in order to enable an operator for example to selection a new measuring window ROI quickly and clearly.
(51) The specific configurations described above of the four illustrated filter units 11, 11, 11 and 11 are given purely by way of example and can be adapted flexibly to the respective requirements.
(52) The control unit 6 can for example use the output values for example in order to update the presentation of the user interface 7, or in order to produce warnings, for instance when the quality values change or depart from a permissible range. If required, further output values can also be defined for one or more of the filter units 11.
(53) It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.