colourbrain® high speed inspection of digital printed decor baumer inspection gmbh inprint 2015...

ColourBrain®High speed inspection of digital printed decor

Baumer Inspection GmbhINPRINT 2015

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Titel: High Speed Inspection of digital printed decor, 2015-10-23

Autor: Thomas Franz

E-mail: [email protected]

Adresse: Baumer Inspection GmbH

Lohnerhofstraße 6

78467 Konstanz

www.baumergroup.com

Geheim zu haltende Information. Alle Rechte an dieser Information, wie Urheber-, Patent-, Gebrauchsmuster-, Design- und/oder Markenrechte verbleiben bei der Baumer Holding AG. Kenntnis von dieser Information lässt Weiterbenutzungsrechte nicht entstehen.

Confidential and proprietary information. All rights, especially the right to apply for and/or acquire copyright, patent, utility model, design and/or trade mark protection are reserved and remain with Baumer Holding AG. Notice of this information neither constitutes nor induces any right for further use.

http://www.baumergroup.com/

BaumerAn international family-owned enterprise

• Headquarter in Frauenfeld,Switzerland

• About 2.300 employees worldwide• 37 locations in 19 countries• Turnover about 400 Mio CHF• D&B Rating Certificate:

•Financial stability •Highest credit rating

• Executive Board: (from left to right)

•Christoph Kluser, Sensor Solutions•Severino Bruno, Finance & Controlling•Dr. Oliver Vietze, CEO & Chairman•Dr. Johann Pohany, Motion Control•Dr. Alf Zips, Process Instrumentation

© Baumer 2014


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Industry segments Baumer sets benchmarks

© Baumer 2014


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Extensive product range The appropriate technology for every application

© Baumer 2014


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Baumer Inspection GmbH Total solutions for surface inspection and OEM partner

35 years of experience in industrial vision scanners 500 inspection systems in operation worldwide 3500 OEM systems with the label of our partner


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Baumer Inspection GmbH Scanner for process monitoring and quality management

Textile Industry: Foil- & Decor paper Industry:

Isolation & Glas

Automatic sorting of cotton with up to 20m/sec.

NonWovens inspection

Inline inspection for defects, colour check, colour appearance

Inspection for defects and for the quality of lacquering and screen printing

Woodworking Industry:

Process control and quality management from press line to furniture production.


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ColourBrain® DecoPrint: Décor foil inspection Décor paper inspection


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ColourBrain® DecoPrintIntegrated scanners: double sided inspection of PVC foil


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ColourBrain®4.0 & Q-brain® & Q-live® Powerful tools to optimize the production process

Q-brain® Classifikation

ColourBrain® Inspection system

.......

Q-live® Data base and statistics


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Why ?

High speed scanners for digital printed decor


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Inspection for Digital Décor PrintingConsiderations regarding single-pass printing on wide web

Array of print heads

For printing a wide web, >1.000mm, with high resolution, a very big number of printing nozzles and overlapping printing heads are needed.

All those printing heads must have a perfect precision regarding time, geometrical position and colour.

Nozzle outs or print head banding or colour drift or substrate variation are normal in high resolution and high speed printing on wide web.


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Inspection for Digital Décor Printing

To safeguard stable and high quality production:

A combination of a high performance printing systems and of sophisticated scanners for process monitoring is a must.


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What

The specification of our scanner


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Inspection for Digital Décor PrintingSpecs of a scanner for process control in single-pass printing

1. Detection of printing problems during print job: Detection of all nozzle failures like missing nozzles, blocked nozzles,

flashes, etc. Detection of problems in synchronization. Detection of blocked printing heads. Detection of smearing, drops, spots, streaks, etc.

2. Monitoring Colour consistency: Colour consistency for all printing heads all over the width of web. Stability of colour all along the printing job.


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Inspection for Digital Décor PrintingThe specifications for our scanner for single-pass printing

Priority one should be single pass printing.

On paper, foil, textile, particle board, glass or PVC.

Strictly modular design to be adapted on all width of web.

High speed inspection for print line running with up to 250 m/min.

Resolution good for 720dpi.


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What else?

Our philosophy and our Target


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Inspection for Digital Décor PrintingBaumer‘s philosophy in colour inspection for process monitoring

overall colour appearance

1. Same visual colour appearance for all printing modules.

2. Identification of colour drifts, crosswise and lengthwise.


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The visual appearancePatented ColourBrain® technology

Multi-coloured texture is represented in mathematical model Colour Appearance is derived from the statistical analysis of the data Colour shifts are the result of complex changes of the data

colour shade #1

colour shade #2


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Inspection for Digital Décor PrintingBaumer‘s philosophy in colour inspection for process monitoring

Single problems

1. Detection of local nozzle problems: Blocked nozzle (open or closed) Discontinuous printing nozzles Shape of drops uneven

2. Automatic check of visibility


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overall colour appearance

1. Same visual colour appearance for all printing modules.

2. Identification of colour drifts, crosswise and lengthwise.

How

The design of the first test module


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Modules with very high resolution for print inspection up to 720dpi.

Array of very fast line scan cameras, designed by Baumer Inspection.

Integrated FPGA for real time image pre-processing

Precise mechanical design with optical bench on total width of inspection.

Controller and computers for image processing are integrated in Modules.

Algorithms for detection of print problems without RIP file information.

High speed inspection for Digital Décor PrintingThe design of the test system


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Print resolution resolution(Pixel/mm)

Resolution (µm/pixel)

Field of view of one module

(mm)

600 dpi 0,0433mm

Raster23,622 42µm 173,4

720 dpi 0,0353mm

Raster28,346 35µm 144,498

Design of Modules Scaling the resolution of the inspection modules


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High speed inspection for Digital Décor PrintingSystem design


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Whats done already


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Prototype module with a scanning width 400 mm

Installed in Hymmen Single Pass printing lines with XAAR printing system.

Different base substrates to analyze resolution needed and to proof concept and algorithms.

Ink with solvent for UV drying, test installation was done after printing before drying.

Resolution 600 dpi.

Speed up to 40m/min.

High speed inspection for Digital Décor PrintingTest installation


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What about results


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High speed inspection for Digital Décor PrintingNozzle out: raw and processed image


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High speed inspection for Digital Décor PrintingNozzle out: raw and processed image


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High speed inspection for Digital Décor PrintingPrint Head banding


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High speed inspection for Digital Décor PrintingStreaks


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1. Nozzle out One or more nozzles blocked.

2. Print Head problems Head banding, Head not working Head control synchronisation,single lines crosswise Head overlap area problems

3. Streaks Continuous or caused by colour drifts

4. Colour variation Head to head Drift during time of print job.

5. Smearing, spots Problems caused by substrate Drops of ink.

High speed inspection for Digital Décor PrintingPriorities are specified by test installation


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What's next


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Design of inspection system for digital printing Verantw: Franz / tf Team:

Basics target Datum:

Prototype web wide Status

Milestones <1>----------------------<2>----------------------<3>--------------------<4>-------------------<5>--------------------<6>------------>

2013

Kick off

Q1/Q2 2014

samples and priorities

Definition of specs

Discussion with partners

Ordering and manufacturing of lab test system

Q3Q4 2014

Lab test system

Design of illumination

Design of optics and camera

Mechanical design of first module prototype.

Images with spec samples

Q1Q2 2015

Evaluation of algorithms by lab system.

Production of first prototype modules

Implementation of algorithms

Test with prototype module at first production sites.

Q3Q4 2015

Optimizing prototype modules.

Ongoing Test with prototype module at more and different production sites.

Q1Q2 2016

Design of first system for production line installation

Production of first inline system

Test and optimization at Baumer/Konstanz

Q3 2016

Installation at clients plant.

TransferKonzept AnalyseDefinition

High speed inspection for Digital Décor PrintingPriorities are specified by test installation


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colourbrain® high speed inspection of digital printed decor baumer inspection gmbh inprint 2015...

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