Introduction and selection of automatic detection system for printing defects
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In the past few years, we have seen the rapid growth of inspection systems in the processing industry. Today, 100% automatic defect detection technology has been realized. Today, you can hear the word "defect detection" in almost all industries. In the packaging industry, it helps to find out all the defects on printed products, and is suitable for different printing methods.
100% automatic defect detection, which means that the system can help the operator to monitor the quality of the product in the printing process, ensuring that every product printed is a good product.
Currently, there are two basic types of detection systems for this technology on the market, 100% sampling and 100% comprehensive.
The 100% sampling type refers to repeatedly selecting a part of the printing in one time, and the part is monitored 100%, and the repetition time may vary from several seconds to several minutes.
100% comprehensive to 100% monitoring of each part of the product processed on the press. Both systems use two camera technologies that are diametrically opposed - progressive (using linear CCD cameras) and block-by-block scanning (using conventional CCD cameras). The 100% comprehensive inspection system based on block-by-block scanning is relatively technically updated, and is better on some packages than progressive scan technology.
Let's take a look at some application examples and analyze the advantages of the 100% inspection system.
Coverage and Sampling Rate The 100% sampling system's detection area is determined by field of view, processing capacity, and system power. A 2 Hz system can capture two images per second, and 10 images per second at 10 Hz. If it is the same field of view and processing time, the sampling area of a 10 Hz system is 5 times that of 2 Hz. For example, two systems with 7x9 inches of field of view (the same processing speed is considered for ease of discussion), sampling 35-inch prints at 800 feet per minute, respectively, with 336,000 squares per minute through the device. inch. The 2 Hz system detects 7,560 square inches of printed material per minute, which is 0.02% of the entire screen area. The 10 Hz system detects 37,800 square inches per minute, which is 11% of the entire print area. Repetitive and non-repetitive deficiencies for non-repetitive deficiencies, is the detection system also familiar? Answer: No. The 100% sampling system only detects defects that the camera sees at a particular moment in a particular print location. Specifically, the 100% sampling type inspection system does not have the ability to find defects on the entire print. They have the advantage of being able to accurately monitor certain specific properties of the processing quality, such as color, overprinting, streaking and repetitive defects. And 100% comprehensive detection technology can help you find the lack of the entire print, but the investment of this system is more than three times the usual type, the customer must prove that there is a real need, the investment can have a tangible return. They also have common uses, such as distinguishing between qualified and non-conforming products. But consider the strategy of removing all non-conforming products and optimizing the benefits of the process. After understanding the differences between the two basic inspection systems, it is necessary to master the waste problem. To explain this, please see the waste and downtime data on Table (1). With this data you can further test which system is what you really need.
If you want to analyze it in detail, the data analysis must have 3 months of information, 6-12 months is ideal, and the data of this form is highly reliable. It lists the amount of waste associated with printing and downtime. With this form, you can determine the wear and tear of each processing problem and make relevant corrective actions. If the biggest part of the printing problem is in the direction, the 100% sampling type detection system is the best solution. It is designed to determine directional problems such as color, overprinting, etc. It can provide effective information for operators and perfect them. Management of the entire processing process. But if the underlying problem lies in non-repetitive deficiencies, your choice should be a 100% comprehensive inspection system. All in all, before investing in a fully automated inspection system, please spend some time and resources on similar data. If you ignore this process, you may be taking a lot of risks, and the problem of print quality can be a big problem. Conclusion Today, there are many types of detection systems on the market, each with its own characteristics. A truly efficient 100% inspection system must have the right technology to specifically correct or prevent the problem of the source of the waste. If the system is properly selected, the reduction in processing costs is significant. However, you must do some preparatory work before you buy. You must determine the type of printing waste you are currently facing and the reasons for its formation. Choose the appropriate detection system for different reasons, and the right medicine can cure the chronic disease.