CN109624502B - Efficient low-loss printed product production system and method - Google Patents
Efficient low-loss printed product production system and method Download PDFInfo
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Abstract
The invention discloses a high-efficiency low-loss printed product production system and a method, wherein the system comprises a printing subsystem, a subsequent processing subsystem and a loss estimation subsystem, and the loss estimation subsystem is configured as follows: the sampling monitoring unit is used for sampling quality parameters of the intermediate products and outputting sampling data of each intermediate product at the production node; the data storage unit is used for storing the standard quality parameters and the sampling data set by the intermediate product; the judging and assigning unit is used for receiving the sampling data output by the sampling monitoring unit, comparing the sampling data with the standard quality parameters and giving corresponding quality parameter values of the intermediate product corresponding to the sampling data; the data processor unit is used for receiving and calculating the quality parameter value accumulated by the current production node of each intermediate product; and the early warning unit receives the quality parameter value, and outputs warning information when the quality parameter value exceeds a preset value, so that unqualified intermediate products are eliminated in advance, and the consumption of subsequent production nodes is reduced.
Description
Technical Field
The invention relates to the technical field of printing, in particular to a high-efficiency low-loss printed product production system and a method.
Background
Printing is a technique of transferring ink to the surface of a material such as paper, fabric, or leather by performing processes such as plate making, inking, and pressing on an original such as characters, pictures, photographs, or forgery prevention, and thereby copying the content of the original in bulk.
For the production of articles with characters and patterns, the general production process can be summarized as follows: the pattern or character to be printed is made into a plate by CTP, then the pattern or character is transferred to the raw material of the product, such as paper, the paper printed with the pattern is processed by the next procedure to generate the relevant product, and finally the product is packed and transported.
In the printing process, production errors exist in each production node, and each error is superposed and accumulated with each other. In the process of printing products in the prior art, the products are often inspected at the last product node, and unqualified products are selected for elimination. Although the above design reduces the number of inspection processes, it increases the cost of subsequent processes. How to efficiently identify unqualified products possibly appearing in printed products and eliminate the unqualified products as soon as possible has great significance for reducing the loss of the printed products and improving the production efficiency of the printed products.
Disclosure of Invention
Aiming at the problems of large production loss and low efficiency of printed products in practical application, the invention aims to provide an efficient low-loss printed product production system which can quickly discriminate the possible damage rate of a single printed product, so that the printed product is eliminated in the previous process and unnecessary loss of the next process is avoided. Based on the above high-efficiency low-loss printed product production system, the second objective of the present invention is to provide a high-efficiency low-loss printed product production method, which has the following specific scheme:
an efficient low-loss printed product production system, comprising a printing subsystem and a subsequent processing subsystem, and further comprising a loss estimation subsystem, wherein the loss estimation subsystem is configured to:
the sampling monitoring unit is configured at each production node in the printing subsystem and the subsequent processing subsystem and used for sampling the quality parameters of the intermediate products at each production node and outputting the sampling data of each intermediate product at the production node;
the data storage unit is configured to be used for storing standard quality parameters set by the intermediate products at each production node and sampling data of each intermediate product at each production node;
the judgment and assignment unit is configured to receive intermediate product sampling data at a production node sampled and output by the sampling monitoring unit, compare the intermediate product sampling data with standard quality parameters at the production node, and assign corresponding quality parameter values of intermediate products corresponding to the sampling data based on the matching degree of the intermediate product sampling data and the standard quality parameters;
the data processor unit is configured to be in data connection with the judgment and assignment unit, and receive and calculate the quality parameter value accumulated by the current production node of each intermediate product;
and the early warning unit is configured to be in data connection with the data processor unit, receive the quality parameter value and output warning information when the quality parameter value exceeds a preset value.
According to the technical scheme, each production node in the generation process is monitored, quality sampling is carried out on each intermediate product output by each production node, the quality parameter value is recorded, the quality parameter value of each intermediate product gradually changes along with the progress of the production process, the early warning unit outputs warning information after the quality parameter value exceeds a preset value, and workers can remove the intermediate products in time according to the warning information, so that the consumption of subsequent processes can be reduced. Because the inspection of above-mentioned defective products is placed in the middle of the production flow and when not producing and finishing, when the defect that can't be mended in the later stage appears in an intermediate product, in time get rid of above-mentioned intermediate product, can effectively reduce corresponding production consume in the later stage production process, promote production efficiency.
Further, the printing subsystem comprises a CTP typesetting process, an exposure process, a developing process and a printing process, wherein the exposure process utilizes an exposure machine to expose CTP; and a developing process, wherein the CTP plate is enabled to display a required designed pattern by using a developing solution, the developed CTP plate is cleaned by clear water, and the designed pattern is printed on the intermediate product.
Further, the post-processing subsystem includes: folding, gluing or stapling, cutting, pasting and final product inspection.
Further, the sampling data includes image information data, image position data, folding position data, glue nail position data, cutting position data, and sealing position data.
Through the technical scheme, the intermediate products at each production node can be subjected to corresponding type quality detection.
Further, the decision assignment unit includes:
the matching degree judging module is configured to receive the sampling data and the standard quality parameters and output a matching degree value according to the difference degree of the sampling data and the standard quality parameters;
the matching degree assignment module is configured for assigning a product to the intermediate product according to the matching degree value;
the production node assignment module is configured to perform basic assignment on each production node;
and the quality parameter value calculation module is configured to receive the product assignment and the basic assignment, and calculate the quality parameter value through a set algorithm.
According to the technical scheme, firstly, the sampling parameters of the intermediate product are compared with the standard quality parameters to obtain product assignment, then, the production nodes are subjected to basic assignment according to the importance of the production nodes, and finally, the two are multiplied to obtain more accurate quality parameter values.
Further, the printed product production system further includes:
and the correcting unit is configured at each production node, receives the sampling data of the previous production node of the intermediate product, and adjusts the process control parameters of the current production node according to a set algorithm.
According to the technical scheme, the defects or the hidden defects of the intermediate product at the current production node are judged by analyzing the sampling data of the previous production node, and then the process control parameters of the current production node are temporarily modified through a set algorithm to correct the defects, so that the quality parameter values of the current intermediate product are changed.
Further, the sampling monitoring unit comprises an image acquisition device, and the image acquisition device acquires image information of the intermediate product at each production node and outputs the image information to the data storage unit.
By the technical scheme, various information of the printing intermediate product can be collected by the image collecting device, and then the relevant matching value can be obtained through image recognition, so that the quality parameter value of the corresponding printing intermediate product can be finally and quickly judged.
Further, the early warning unit comprises a production data information early warning module, and is configured to highlight the intermediate product number in a production data information report when a quality parameter value of an intermediate product exceeds a preset value, or output an audible and visual warning signal at a production node.
Through the technical scheme, after the quality parameter value of a certain intermediate product exceeds the preset range, the quality parameter value can be highlighted in the generated data report, the worker is reminded to timely remove the intermediate product with the large elimination risk in the later period, or the worker is reminded to eliminate the intermediate product at the production node, and the production resource of the subsequent production node is prevented from being consumed.
Based on the high-efficiency low-loss printed product production system, the invention also provides a high-efficiency low-loss printed product production method, which comprises the following steps:
s100, establishing a production flow and dividing production nodes;
s200, arranging a sampling monitoring unit for acquiring quality parameters of the intermediate product at each production node;
s300, judging and giving quality parameter values of each intermediate product according to the output result of the sampling monitoring unit and a set algorithm;
s400, determining whether the intermediate product flows to the next production node or not based on the quality parameter value accumulated by the intermediate product at a certain production node.
Further, the step S300 specifically includes:
s301, receiving the sampling data of the sampling monitoring unit and the standard quality parameters corresponding to the production node, and outputting a matching degree value according to the difference degree of the sampling data and the standard quality parameters;
s302, performing product assignment on the intermediate product according to the matching value;
s303, performing basic assignment on each production node;
s304, receiving the product assignment and the basic assignment, and calculating by a set algorithm to obtain the quality parameter value.
Through the technical scheme, the intermediate products without qualified prospects can be eliminated from the product line in advance, the loss of production data in subsequent production nodes is reduced, and the production efficiency can be improved. In the production process, the working state of each production node can be known in time.
Compared with the prior art, the invention has the following beneficial effects:
(1) monitoring each production node in the generation process, sampling the quality of each intermediate product output by each production node and recording the quality parameter value, wherein the quality parameter value of each intermediate product gradually changes along with the progress of the production process, and when the quality parameter value exceeds a preset value, an early warning unit outputs warning information, so that a worker can remove the intermediate products in time according to the warning information, and the loss of subsequent processes can be reduced;
(2) the production nodes in the generation flow are monitored, the working state of the equipment of each production node is known in time, the equipment is debugged, and the production efficiency is guaranteed.
Drawings
FIG. 1 is a schematic view of an integral production node of the present invention;
FIG. 2 is a block diagram of a wear estimation subsystem according to the present invention;
FIG. 3 is a schematic flow chart of the method of the present invention.
Reference numerals: 100. a printing subsystem; 200. a subsequent processing subsystem; 300. a wear estimation subsystem; 301. a sampling monitoring unit; 302. a data storage unit; 303. a judgment assignment unit; 304. a data processor unit; 305. and an early warning unit.
Detailed Description
In the current production process of printed products, various losses can be generated, for example, printed patterns have problems, products need to be eliminated, the folded positions of the products do not meet the specifications, the products need to be eliminated, and the like. The product is eliminated, the production node with the defect is not the last production node, and sometimes even the previous printing process has problems, such as printing pattern typesetting storage defects and the like, and the existence of the defects directly causes the subsequent production and processing to become meaningless, thereby increasing the production loss and wasting precious production resources. If each intermediate product in production can be monitored in the production process, the future qualification rate of the intermediate product is judged in advance, and the intermediate product is eliminated in advance under the condition that the intermediate product does not have the qualified quality prospect, so that the consumption of subsequent production resources can be avoided, and the production efficiency can be improved.
The present invention will be described in further detail with reference to examples and drawings, but the present invention is not limited to these examples.
As shown in fig. 1, an efficient low-loss printed product production system includes a printing subsystem 100, a post-processing subsystem 200, and a loss estimation subsystem 300.
As shown in fig. 1, the printing subsystem 100 includes a CTP typesetting process, an exposure process, a developing process and a printing process, wherein the exposure process exposes CTPs by using an exposure machine; and a developing process, wherein the CTP plate is enabled to display a required designed pattern by using a developing solution, the developed CTP plate is cleaned by clear water, and the designed pattern is printed on the intermediate product.
As shown in fig. 1, the post-processing subsystem 200 includes: folding, gluing or stapling, cutting, pasting and final product inspection.
It should be noted that, in the above steps, the setting sequence of the processes can be adjusted according to different product requirements.
In detail, as shown in fig. 2, the wear estimation subsystem 300 is configured to: a sampling monitoring unit 301, a data storage unit 302, a decision assignment unit 303, a data processor unit 304 and an early warning unit 305.
The sampling monitoring unit 301 is disposed at each production node in the printing subsystem 100 and the subsequent processing subsystem 200, and is configured to sample quality parameters of the intermediate product at each production node and output sampling data of each intermediate product at the production node. The sampling monitoring unit 301 may employ a CCD camera disposed on the production line, an image capturing device or a position sensor for capturing an image of the intermediate product, an infrared edge detecting device, or the like, to capture an image, a shape, and a size of the intermediate product.
The data storage unit 302 is configured to store standard quality parameters set by the intermediate product at each production node and sample data of each production intermediate product at each production node. In practical applications, the data storage unit 302 may be implemented by a computer and a database in data connection with the sampling monitoring unit 301 at each production node on the production line.
The evaluation unit 303 is configured to receive the sampling data output by the sampling monitoring unit 301, compare the sampling data with the standard quality parameters, and assign corresponding quality parameter values to the intermediate product corresponding to the sampling data based on the matching degree between the sampling data and the standard quality parameters. The above-mentioned judgment and assignment unit 303 is implemented by using a program module built in a computer, and calls up sampling data and performs corresponding analysis on the sampling data.
The data processor unit 304 is configured to be in data connection with the decision and assignment unit 303, and to receive and calculate the accumulated quality parameter value of the current production node of each intermediate product.
The pre-warning unit 305 is configured to be in data connection with the data processor unit 304, receive the quality parameter value, and output warning information when the quality parameter value exceeds a preset value.
The sampling data comprise image information data, image position data, folding position data, glue nail position data, cutting position data and sealing position data, and the technical scheme can be used for detecting the quality of the intermediate products at each production node in a corresponding type.
The evaluation unit 303 includes a matching degree evaluation module, a production node evaluation module, and a quality parameter value calculation module.
The matching degree judging module is configured to receive the sampling data and the standard quality parameter and output a matching degree value according to the difference degree of the sampling data and the standard quality parameter. And the matching degree assignment module is configured to assign a product to the intermediate product according to the matching degree value. The production node assignment module is configured to perform a base assignment for each production node. And the quality parameter value calculation module is configured to receive the product assignment and the basic assignment, and calculate the quality parameter value through a set algorithm. According to the technical scheme, firstly, the sampling parameters of the intermediate product are compared with the standard quality parameters to obtain product assignment, then, the production nodes are subjected to basic assignment according to the importance of the production nodes, and finally, the two are multiplied to obtain more accurate quality parameter values.
Preferably, the printed product production system further comprises a correction unit, wherein the correction unit is configured at each production node, receives sampling data of a previous production node of the intermediate product, and adjusts the process control parameters of the current production node according to a set algorithm. The method comprises the steps of judging whether the defects or the hidden defects of the intermediate products at the current production nodes are located by analyzing the sampling data of the previous production nodes, then temporarily modifying the process control parameters of the current production nodes through a set algorithm, correcting the defects and further changing the quality parameter values of the current intermediate products. For example, if the edge line of the cardboard deviates in the cutting operation of the previous process, the previous process may correct the edge line.
In a particular embodiment, the sampling monitoring unit 301 includes an image capture device that captures image information of the intermediate product at various production nodes and outputs the image information to the data storage unit 302. The image acquisition device can be used for acquiring various information of the printing intermediate product, and then the related matching degree value can be obtained through image recognition, and finally the quality parameter value of the corresponding printing intermediate product is rapidly judged.
The pre-warning unit 305 includes a production data information pre-warning module configured to highlight the intermediate product number in the production data information report when the quality parameter value of an intermediate product exceeds a preset value, or output an audible and visual warning signal at a production node. The acousto-optic warning signals are completed by LED warning lamps arranged at all production nodes and a voice player. When the quality parameter value of a certain intermediate product exceeds a preset range, the quality parameter value can be highlighted in a generated data report to remind a worker to remove the intermediate product with a large elimination risk in the later period in time, or the worker is reminded to eliminate the intermediate product at a production node to avoid consuming the production resources of the subsequent production node.
By monitoring each production node in the generation flow, sampling the quality of each intermediate product output by each production node and recording the quality parameter value, the quality parameter value of each intermediate product gradually changes along with the progress of the production flow, and when the quality parameter value exceeds a preset value, the early warning unit 305 outputs warning information, and a worker can remove the intermediate products in time according to the warning information, so that the consumption of subsequent processes can be reduced. Because the inspection of above-mentioned defective products is placed in the middle of the production flow and when not producing and finishing, when the defect that can't be mended in the later stage appears in an intermediate product, in time get rid of above-mentioned intermediate product, can effectively reduce corresponding production consume in the later stage production process, promote production efficiency.
Based on the above high-efficiency low-loss printed product production system, the present invention further provides a high-efficiency low-loss printed product production method, as shown in fig. 3, including:
s100, establishing a production flow and dividing production nodes;
s200, arranging a sampling monitoring unit 301 for acquiring quality parameters of the intermediate product at each production node;
s300, judging and giving quality parameter values of each intermediate product according to the output result of the sampling monitoring unit 301 and a set algorithm;
s400, determining whether the intermediate product flows to the next production node or not based on the quality parameter value accumulated by the intermediate product at a certain production node.
Further, the step S300 specifically includes:
s301, receiving the sampling data of the sampling monitoring unit 301 and the standard quality parameters corresponding to the production node, and outputting a matching degree value according to the difference degree of the sampling data and the standard quality parameters;
s302, performing product assignment on the intermediate product according to the matching value;
s303, performing basic assignment on each production node;
s304, receiving the product assignment and the basic assignment, and calculating by a set algorithm to obtain the quality parameter value.
And determining whether the intermediate product flows to the next production node or not based on the value of the quality parameter accumulated by the intermediate product at a certain production node.
Through the technical scheme, the intermediate products without qualified prospects can be eliminated from the product line in advance, the loss of production data in subsequent production nodes is reduced, and the production efficiency can be improved. In the production process, the working state of each production node can be known in time.
The above description is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above embodiments, and all technical solutions belonging to the idea of the present invention belong to the protection scope of the present invention. It should be noted that modifications and embellishments within the scope of the invention may occur to those skilled in the art without departing from the principle of the invention, and are considered to be within the scope of the invention.
Claims (6)
1. An efficient low-loss printed product manufacturing system comprising a printing subsystem (100) and a subsequent processing subsystem (200), further comprising a loss estimation subsystem (300), wherein the loss estimation subsystem (300) is configured to:
the sampling monitoring unit (301) is configured at each production node in the printing subsystem (100) and the subsequent processing subsystem (200) and is used for sampling the quality parameters of the intermediate products at each production node and outputting the sampling data of each intermediate product at the production node;
a data storage unit (302) configured to store standard quality parameters set by the intermediate products at each production node and sample data of each intermediate product at each production node;
the judging and assigning unit (303) is configured to receive intermediate product sampling data at a production node sampled and output by the sampling monitoring unit (301), compare the intermediate product sampling data with standard quality parameters at the production node, and assign corresponding quality parameter values of intermediate products corresponding to the sampling data based on the matching degree of the intermediate product sampling data and the standard quality parameters;
the data processor unit (304) is in data connection with the judgment and assignment unit (303), and is used for receiving and calculating the accumulated quality parameter value of the current production node of each intermediate product;
the early warning unit (305) is in data connection with the data processor unit (304), receives the quality parameter value and outputs warning information when the quality parameter value exceeds a preset value;
the printing subsystem (100) comprises a CTP typesetting process, an exposure process, a developing process and a printing process, wherein the exposure process utilizes an exposure machine to expose CTP; in the developing process, a developing solution is used for enabling the CTP plate to display a required designed pattern, the developed CTP plate is washed by clear water, and then the designed pattern is printed on an intermediate product;
the post-processing subsystem (200) comprises: folding, gluing or stapling, cutting, pasting and final product inspection;
the sampling data comprises image information data, image position data, folding position data, glue nail position data, cutting position data and sealing position data;
the decision assigning unit (303) comprises:
the matching degree judging module is configured to receive the sampling data and the standard quality parameters and output a matching degree value according to the difference degree of the sampling data and the standard quality parameters;
the matching degree assignment module is configured for assigning a product to the intermediate product according to the matching degree value;
the production node assignment module is configured to perform basic assignment on each production node;
and the quality parameter value calculation module is configured to receive the product assignment and the basic assignment, and calculate the quality parameter value through a set algorithm.
2. The system of claim 1, further comprising:
and the correcting unit is configured at each production node, receives the sampling data of the previous production node of the intermediate product, and adjusts the process control parameters of the current production node according to a set algorithm.
3. The system of claim 1, wherein the sampling monitoring unit (301) comprises an image acquisition device, and the image acquisition device acquires image information of the intermediate product at each production node and outputs the image information to the data storage unit (302).
4. The system according to claim 1, wherein the pre-warning unit (305) comprises a production data information pre-warning module configured to highlight the intermediate product number in the production data information report or output an audible and visual warning signal at the production node when the quality parameter value of an intermediate product exceeds a preset value.
5. A method for producing high-efficiency low-loss printed products, which is applied to the system for producing high-efficiency low-loss printed products as claimed in any one of claims 1 to 4, and comprises the following steps:
s100, establishing a production flow and dividing production nodes;
s200, arranging a sampling monitoring unit (301) for acquiring quality parameters of the intermediate product at each production node;
s300, judging and giving quality parameter values of each intermediate product according to the output result of the sampling monitoring unit (301) and a set algorithm;
s400, determining whether the intermediate product flows to the next production node or not based on the quality parameter value accumulated by the intermediate product at a certain production node.
6. The method according to claim 5, wherein the step S300 comprises:
s301, receiving the sampling data of the sampling monitoring unit (301) and the standard quality parameters corresponding to the production node, and outputting a matching degree value according to the difference degree of the sampling data and the standard quality parameters;
s302, performing product assignment on the intermediate product according to the matching value;
s303, performing basic assignment on each production node;
s304, receiving the product assignment and the basic assignment, and calculating by a set algorithm to obtain the quality parameter value.
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| DE3100304A1 (en) * | 1980-01-09 | 1981-11-26 | Dai Nippon Insatsu K.K., Tokyo | PRESSURE TEST DEVICE |
| CN1586892A (en) * | 2004-09-02 | 2005-03-02 | 中国印钞造币总公司 | On-line automatic controlsystem for printing quality |
| CN102565083A (en) * | 2012-01-12 | 2012-07-11 | 北京印刷学院 | Offline inspection system and method for printed electronic product |
| CN106018426A (en) * | 2016-07-20 | 2016-10-12 | 武汉大学 | Printed product quality online detection system |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3100304A1 (en) * | 1980-01-09 | 1981-11-26 | Dai Nippon Insatsu K.K., Tokyo | PRESSURE TEST DEVICE |
| CN1586892A (en) * | 2004-09-02 | 2005-03-02 | 中国印钞造币总公司 | On-line automatic controlsystem for printing quality |
| CN102565083A (en) * | 2012-01-12 | 2012-07-11 | 北京印刷学院 | Offline inspection system and method for printed electronic product |
| CN106018426A (en) * | 2016-07-20 | 2016-10-12 | 武汉大学 | Printed product quality online detection system |
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