Method for predicting ink consumption

A system and method relates to an ink volume determination for determining the amount of ink to be applied by the printer. The ink volume determination involves generating a composite cylinder layout of at least one image for the engraved cylinder, generating a set of data corresponding to the composite cylinder layout and then using the set of data to determine the volume of ink. The printer is then filled with a volume of ink related to this calculated ink volume during a printing process. The method of determining ink volume may be used independently of the printing process, for example, in order to control or manage the amount of ink used in the printing press.

Skip to:  ·  Claims  ·  References Cited  · Patent History  ·  Patent History

Claims

1. A method for determining a volume of ink for an engraved cylinder, said method comprising the steps of:

(a) generating a composite cylinder layout of at least one image for said engraved cylinder;
(b) generating a set of data corresponding to said composite cylinder layout; and
(c) using said set of data.Iadd.and at least one engraving parameter.Iaddend.to determine said volume of ink.

2. The method as recited in claim 1 wherein said generating step (a) further comprises the steps of:

(a)(i) inputting said at least one image into a processor;
(a)(ii) composing said composite cylinder layout of said at least one image using said processor.

3. The method as recited in claim 1 wherein said composite cylinder layout comprises a plurality of images; said generating step (a) further comprising the steps of:

(a)(i) inputting said plurality of images into a processor;
(a)(ii) composing said composite cylinder layout of said plurality of images using said processor.

5. The method as recited in claim 4 wherein said at least one engraving parameter comprises at least one of the following: engraving width, taper, circumferential linearization, balance correction, edge enhancement, density threshold levels, fast forward, screen, and screen angle.

8. The method as recited in claim 5 wherein said step (a) further comprises the step of:

(a)(i) generating a histogram corresponding to densities associated with at least a portion of engraved cells on said engraved cylinder.

9. The method as recited in claim 7 wherein said cell shape parameters comprise at least one of the following: channel width, highlight cell width, wall size, vertical spacing, channel voltage, highlight voltage, shadow voltage, shadow cell width, and stylus angle.

11. The method as recited in claim 7 wherein said step (b) further comprises the step of:

tuning said cell description in consideration of whether said cell description comprises a channel.

12. The method as recited in claim 7 wherein said step (b) further comprises the step of:

inputting a minimum diagonal wall size into a processor.

13. The method as recited in claim 7 wherein said step (b) further comprises the step of:

inputting a vertical cell spacing into a processor.

16. The method as recited in claim 1 wherein said method further comprises the step of:

applying said volume of ink from said engraved cylinder to a substrate.

21. The method as recited in claim 20 wherein said at least one engraving parameter comprises at least one of the following: engraving width, taper, circumferential linearization, balance correction, edge enhancement, density threshold levels, fast forward, screen, and screen angle.

22. A method for predicting ink usage by an engraved cylinder on a printing press during a printing process, said method comprising the steps of:

(a) determining ink volume required by at least a portion of the engraved cylinder during the printing process; and
(b) supplying a quantity of ink to the printing press in an amount corresponding to said ink volume;
said step (a) further comprising the step of:
(a)(i) generating a histogram corresponding to densities associated with at least a portion of cells on said engraved cylinder.

24. The method as recited in claim 23 wherein said cell shape parameters comprise at least one or the following: channel width, highlight cell width, wall size, vertical spacing, channel voltage, highlight voltage, shadow voltage, shadow cell width, and stylus angle.

25. The method as recited in claim 23 wherein said step (b) further comprises the step of:

tuning said cell description in consideration of whether said cell description comprises a channel.

26. The method as recited in claim 23 wherein said method further comprises the step of:

inputting a minimum diagonal wall size.

28. The method as recited in claim 17 wherein said method further comprises the step of:

using the following equation to determine said ink volume if a cell description comprises a channel: ##EQU10##.theta. is a stylus tip angle; s is screen in lines/micron;
b is a length of a side of a normal cell in microns; ##EQU11## P is a period or a sine wave;.phi. is a screen angle;
D.sub.0 =depth of channel in microns; and
D.sub.1 =total depth a stylus travels into copper.

30. A method of reproducing an image comprising the steps of:

generating an engraving signal representing densities of a series of pixels associated with said image;
rotating a printing cylinder about a cylindrical axis thereof;
oscillating an engraving tool into engraving contact with said printing cylinder, along an engraving track, concomitantly with said rotating and under control of an engraving head signal related to said engraving signal such that said engraving tool engraves into a surface of said printing cylinder a series or cells along said engraving track and corresponding to said pixels, each of said series of cells having a maximum depth corresponding to a density or its associated pixels;
activating a processor to determine a cross-sectional area or any of said series of cells at any cell location along a line extending in a direction along said engraving track;
causing said processor to calculate a total volume of all of said cells by integrating said cross-sectional area along a length of said engraving track;
mounting said printing cylinder on a printing press;
applying ink to said printing cylinder in an amount given by an equation:
V=calculated total cell volume
R=ink release factor
N=number of copies to be printed; and
using said printing cylinder to print N copies of said image.

31. The method as recited in claim 30 wherein V is determined by the steps of:

(a) generating a composite cylinder layout of at least one image for said engraved cylinder;
(b) generating a set of data corresponding to said composite cylinder layout; and
(c) using said set of data to determine said volume of ink.

32. The method as recited in claim 31 wherein said generating step (a) further comprises the steps of:

(a)(i) inputting said at least one image into said processor;
(a)(ii) composing said composite cylinder layout of said at least one image using said processor.

33. The method as recited in claim 32 wherein said step (a)(i) further comprises the step of:

(a)(i)(1) inputting at least one engraving parameter.

34. The method as recited in claim 33 wherein said engraving parameter comprises at least one of the following: engraving width, taper, circumferential linearization, balance correction, edge enhancement, density threshold levels, fast forward, screen, and screen angle.

35. The method as recited in claim 34 wherein said step (b) further comprises the step of:

(b)(i) determining a cell description using cell shape parameters.

36. The method as recited in claim 35 wherein said cell shape parameters comprise at least one of the following: channel width, highlight cell width, wall size, vertical spacing, channel voltage, highlight voltage, shadow voltage, shadow cell width, and stylus angle.

37. The method as recited in claim 36 wherein said step (b) further comprises the step of:

tuning said cell description in consideration of whether said cell description comprises a channel.

38. The method as recited in claim 35 wherein said method further comprises the steps of:

inputting a minimum diagonal wall size into said processor.

39. The method as recited in claim 35 wherein said method further comprises the steps of:

inputting a vertical cell spacing into said processor.

40. The method as recited in claim 31 wherein said step (c) further comprises the step of:

(c)(i) using the following equation to determine said ink volume if a cell description comprises a channel: ##EQU15##.theta. is a stylus tip angle; s is screen in lines/micron;
b is a length of a side of a normal cell in microns; ##EQU16## P is a period of a sine wave;.phi. is a screen angle;
D.sub.0 =depth of channel in microns; and
D.sub.1 =total depth a stylus travels into copper.

42. A printing system comprising:

a printer having an ink well;
an engraved cylinder rotatably mounted on said printer, said engraved cylinder having a plurality of cells thereon;
a computer;
means located in said computer for determining an ink volume required by at least a portion of the engraved cylinder during a printing process.Iadd.and without simultaneously rotatably scanning an input image corresponding to said portion of the engraved cylinder.Iaddend.;
said means comprising generating means for generating a set of data corresponding to a composite cylinder layout which is input into said computer and also for using said set of data.Iadd.and at least one input parameter.Iaddend.to determine said ink volume in order to manage ink filled in said ink well.

43. The printing system as recited in claim 42 wherein said generating means further comprises receiving means for receiving at least one input parameter, said input parameter comprising at least one of the following: engraving width, taper, circumferential linearization, balance correction, edge enhancement, density threshold levels, fast forward, screen, and screen angle.

45. A system for managing ink comprising:

input means for inputting at least one parameter associated with at least one ink-receiving area; and
means for receiving image data for at least a portion of an image to be engraved; for determining densities associated with said image, said densities being determined without simultaneously rotatably scanning said at least a portion of said image to be engraved; and also for using said at least one parameter and said densities for facilitating the management of ink..Iaddend..Iadd.46. The system as recited in claim 45 wherein said system further comprises:
means for determining an amount of ink in response to both said at least one parameter and said densities..Iaddend..Iadd.47. The system as recited in claim 46 wherein said amount of ink comprises a volume..Iaddend..Iadd.48. The method as recited in claim 46 wherein said method further comprises the step of:
using said at least one parameter and said densities for facilitating determining an amount of ink required by a printer..Iaddend..Iadd.49. The system as recited in claim 45 wherein said means for generating comprises:
a processor for composing a layout of said at least one image..Iaddend..Iadd.50. The system as recited in claim 45 wherein said generating means comprises means for generating a histogram corresponding to densities associated with at least a portion of said image..Iaddend..Iadd.51. The system as recited in claim 45 wherein said system further comprises means for determining an amount of ink to be used by a workpiece using said image data and said at least one parameter.

.Iaddend..Iadd.52. The system as recited in claim 51 wherein said workpiece comprises a cylinder..Iaddend..Iadd.53. A system for managing ink comprising:

input means for inputting at least one parameter; and
means for receiving image data for at least a portion of an image to be engraved; for determining densities associated with said image; and also for using said at least one parameter and said densities for facilitating the management of ink;
said means for receiving further comprising;
means for determining a cell description using cell shape parameters..Iaddend..Iadd.54. The system as recited in claim 53 wherein said system further comprises:
tuning means for tuning said cell description using said at least one

parameter..Iaddend..Iadd.55. The system as recited in claim 54 wherein said at least one parameter comprises at least one of the following: channel width, taper, circumferential linearization, balance correction, edge enhancement, density threshold levels, fast forward, screen, screen angle, highlight cell width, wall size, vertical spacing, channel voltage, highlight voltage, channel depth, cell depth, cell length, shadow voltage, shadow cell width and/or stylus angle..Iaddend..Iadd.56. A system for managing ink comprising:

input means for inputting at least one parameter; and
means for receiving image data for at least a portion of an image to be engraved; for determining densities associated with said image; and also for using said at least one parameter and said densities for facilitating the management of ink;
said at least one parameter comprising at least one of the following; channel width, taper, circumferential linearization, balance correction, edge enhancement, density threshold levels, fast forward, screen, screen angle, highlight cell width, wall size, vertical spacing, channel voltage, highlight voltage, channel depth, cell depth, cell length, shadow voltage,

shadow cell width and/or stylus angle..Iaddend..Iadd.57. A system for managing ink comprising:

input means for inputting at least one parameter; and
means for receiving image data for at least a portion of an image to be engraved; for determining densities associated with said image; and also for using said at least one parameter and said densities for facilitating the management of ink;
said means for receiving uses the following formula to determine an amount of ink: ##EQU20##.theta. is a stylus tip angle; s is screen in lines/micron;
b is a length of a side of a normal cell is microns; ##EQU21## P is the period of the sine wave mentioned earlier herein;.phi. is a screen angle;
D.sub.0 =depth of channel in microns; and

D.sub.1 =total depth a stylus travels into copper..Iaddend..Iadd.58. A system for managing ink comprising:

input means for inputting at least one parameter; and
means for receiving image data for at least a portion of an image to be engraved; for determining densities associated with said image; and also for using said at least one parameter and said densities for facilitating the management of ink;
said means for receiving uses the following formula to determine an amount of ink: ##EQU22##.theta. is a stylus tip angle; s is screen in lines/micron;
b is a length of a side of a normal cell in microns; ##EQU23## P is the period of the sine wave mentioned earlier herein; ##EQU24## L is the cell length in direction of cutting; D.sub.1 is a depth of a cell; and
D.sub.0 is the amplitude of a sine wave (to be derived from user inputs)

minus the depth of the cell..Iaddend..Iadd.59. A method for managing ink comprising the steps of:

inputting at least one parameter associated with an area for receiving ink;
receiving image data for at least a portion of an image to be engraved without simultaneously rotatably scanning said portion of said image to be engraved;
determining densities associated with said image; and
using said at least one parameter and said densities for facilitating the management of ink..Iaddend..Iadd.60. The method as recited in claim 59 wherein said method further comprises the step of:
determining an amount of ink in response to both said at least one parameter and said densities..Iaddend..Iadd.61. The method as recited in claim 59 wherein said method further comprises the step of:

composing a layout of said at least one image..Iaddend..Iadd.62. The method as recited in claim 59 wherein said method further comprises the step of:

determining an amount of ink to be used by a workpiece using said image data and said at least one parameter..Iaddend..Iadd.63. The method as recited in claim 62 wherein said workpiece comprises a cylinder..Iaddend..Iadd.64. A method for managing ink comprising the steps of:
inputting at least one parameter;
receiving image data for at least a portion of an image to be engraved;
determining densities associated with said image;
using said at least one parameter and said densities for facilitating the management of ink; and
generating a histogram corresponding to densities associated with said at least a portion of said image..Iaddend..Iadd.65. A method for managing ink comprising the steps of:
inputting at least one parameter;
receiving image data for at least a portion of an image to be engraved;
determining densities associated with said image;
using said at least one parameter and said densities for facilitating the management of ink; and
determining a cell description using cell shape parameters.

.Iaddend..Iadd. 6. The method as recited in claim 65 wherein said method further comprises the step of:

tuning said cell description using said at least one parameter..Iaddend..Iadd.67. The method as recited in claim 66 wherein said method further comprises the step of:
inputting at least one parameter comprising at least one of the following: channel width, taper, circumferential linearization, balance correction, edge enhancement, density threshold levels, fast forward, screen, screen angle, highlight cell width, wall size, vertical spacing, channel voltage, highlight voltage, channel depth, cell depth, cell length, shadow voltage, shadow cell width and/or stylus angle..Iaddend..Iadd.68. A method for managing ink comprising the steps of:
inputting at least one parameter;
receiving image data for at least a portion of an image to be engraved;
determining densities associated with said image;
using said at least one parameter and said densities for facilitating the management of ink; and
inputting at least one parameter comprising at least one of the following: channel width, taper, circumferential linearization, balance correction, edge enhancement, density threshold levels, fast forward, screen, screen angle, highlight cell width, wall size, vertical spacing, channel voltage, highlight voltage, channel depth, cell depth, cell length, shadow voltage,

shadow cell width and/or stylus angle..Iaddend..Iadd.69. A method for managing ink comprising the steps of:

inputting at least one parameter;
receiving image data for at least a portion of an image to be engraved;
determining densities associated with said image;
using said at least one parameter and said densities for facilitating the management of ink; and
using the following equation to determine an amount of ink: ##EQU25##.theta. is a stylus tip angle; s is screen in lines/micron;
b is a length of a side of a normal cell in microns; ##EQU26## P is the period of the sine wave mentioned earlier herein;.phi. is a screen angle;
D.sub.0 =depth of channel in microns; and

D.sub.1 =total depth a stylus travels into copper..Iaddend..Iadd.70. A method for managing ink comprising the steps of:

inputting at least one parameter;
receiving image data for at least a portion of an image to be engraved;
determining densities associated with said image;
using said at least one parameter and said densities for facilitating the management of ink; and
using the following equation to determine an amount of ink; ##EQU27##.theta. is a stylus tip angle; s is screen in lines/micron;
b is a length of a side of a normal cell in microns; ##EQU28## P is the period of the sine wave mentioned earlier herein; ##EQU29## L is the cell length in direction of cutting; D.sub.1 is a depth of a cell; and
D.sub.0 is the amplitude of a sine wave (to be derived from user inputs)

minus the depth of the cell..Iaddend..Iadd.71. An engraving system comprising:

an engraver having an engraving head for engraving a workpiece; and
a computer coupled to said engraver for inputting at least one parameter associated with an engraved area for receiving ink, for receiving image data for at least a portion of an image to be engraved without simultaneously rotatably scanning said portion of said image to be engraved; for determining densities associated with said image; and also for using said at least one parameter and said densities for facilitating the management of ink..Iaddend..Iadd.72. The engraving system as recited in claim 71 wherein said computer further comprises:
means for determining an amount of ink in response to both said at least one parameter and said densities..Iaddend..Iadd.73. The engraving system as recited in claim 72 wherein said amount of ink comprises a volume of ink..Iaddend..Iadd.74. The engraving system as recited in claim 71 wherein said computer further comprises:
a processor for composing a layout of said at least one image.

.Iaddend..Iadd.75. The engraving system as recited in claim 71 wherein said computer further comprises means for determining an amount of ink to be used by a workpiece using said image data and said at least one parameter..Iaddend..Iadd.76. The engraving system as recited in claim 75 wherein said workpiece comprises a cylinder..Iaddend..Iadd.77. An engraving system comprising:

an engraver having an engraving head for engraving a workpiece; and
a computer coupled to said engraver for inputting at least one parameter, for receiving image data for at least a portion of an image to be engraved; for determining densities associated with said image; and also for using said at least one parameter and said densities for facilitating the management of ink;
said computer further comprising:
generating means for generating a histogram corresponding to densities associated with at least a portion of said image..Iaddend..Iadd.78. The engraving system as recited in claim 77 wherein said generating means comprises:
means for determining a cell description using cell shape parameters..Iaddend..Iadd.79. The engraving system as recited in claim 78 wherein said computer further comprises:
tuning means for tuning said cell description using said at least one

parameter..Iaddend..Iadd.80. The engraving system as recited in claim 79 wherein said at least one parameter comprises at least one of the following; channel width, taper, circumferential linearization, balance correction, edge enhancement, density threshold levels, fast forward, screen, screen angle, highlight cell width, wall size, vertical spacing, channel voltage, highlight voltage, channel depth, cell depth, cell length, shadow voltage, shadow cell width and/or stylus angle..Iaddend..Iadd.81. An engraving system comprising:

an engraver having an engraving head for engraving a workpiece; and
a computer coupled to said engraver for inputting at least one parameter, for receiving image data for at least a portion of an image to be engraved; for determining densities associated with said image; and also for using said at least one parameter and said densities for facilitating the management of ink;
said at least one parameter comprises at least one of the following; channel width, taper, circumferential linearization, balance correction, edge enhancement, density threshold levels, fast forward, screen, screen angle, highlight cell width, wall size, vertical spacing, channel voltage, highlight voltage, channel depth, cell depth, cell length, shadow voltage,

shadow cell width and/or stylus angle..Iaddend..Iadd.82. An engraving system comprising:

an engraver having an engraver head for engraving a workpiece; and
a computer coupled to said engraver for inputting at least one parameter, for receiving image data for at least a portion of an image to be engraved; for determining densities associated with said image; and also for using said at least one parameter and said densities for facilitating the management of ink;
wherein said computer uses the following formula to determine an amount of ink: ##EQU30##.theta. is a stylus tip angle; s is screen in lines/microns;
b is a length of a side of a normal cell in microns; ##EQU31## P is the period of the sine wave mentioned earlier herein;.phi. is a screen angle;
D.sub.0 =depth of channel in microns; and

D.sub.1 =total depth a stylus travels into copper..Iaddend..Iadd.83. An engraving system comprising:

an engraver having an engraver head for engraving a workpiece; and
a computer coupled to said engraver for inputting at least one parameter, for receiving image data for at least a portion of an image to be engraved; for determining densities associated with said image; and also for using said at least one parameter and said densities for facilitating the management of ink;
wherein said computer uses the following formula to determine an amount of ink: ##EQU32##.theta. is a stylus tip angle; s is screen in lines/micron;
b is a length of a side of a normal cell in microns; ##EQU33## P is the period of the sine wave mentioned earlier herein; ##EQU34## L is the cell length in direction of cutting;.sub.D is a depth of a cell; and
D.sub.0 is the amplitude of a sine wave (to be derived from user inputs) minus the depth of the cell..Iaddend.
Referenced Cited
U.S. Patent Documents
3918348 November 1975 Runft
3931570 January 6, 1976 George et al.
4003311 January 18, 1977 Bardin
4072928 February 7, 1978 Wilder
4451856 May 29, 1984 Buechler
4628728 December 16, 1986 Taylor et al.
4944593 July 31, 1990 Kalstroem et al.
5029011 July 2, 1991 Fraser
5036403 July 30, 1991 Hupka et al.
5293426 March 8, 1994 Wouch et al.
5387976 February 7, 1995 Lesniak
5414452 May 9, 1995 Accatino et al.
5438864 August 8, 1995 Morgan
5519418 May 21, 1996 Nishikawa et al.
Foreign Patent Documents
2012213 July 1979 GBX
Other references
  • The Gravure Association of America, The gravure Engraving Manual (1987). Heimann GmbH, Drucktechnishe Beratung-Graphischer Handel (Pamphlet, Hamm, Germany, 1984). Heimann GmbH, Check-Master (Pamphlet, Date Unknown). Ahauser Tiefdruck-Gravuren GmbH & Co., Engraving Tester ET2000 (Pamphlet, Date Unknown). Promatec Graphique, M2B2 modele depose Micro Surface Sarl (Pamphlet, Antony, France, 1987). VIP-Video-Image-Processing (Pamphlet, Author unkown, date unkown). "How much flexo or gravure ink do you need?", author unknown, pp. 20-21 (Jan., 1973).
Patent History
Patent number: RE35911
Type: Grant
Filed: Mar 28, 1997
Date of Patent: Sep 29, 1998
Assignee: Ohio Electronic Engravers, Inc. (Dayton, OH)
Inventors: David R. Seitz (Vandalia, OH), Juli Ann Stuve (Dayton, OH)
Primary Examiner: Eric Frahm
Law Firm: Jacox, Meckstroth & Jenkins
Application Number: 8/828,321
Classifications
Current U.S. Class: 358/299; 356/379
International Classification: B41C 102; G01C 1128;