ColourBrain® High speed inspection of digital printed decor Baumer Inspection Gmbh INPRINT 2015 Seite: 1

Baumer Inspection Gmbh INPRINT 2015 Seite: 2 Titel:High Speed Inspection of digital printed decor, Autor:Thomas Franz Adresse:Baumer Inspection GmbH Lohnerhofstraße Konstanz 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.

Baumer An international family-owned enterprise Headquarter in Frauenfeld, Switzerland About 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 Baumer Inspection Gmbh INPRINT 2015 Seite: 3

Industry segments Baumer sets benchmarks © Baumer 2014 Baumer Inspection Gmbh INPRINT 2015 Seite: 4

Extensive product range The appropriate technology for every application © Baumer 2014 Baumer Inspection Gmbh INPRINT 2015 Seite: 5

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 Baumer Inspection Gmbh INPRINT 2015 Seite: 6

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. Baumer Inspection Gmbh INPRINT 2015 Seite: 7

ColourBrain ® DecoPrint: Décor foil inspection Décor paper inspection Baumer Inspection Gmbh INPRINT 2015 Seite: 8

ColourBrain® DecoPrint Integrated scanners: double sided inspection of PVC foil Baumer Inspection Gmbh INPRINT 2015 Seite: 9

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 Baumer Inspection Gmbh INPRINT 2015 Seite: 10

Why ? High speed scanners for digital printed decor Baumer Inspection Gmbh INPRINT 2015 Seite: 11

Inspection for Digital Décor Printing Considerations 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. Baumer Inspection Gmbh INPRINT 2015 Seite: 12

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. Baumer Inspection Gmbh INPRINT 2015 Seite: 13

What The specification of our scanner Baumer Inspection Gmbh INPRINT 2015 Seite: 14

Inspection for Digital Décor Printing Specs 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. Baumer Inspection Gmbh INPRINT 2015 Seite: 15

Inspection for Digital Décor Printing The 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. Baumer Inspection Gmbh INPRINT 2015 Seite: 16

What else? Our philosophy and our Target Baumer Inspection Gmbh INPRINT 2015 Seite: 17

Inspection for Digital Décor Printing Baumer‘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. Baumer Inspection Gmbh INPRINT 2015 Seite: 18

The visual appearance Patented 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 Baumer Inspection Gmbh INPRINT 2015 Seite: 19

Inspection for Digital Décor Printing Baumer‘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 Baumer Inspection Gmbh INPRINT 2015 Seite: 20 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 Baumer Inspection Gmbh INPRINT 2015 Seite: 21

 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 Printing The design of the test system Baumer Inspection Gmbh INPRINT 2015 Seite: 22

Print resolution resolution (Pixel/mm) Resolution (µm/pixel) Field of view of one module (mm) 600 dpi 0,0433mm Raster 23,62242µm173,4 720 dpi 0,0353mm Raster 28,34635µm144,498 Design of Modules Scaling the resolution of the inspection modules Baumer Inspection Gmbh INPRINT 2015 Seite: 23

High speed inspection for Digital Décor Printing System design Baumer Inspection Gmbh INPRINT 2015 Seite: 24

High speed inspection for Digital Décor Printing System design Baumer Inspection Gmbh INPRINT 2015 Seite: 25

High speed inspection for Digital Décor Printing System design Baumer Inspection Gmbh INPRINT 2015 Seite: 26

High speed inspection for Digital Décor Printing System design Baumer Inspection Gmbh INPRINT 2015 Seite: 27

Whats done already Baumer Inspection Gmbh INPRINT 2015 Seite: 28

 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 Printing Test installation Baumer Inspection Gmbh INPRINT 2015 Seite: 29

High speed inspection for Digital Décor Printing Test installation Baumer Inspection Gmbh INPRINT 2015 Seite: 30

High speed inspection for Digital Décor Printing Test installation Baumer Inspection Gmbh INPRINT 2015 Seite: 31

What about results Baumer Inspection Gmbh INPRINT 2015 Seite: 32

High speed inspection for Digital Décor Printing Nozzle out: raw and processed image Baumer Inspection Gmbh INPRINT 2015 Seite: 33

High speed inspection for Digital Décor Printing Nozzle out: raw and processed image Baumer Inspection Gmbh INPRINT 2015 Seite: 34

High speed inspection for Digital Décor Printing Print Head banding Baumer Inspection Gmbh INPRINT 2015 Seite: 35

High speed inspection for Digital Décor Printing Streaks Baumer Inspection Gmbh INPRINT 2015 Seite: 36

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 Printing Priorities are specified by test installation Baumer Inspection Gmbh INPRINT 2015 Seite: 37

What's next Baumer Inspection Gmbh INPRINT 2015 Seite: 38

Design of inspection system for digital printing Verantw: Franz / tfTeam: BasicstargetDatum: Prototype web wide Status Milestones > 2013 Kick off Q1/Q  samples and priorities  Definition of specs  Discussion with partners  Ordering and manufacturing of lab test system Q3Q  Lab test system  Design of illumination  Design of optics and camera  Mechanical design of first module prototype.  Images with spec samples Q1Q  Evaluation of algorithms by lab system.  Production of first prototype modules  Implementation of algorithms  Test with prototype module at first production sites. Q3Q  Optimizing prototype modules.  Ongoing Test with prototype module at more and different production sites. Q1Q  Design of first system for production line installation  Production of first inline system  Test and optimization at Baumer/Konstanz Q  Installation at clients plant. Transfer Konzept Analyse Definition High speed inspection for Digital Décor Printing Priorities are specified by test installation Baumer Inspection Gmbh INPRINT 2015 Seite: 39

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