When multi-color information is to be imaged or printed in a printer or press, a final compound color is generally obtained by superimposing print separations that each have a different basic color. Depending on the application, three, four, five or even more separations may be employed and may be printed consecutively on a printing medium. The superposition or alignment of print separations gives the impression of a full color image having colors that may be different from the basic colors. However, this requires that the pixels of the different color separations be properly aligned with each other. The alignment process and the alignment itself are called registration. Color plane registration (CPR) errors can cause visible print artifacts, if the alignment error is greater than some threshold level, for instance 50 microns. The CPR error tend to vary over time and when the printed image or printing conditions change, such as when printing on different types of paper.
Modern printing systems, such as digital presses and high speed printers, have therefore been equipped with automated means to regularly measure the CPR errors. For instance, calibration marks may be printed on a test page, and an imaging device, such as an in-line scanner or camera, captures an image of the printed marks. The image may then be analyzed to determine the CPR error. For instance, the distance between the printed separation marks of different color separations or the optical density of the printed marks may be measured and analyzed to determine a mis-registration between different separations. Once the CPR error has been determined, the printing system can be adjusted to correct for the error.
However, even with these corrections the printing results are often still unsatisfactory.
a and 2b illustrate an exemplary calibration pattern used for color plane registration, wherein
a and 3b illustrate the effects of horizontal (
c illustrates the effects of tilt errors in an image capturing device.
A method for monitoring an image capturing device according to an example comprises a step of determining a distortion of an image of a printing medium, said image being an image that has been captured by means of an image capturing device, wherein said image comprises a calibration pattern with a plurality of calibration marks printed on said printing medium, said calibration pattern comprising at least a first sub-set of calibration marks relating to a first separation and a second sub-set of calibration marks relating to a second separation. Said distortion is determined by analyzing said first sub-set of calibration marks, and said image is corrected based on said determined distortion. The method further comprises a step of determining a displacement of said second sub-set of calibration marks with respect to said first sub-set of calibration marks.
A printing medium may be any medium onto which an image with a calibration pattern may be applied. The printing medium may be a sheet of paper fed into a printer. However, the printing medium may also be an intermediate transfer medium that bears an image before it is being passed on or transferred to some other medium. An example of a transfer medium is a transfer drum in a press.
In an example, said distortion comprises a tilt and/or a horizontal scaling and/or a vertical scaling of said first sub-set of calibration marks.
Said first separation and said second separation may be printed consecutively.
Said first separation and said second separation may be printed consecutively either on a printing medium such as a sheet of paper, or on a transfer medium from which the separations are subsequently transferred to the printing medium.
Said calibration pattern may further comprise a third sub-set of calibration marks relating to a third separation, and said method may comprise a step of determining a displacement of said third sub-set of calibration marks with respect to said first sub-set of calibration marks.
In an example, said distortion may be determined by analyzing only said first sub-set of calibration marks. In particular, said distortion may be determined without analyzing said second sub-set and/or further sub-sets of calibration marks.
The step of correcting said image based on said determined distortion may comprise the step of correcting both said first sub-set of calibration marks and said second sub-set of calibration marks, and possibly further sub-sets of calibration marks.
In an example, said first sub-set of calibration marks comprises a plurality of calibration marks arranged in an array of rows and columns. The calibration marks may include circles or squares, or any other suitable geometric form.
Said step of analyzing said first sub-set of calibration marks may comprise the steps of determining horizontal and/or vertical distances between neighboring calibration marks, and comparing the distances with predetermined reference distances.
In an example, said step of analyzing said first sub-set of calibration marks may comprise a step of fitting said plurality of calibration marks to a grid pattern. The fitting may comprise a least-mean-square fit.
In an example said step of analyzing said first sub-set of calibration marks may comprise a step of determining a horizontal tilt angle and/or vertical tilt angle of said grid pattern with respect to a predetermined reference direction.
Said step of correcting said image may comprise the steps of determining horizontal and/or vertical distances in said grid pattern, comparing said horizontal and/or vertical distances to predetermined reference distances to determine horizontal and/or vertical scaling factors, and applying said scaling factors to said first sub-set of calibration marks to obtain a corrected grid pattern. Said scaling factors may further be applied to said second sub-set of calibration marks, and possibly to further sub-sets of calibration marks.
In an example, said step of determining said displacement of said second sub-set of calibration marks with respect to said first sub-set of calibration marks may comprise a step of comparing said second sub-set of calibration marks to which said scaling factors have been applied with said corrected grid pattern.
Said second sub-set of calibration marks may comprise at least one calibration mark, in particular a circle or a square.
Said distortion of said calibration pattern may be determined and corrected continuously or at regular intervals for a plurality of printing media printed consecutively. In particular, the method according to the present invention allows an image capturing device of a printing system or a press to self-monitor distortions and to auto-calibrate continuously to compensate for tilt and/or scaling errors.
Said displacement of said second sub-set of calibration marks with respect to said first sub-set of calibration marks may likewise be determined continuously or at regular intervals for said plurality of printing media printed consecutively.
In an example, the method further comprises the step of printing said calibration pattern on said printing medium and/or the step of capturing an image of said calibration pattern by means of said image capturing device.
In this aspect, the improvement may relate to a method for monitoring an image capturing device, comprising the steps of printing a calibration pattern comprising a plurality of calibration marks on a printing medium, said calibration pattern comprising at least a first sub-set of calibration marks relating to a first separation and a second sub-set of calibration marks relating to a second separation. The method according to this aspect further comprises the steps of capturing an image of said calibration pattern by means of an image capturing device, determining a distortion of said image by analyzing said first sub-set of calibration marks, wherein said distortion comprises at least a tilt and/or a scaling of said calibration pattern, correcting said image based on said determined distortion, and determining a displacement of said second sub-set of calibration marks with respect to said first sub-set of calibration marks based on said corrected image.
The invention also relates to a system for monitoring an image capturing device, said system comprising an evaluation means to determine a distortion of an image of a printing medium, said image having been captured by means of an image capturing device, wherein said image comprises a calibration pattern with a plurality of calibration marks printed on said printing medium, wherein said calibration pattern comprises at least a first sub-set of calibration marks relating to a first separation and a second sub-set of calibration marks relating to a second separation. Said evaluation means determines said distortion by analyzing said first sub-set of calibration marks. The system further comprises a correction means to correct said image based on said determined distortion, and to determine a displacement of said second sub-set of calibration marks with respect to said first sub-set of calibration marks.
In an example, said evaluation means determines a tilt and/or a scaling of said first sub-set of calibration marks.
The system may further comprise a printing means to print said calibration pattern comprising said plurality of calibration marks on said printing medium.
The system may also comprise said image capturing device to capture said image of said calibration pattern.
In an aspect, the improvement relates to a printing device comprising a printing means to print a calibration pattern on a printing medium, said calibration pattern comprising at least a first sub-set of calibration marks relating to a first separation and a second sub-set of calibration marks relating to a second separation. In this aspect, the printing device may further comprise an image capturing device to capture an image of said calibration pattern, an evaluation means to determine a distortion of said image, wherein said distortion comprises at least a tilt and/or a scaling of said calibration pattern and wherein said evaluation means determines said distortion by analyzing said first sub-set of calibration marks, and a correction means to correct said image based on said determined distortion, and to determine a displacement of said second sub-set of calibration marks with respect to said first sub-set of calibration marks.
Said image capturing device may comprise a camera and/or a scanner, in particular an in-line camera or an in-line scanner.
The improvement also relates to a computer-readable medium comprising computer-readable instructions, wherein said computer-readable instructions, when read in a computer device, cause said computer device to perform a method with some or all of the steps as described above.
Examples will now be described in greater detail with reference to
Each of the imaging stations 14a to 14d corresponds to a different print separation with a different basic color. The different separations are printed consecutively, and the full color image that results is a superposition of the different print separations. The schematic illustration of
However, the schematic drawing of
The printing medium with the superimposed image may be captured by means of an image capturing device, such as an in-line camera 16. The image data is passed to a control device 18 via a data line 20. The control device 18 checks the alignment and the superposition of the print separations, and may adjust the print settings at each of the imaging stations 14a to 14d via respective control lines 22a to 22d, if the separations are printed out of registration. This process is usually called color plane registration, and is described in further detail in related applications U.S. Pat. No. 6,456,311 B1, U.S. Pat. No. 7,679,630 B2, and US 2012/0105876 A1.
Conventional color plane registration often involves the printing of designated calibration patterns on a printing medium that facilitate to check whether the color separations are properly aligned. Such calibration patterns typically comprise calibration marks of each of the basic colors, which may be printed either on designated test pages or in the side margins and/or top margins of regular print pages. Some such calibration patterns and their analysis are described in further detail in U.S. '630 and U.S. '876. Modern presses or high speed printers sometimes print calibration patterns on every single page that is printed, to allow for a continuous analysis and correction of the color plane registration.
An exemplary calibration pattern 24 as it may be printed in the top margin or side margin of a printing medium is shown in
In the calibration pattern 24, the black calibration marks 26a to 26e form a first sub-set that serves as a reference against which deviations of the other calibration marks 28, 30 and 32 may be measured.
The inventors found that one reason for the persistence of CPR errors despite the measures described above are distortions in the image capturing device itself, such as horizontal scaling, vertical scaling and skew alignment errors of the in-line camera 16 or in-line scanner. Such errors may be due to imprecise assembly of the device, but may also be due to drift over time and noise and tilt along the print run. Although the in-line camera 16 is calibrated to be perfectly aligned, this procedure has limited accuracy and cannot result in zero tilt. In addition, the in-line camera 16 may suffer from drift along time and noise and tilt along run. The distortion of the imaging capturing device field of view can also suffer from drift along run, which may result in horizontal and vertical scaling.
a shows an image of the ideal calibration pattern shown in
c shows another image of the perfect calibration pattern shown in
Distortions in the image capturing device 16 may hence lead to erroneous color plane registration correction, which may introduce rather than correct registration errors.
The inventors found that these errors may be avoided with a method and system for monitoring and calibrating the image capturing device, using a first sub-set of calibration marks as a reference to correct for scaling and tilt errors introduced by the image capturing device. An example of the method and system according to the invention will now be described in detail with reference to
The reference grid 34 may be determined by first determining the centers of each of the circular calibration marks 26a to 26e, and then fitting a rectangular grid to the circles, wherein the vertices of the grid correspond to the centers of the circles. The fit may involve a least-mean-square fit, but other techniques may be employed as well.
Once the reference grid 34 has been obtained, a tilt angle α between the reference grid 34 and a horizontal or vertical reference direction is determined. As illustrated in
Next, the horizontal distances x and the vertical distances y between neighboring vertices in the reference grid 34 are determined, as illustrated in
The corrected image shown in
The control device 18 may store the determined tilt angle α and the horizontal and vertical scaling factors x0/x and y0/y determined from the reference grid 34 to process further data captured by the in-line camera 16. The calibration pattern 24 may be printed in the top margin or side margin of every page that is printed. Every page may then be captured by means of the in-line camera 16, and forwarded for analysis to the control device 18 via data line 20. Every printed calibration pattern may hence be analyzed as described with reference to
The description of the preferred embodiments and the Figures merely serves to illustrate the invention and the numerous advantages it entails, but should not be understood to imply any limitation. The scope of the invention is to be determined solely by means of the appended claims.