DATA PROCESSING APPARATUS, DATA PROCESSING METHOD, PROGRAM, TEST APPARATUS, AND PRINTING SYSTEM

A data processing apparatus, a data processing method, a program, a test apparatus, and a printing system that may suppress a decrease in productivity caused by occurrence of an image defect are provided. A data processing apparatus acquires captured data of a printed image (160), specifies a defect position indicating a position of a defect in the printed image by analyzing the captured data (174), estimates one or more defective printing element candidates as candidates of a defective printing element (178), derives a probability that the defective printing element candidate actually causes occurrence of the defect (164), and provides notification of the probability that the defective printing element candidate actually causes the occurrence of the defect (168).

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a data processing apparatus, a data processing method, a program, a test apparatus, and a printing system.

2. Description of the Related Art

In an ink jet printing apparatus comprising an ink jet head, an image defect such as a streak may occur because of variation in jetting performance of the ink jet head such as a decrease in jetting performance of a nozzle. In a case where the jetting performance of the ink jet head varies, the jetting performance of the ink jet head can be recovered by performing maintenance such as wiping.

JP2013-208838A discloses an ink jet printing apparatus that detects a defect of a stain and a defect of a nozzle malfunction by comparing a density value in captured data of a printed image with a density value of reference printing data input into a printing unit.

In the apparatus according to JP2013-208838A, in a case where the nozzle malfunction has occurred, a head in which the defect has occurred is detected, a defective jetting part in the head in which the defect has occurred is specified, and notification of the head in which the defective jetting part is present is provided.

SUMMARY OF THE INVENTION

However, the nozzle malfunction detected in the apparatus according to JP2013-208838A is a defect that occurs with a specific frequency. In a case where a frequency with which a defect occurs is relatively high, and maintenance of the head is performed each time the defect occurs, this may result in a decrease in productivity.

As a countermeasure that avoids maintenance of the nozzle, it is considered to specify a nozzle in which the nozzle malfunction has occurred and perform jetting correction of the specified nozzle. However, in the apparatus according to JP2013-208838A, it is difficult to specify the nozzle in which the nozzle malfunction has occurred.

While an issue in the ink jet printing apparatus has been illustrated here, the same issue as the above issue is also present in a printing apparatus of other than an ink jet method such as a printing apparatus comprising a printing element of an electrophotographic method.

The present invention has been conceived in view of such circumstances, and an object of the present invention is to provide a data processing apparatus, a data processing method, a program, a test apparatus, and a printing system that may suppress a decrease in productivity caused by occurrence of an image defect.

In order to achieve the object, the following aspects of the invention are provided.

A data processing apparatus according to the present disclosure is a data processing apparatus comprising one or more processors, and one or more memories in which a program executed by the one or more processors is stored, in which the one or more processors are configured to, by executing an instruction of the program, acquire captured data generated by capturing a printed image printed on a printing medium, specify a defect position indicating a position of a defect in the printed image by analyzing the captured data, estimate one or more defective printing element candidates as candidates of a defective printing element from a plurality of printing elements provided in a printing head, from the defect position in the printed image, derive a probability that the defective printing clement candidate actually causes occurrence of the defect, and provide notification of defective printing element candidate information including the probability of actually causing the occurrence of the defect for each defective printing element candidate.

According to the data processing apparatus according to the present disclosure, the probability of actually causing the occurrence of the defect is derived and provided by notification for one or more defective printing element candidates estimated based on the defect position in the printed image. Accordingly, a user may employ processing that suppresses a decrease in productivity by eliminating the image defect, such as correction of the printing head and recovery processing of the printing head.

The printing element is provided in the printing head and forms a pixel constituting the printed image on the printing medium. Examples of the printing element include a nozzle provided in an ink jet head.

In the data processing apparatus according to another aspect, the one or more processors may be configured to derive a peak position in a profile of the defect from the captured data, and derive the probability that the defective printing element candidate actually causes the occurrence of the defect, based on the peak position.

According to the present aspect, the probability of actually causing the occurrence of the defect for each defective printing element candidate is derived based on the peak position in the profile of the defect.

In this aspect, the probability of actually causing the occurrence of the defect for each defective printing element candidate may be derived based on a distance between the peak position in the profile of the defect and the defective printing element candidate.

In this aspect, the distance between each defective printing element candidate and the peak position in the profile of the defect may be calculated, and a ratio of the distance calculated for each defective printing element candidate may be used as the probability of actually causing the occurrence of the defect for each defective printing element candidate.

In the data processing apparatus according to another aspect, the one or more processors may be configured to derive the probability that the defective printing element candidate actually causes the occurrence of the defect, by applying a trained learning model.

According to the present aspect, the probability that the defective printing element candidate actually causes the occurrence of the defect may be derived with high accuracy.

In the data processing apparatus according to another aspect, the one or more processors may be configured to provide notification of a position of the defective printing element candidate in the printing head.

According to the present aspect, the user may perceive the position of the defective printing element candidate.

In the data processing apparatus according to another aspect, the one or more processors may be configured to provide notification of a printing element number assigned to the printing elements provided in the printing head for the defective printing element candidate.

According to the present aspect, the user may perceive the number of the defective printing element candidate.

In the data processing apparatus according to another aspect, the one or more processors may be configured to provide notification of a color printed by the defective printing element candidate.

According to the present aspect, the user may perceive the color printed by the defective printing element candidate.

In the data processing apparatus according to another aspect, the one or more processors may be configured to provide notification of an occurrence frequency of the defective printing element candidate.

According to the present aspect, the user may perceive the occurrence frequency of the defective printing clement candidate.

In the data processing apparatus according to another aspect, the one or more processors may be configured to provide notification of an occurrence count of the defective printing element candidate.

According to the present aspect, the user may perceive the occurrence count of the defective printing element candidate.

A data processing method according to the present disclosure is a data processing method comprising, via a computer, acquiring captured data generated by capturing a printed image printed on a printing medium, specifying a defect position indicating a position of a defect in the printed image by analyzing the captured data, estimating one or more defective printing clement candidates as candidates of a defective printing element from a plurality of printing elements provided in a printing head, from the defect position in the printed image, deriving a probability that the defective printing element candidate actually causes occurrence of the defect, and providing notification of defective printing element candidate information including the probability of actually causing the occurrence of the defect for each defective printing element candidate.

A program according to the present disclosure is a program causing a computer to implement a function of acquiring captured data generated by capturing a printed image printed on a printing medium, a function of specifying a defect position indicating a position of a defect in the printed image by analyzing the captured data, a function of estimating one or more defective printing element candidates as candidates of a defective printing element from a plurality of printing elements provided in a printing head, from the defect position in the printed image, a function of deriving a probability that the defective printing clement candidate actually causes occurrence of the defect, and a function of providing notification of defective printing element candidate information including the probability of actually causing the occurrence of the defect for each defective printing element candidate.

A test apparatus according to the present disclosure is a test apparatus comprising an imaging apparatus that captures a printed image printed on a printing medium, one or more processors, and one or more memories in which a program executed by the one or more processors is stored, in which the one or more processors are configured to, by executing an instruction of the program, acquire captured data generated using the imaging apparatus, specify a defect position indicating a position of a defect in the printed image by analyzing the captured data, estimate one or more defective printing element candidates as candidates of a defective printing element from a plurality of printing elements provided in a printing head, from the defect position in the printed image, derive a probability that the defective printing clement candidate actually causes occurrence of the defect, and provide notification of defective printing element candidate information including the probability of actually causing the occurrence of the defect for each defective printing element candidate.

A printing system according to the present disclosure is a printing system comprising one or more printing heads, a moving apparatus that relatively moves the printing head and a printing medium, an imaging apparatus that captures a printed image printed on the printing medium using the printing head, a data processing apparatus that processes captured data generated using the imaging apparatus, one or more first processors, and one or more first memories in which a first program executed by the one or more first processors is stored, in which the one or more first processors are configured to, by executing an instruction of the first program, acquire captured data generated by capturing the printed image printed on the printing medium, specify a defect position indicating a position of a defect in the printed image by analyzing the captured data, estimate one or more defective printing element candidates as candidates of a defective printing element from a plurality of printing elements provided in the printing head, from the defect position in the printed image, derive a probability that the defective printing element candidate actually causes occurrence of the defect, and provide notification of defective printing element candidate information including the probability of actually causing the occurrence of the defect for each defective printing clement candidate.

The printing system according to another aspect may further comprise a recovery processing apparatus that performs recovery processing on the printing head.

According to the present aspect, the user who has perceived the defective printing clement candidate may perform the recovery processing on the printing head.

A cleaning apparatus that cleans the printing head may be applied as the recovery processing apparatus. Cleaning of the printing head may include wiping of a printing surface.

The printing system according to another aspect may further comprise one or more second processors, and one or more second memories in which a second program executed by the one or more second processors is stored, in which the one or more second processors are configured to, by executing an instruction of the second program, perform the recovery processing of the defective printing element candidate using the recovery processing apparatus.

According to the present aspect, the user may perform the recovery processing of the defective printing element candidate using the recovery processing apparatus.

In the printing system according to another aspect, the one or more first processors may be configured to provide notification indicating that replacement of the printing head provided with the defective printing element candidate is required.

According to the present aspect, the user may determine whether or not to replace the printing head.

In a case where the printing head is configured to be partially replaceable, the user may replace a part of the printing head.

The printing system according to another aspect may further comprise one or more third processors, and one or more third memories in which a third program executed by the one or more third processors is stored, in which the one or more third processors are configured to, by executing an instruction of the third program, perform masking processing of masking the defective printing clement candidate as an unused printing element, and perform printing at a printing position at which the unused printing element performs printing, using a normal printing clement.

According to the present aspect, corrected printing in which the occurrence of the defect in the printed image is suppressed may be performed.

In the printing system according to another aspect, the one or more third processors may be configured to acquire information about a defective printing element stored in advance, perform masking processing of masking the defective printing element as the unused printing element, and perform printing at the printing position at which the unused printing element performs printing, using the normal printing element.

According to the printing system of the present aspect, corrected printing may be performed using the information about the defective printing element stored in advance.

According to the present disclosure, the probability of actually causing the occurrence of the defect is derived and provided by notification for one or more defective printing element candidates estimated based on the defect position in the printed image. Accordingly, the user may employ processing that suppresses a decrease in productivity by eliminating the image defect, such as correction of the printing head and recovery processing of the printing head.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, an embodiment of the present invention will be described in detail in accordance with the accompanying drawings. In the present specification, the same constituents will be designated by the same reference numerals, and duplicate descriptions will be omitted, as appropriate.

Overall Configuration of Ink Jet Printing System

FIG.1is an overall configuration diagram of an ink jet printing system according to the embodiment. Arrow lines illustrated inFIG.1indicate a substrate transport direction that is a transport direction of a film substrate1in each apparatus provided in an ink jet printing system10. The substrate transport direction indicates a direction in which the film substrate1proceeds.

The ink jet printing system10is a printing system to which a single pass method is applied and prints a color image on the film substrate1using aqueous color inks. The film substrate1is a transparent medium used for flexible packaging and is a non-permeable medium.

Examples of the film substrate1include oriented nylon (ONY), oriented polypropylene (OPP), and polyethylene terephthalate (PET). The ink jet printing system10creates a printed article of reverse printing that is visually recognized from a substrate support surface1B on a side opposite to a printing surface1A with respect to the film substrate1. The ink jet printing system10can also create a printed article of surface printing that is visually recognized from the printing surface1A.

Being non-permeable refers to having non-permeability with respect to an aqueous primer and an aqueous ink, described later. Flexible packaging refers to packaging using a material that deforms depending on a shape of an article to be packaged. Being transparent refers to having visible light transmittance of greater than or equal to 30% and less than or equal to 100% and preferably greater than or equal to 70% and less than or equal to 100%. The film substrate1according to the embodiment is an example of a printing medium.

The ink jet printing system10comprises a substrate supply apparatus12, a precoating apparatus14, a jetting apparatus16, a drying apparatus18, a test apparatus20, a collecting apparatus22, and a transport apparatus24. Hereinafter, each part will be described in detail.

Substrate Supply Apparatus

A transport method of a roll-to-roll method is applied to the ink jet printing system10. The substrate supply apparatus12comprises a feed roll on which the film substrate1before the image is printed is wound. The feed roll comprises a reel that is supported in a rotatable manner.

The substrate supply apparatus12may comprise a corona treatment apparatus that performs reforming processing on the printing surface1A of the film substrate1. The printing surface1A of the film substrate1on which the reforming processing is performed has surface free energy suitable for an aqueous mixture of the aqueous primer and the aqueous ink and may secure wettability suitable for the aqueous mixture. The film substrate1is transported to the precoating apparatus14.

The precoating apparatus14is disposed at a position that is downstream of the substrate supply apparatus12and upstream of the jetting apparatus16in the substrate transport direction. The precoating apparatus14coats the printing surface1A of the film substrate1with a precoating liquid.

The precoating apparatus14may comprise a precoating drying apparatus. The precoating drying apparatus dries the precoating liquid with which the film substrate1is coated. A liquid such as an aqueous primer liquid containing a component that insolubilizes or thickens the aqueous ink may be applied as the precoating liquid. The film substrate1that is coated with the precoating liquid and on which the precoating liquid is dried is transported to the jetting apparatus16.

Jetting Apparatus

The jetting apparatus16comprises an ink jet head30K, an ink jet head30C, an ink jet head30M, and an ink jet head30Y.

The ink jet head30K, the ink jet head30C, the ink jet head30M, and the ink jet head30Y jet a black ink, a cyan ink, a magenta ink, and a yellow ink, respectively. Hereinafter, the ink jet head30K and the like will be referred to as an ink jet head30unless otherwise required to distinguish therebetween.

The aqueous ink jetted from the ink jet head30refers to an ink obtained by dissolving or dispersing a coloring material such as a pigment in a solvent soluble in water. An organic-based pigment is used as the pigment of the aqueous ink. A viscosity of the aqueous ink is greater than or equal to 0.5 centipoises and less than or equal to 5.0 centipoises.

The ink jet head30prints the color image on the film substrate1by jetting the color inks to the printing surface1A of the film substrate1transported using the transport apparatus24.

A disposition and a posture in which a nozzle surface for jetting the ink is positioned and directed to face a substrate transport surface of a substrate transport path that is a transport path of the film substrate1are applied to the ink jet head30. The ink jet head30is disposed at an equal interval along the substrate transport direction.

The ink jet head30comprises a plurality of nozzles. The nozzles may include nozzle openings and ink flow channels. The ink jet head30comprises an energy generation element for each nozzle. A plurality of nozzle openings are disposed on the nozzle surface of the ink jet head30. A water-repellent film is formed on the nozzle surface of the ink jet head30.

Piezoelectric elements may be applied as the energy generation elements. The ink jet head30comprising the piezoelectric elements jets ink liquid droplets from the nozzle openings using flexural deformation of the piezoelectric elements. Heaters may be applied as the energy generation elements. The ink jet head30comprising the heaters jets ink liquid droplets from the nozzle openings using a film boiling phenomenon of the ink.

A line type head in which a plurality of nozzles are disposed along an overall length of the film substrate1in a substrate width direction is applied as the ink jet head30. The ink jet printing system10may perform printing of the single pass method of performing printing on an entire surface of a printing region of the film substrate1by relatively moving the ink jet head30and the film substrate1once. A serial type head may also be applied as the ink jet head30.

A structure in which a plurality of head modules are connected in the substrate width direction may be applied to the line type ink jet head30. The substrate width direction is a direction that is orthogonal to the substrate transport direction and that is parallel to the printing surface of the film substrate1. The substrate transport direction according to the embodiment is an example of a medium transport direction. The substrate width direction according to the embodiment is an example of a medium width direction.

While an aspect in which the aqueous ink of four colors is applied is illustrated inFIG.1, ink colors are not limited to the four colors of black, cyan, magenta, and yellow. For example, an aspect in which a light color ink of light magenta, light cyan, or the like is applied, or an aspect in which a specific color ink of white, green, orange, violet, clear, metallic, or the like is applied can be applied. In addition, a disposition order of the ink jet heads of each color is not limited to the example illustrated inFIG.1.

The jetting apparatus16comprises a scanner32. The scanner32comprises an imaging device that captures a test pattern image printed on the printing surface of the film substrate1and that converts a captured image into an electric signal.

InFIG.1, an illumination apparatus that irradiates the printing surface of the film substrate1with illumination light is not illustrated. In a case where a transparent film substrate1is applied, the illumination apparatus is disposed on a side of the film substrate1closer to the substrate support surface1B. Meanwhile, in a case where an opaque film substrate1such as paper is applied, the illumination apparatus is disposed on a side of the film substrate1closer to the printing surface1A.

The test pattern image may be referred to as a test chart, a test pattern, a test image, and the like. Examples of the test pattern image include a test pattern image referred to as a ladder pattern, a l-on N-off pattern, and the like.

Examples of the imaging device include a CCD image sensor and a color CMOS image sensor. CMOS is the abbreviation for Complementary Metal Oxide Semiconductor.

The ink jet printing system10specifies a defective nozzle in the ink jet head30based on read data of the test pattern image output from the scanner32. The ink jet printing system10performs jetting correction of the ink jet head30using defective nozzle information.

The film substrate1on which the test pattern image is captured using the scanner32is transported to the drying apparatus18.

The ink jet printing system10comprises a maintenance apparatus that performs maintenance of the ink jet head30. InFIG.1, the maintenance apparatus is not illustrated. The maintenance apparatus is illustrated inFIG.2using reference numeral70.

Drying Apparatus

The drying apparatus18is disposed at a position that is downstream of the jetting apparatus16in the substrate transport direction and that is upstream of the test apparatus20in the substrate transport direction. The drying apparatus18comprises a drying module that dries the aqueous ink adhered to the printing surface1A of the film substrate1. The film substrate1on which the aqueous ink is dried is transported to the test apparatus20.

Test Apparatus

The test apparatus20is disposed at a position that is downstream of the drying apparatus18in the substrate transport direction and that is upstream of the collecting apparatus22in the substrate transport direction. The test apparatus20tests whether or not there is a defect in a printed image printed on the film substrate1.

The test apparatus20comprises an imaging unit that captures the printed image, and an illumination unit that irradiates the film substrate1with illumination light. The ink jet printing system10may determine whether or not there is a defect in the printed image based on captured data of the printed image. The film substrate1for which the captured image is tested using the test apparatus20is transported to the collecting apparatus22.

Collecting Apparatus

The collecting apparatus22collects the film substrate1on which the image is printed. Specifically, the film substrate1on which the image is printed is wound onto a winding roll.

Transport Apparatus

The roll-to-roll method is applied to the transport apparatus24. The transport apparatus24transports the film substrate1from the substrate supply apparatus12to the collecting apparatus22along the substrate transport path in the substrate transport direction in an order of the substrate supply apparatus12, the precoating apparatus14, the jetting apparatus16, the drying apparatus18, the test apparatus20, and the collecting apparatus22. The substrate supply apparatus12and the collecting apparatus22may be included in the transport apparatus24.

The transport apparatus24comprises a plurality of pass rollers34. One or more pass rollers34are disposed in each of the substrate supply apparatus12, the precoating apparatus14, the jetting apparatus16, the drying apparatus18, the test apparatus20, and the collecting apparatus22.

The transport apparatus24comprises one or more tension pickups36disposed in each of the substrate supply apparatus12, the precoating apparatus14, the jetting apparatus16, the drying apparatus18, the test apparatus20, and the collecting apparatus22. The tension pickups36detect tension applied to the film substrate1. Detection signals of the tension pickups36are transmitted to a transport control portion. The transport control portion is illustrated inFIG.6using reference numeral102. InFIG.1, the tension pickup36provided in the jetting apparatus16is illustrated, and the tension pickups36provided in the substrate supply apparatus12and the like are not illustrated.

Configuration Example of Maintenance Apparatus

FIG.2is a schematic diagram illustrating a configuration example of the maintenance apparatus applied to the ink jet printing system illustrated inFIG.1. The maintenance apparatus70illustrated inFIG.2is disposed to be arranged with the jetting apparatus16in a direction passing through the page ofFIG.1.

The maintenance apparatus70illustrated inFIG.2comprises a head moving apparatus72, a wiping apparatus74, and a capping apparatus76. The head moving apparatus72moves the ink jet head30between a printing position and maintenance positions.

FIG.2illustrates a configuration in which a carriage80connected to the ink jet head30and a guide82for supporting the carriage80are comprised, as a configuration example of the head moving apparatus72. InFIG.4, a linear motion mechanism connected to the carriage80and a motor and the like connected to the linear motion mechanism are not illustrated.

The printing position is a position of the ink jet head30at which printing is performed on the film substrate1by jetting the ink from the ink jet head30. InFIG.2, the ink jet head30positioned at the printing position is illustrated using a solid line. The maintenance positions are positions of the ink jet head30at which the maintenance of the ink jet head30is performed.

The maintenance of the ink jet head30includes wiping of nozzle surfaces37to which the wiping apparatus74is applied, purging that discharges the ink to the capping apparatus76from the nozzle openings by operating a jetting element of each nozzle, and moisturizing to which a moisturizing liquid inside the capping apparatus76is applied.

The capping apparatus76is connected to a discharge tank90through a discharge flow channel86and a discharge pump88. The ink discharged to the capping apparatus76is fed to the discharge tank90by operating the discharge pump88.

InFIG.2, the ink jet head30at a position at which the maintenance to which the capping apparatus76is applied is performed among the maintenance positions is illustrated using a dot-dashed line. The maintenance positions include a position at which the wiping of the nozzle surfaces37is performed using the wiping apparatus74.

The wiping apparatus74wipes the nozzle surfaces37of the ink jet head30moving along the guide82by causing a web that is a wiping member having a sheet shape to travel and bringing the traveling web into contact with the nozzle surfaces37.

The maintenance apparatus70comprises a head elevating apparatus. The head elevating apparatus elevates the ink jet head30at the printing position. In addition, the head elevating apparatus elevates the ink jet head30in a case where purging processing of the ink jet head30is performed and in a case where moisturizing processing of the ink jet head30is performed using the capping apparatus. The head elevating apparatus is not illustrated.

Raising of the ink jet head30is moving of the ink jet head30in an upward direction of a height direction indicated using reference numeral Z inFIG.5. Lowering of the ink jet head30is moving of the ink jet head30in a downward direction of the height direction. The upward direction is a direction having a component in a vertical upward direction, and the downward direction is a direction having a component in a vertical downward direction. The maintenance apparatus70illustrated inFIG.2is an example of a recovery processing apparatus that performs recovery processing of a defective printing element candidate. [Configuration Example of Ink Jet Head]

FIG.3is a perspective view illustrating a configuration example of the ink jet head. The ink jet head30illustrated inFIG.3has a structure in which a plurality of head modules38are linearly connected along a longitudinal direction of the ink jet head30. The plurality of head modules38are integrated and supported using a head frame39.

The ink jet head30is a line head in which a plurality of nozzles are disposed along a length corresponding to an overall width of the film substrate1in the substrate width direction. InFIG.3, the nozzles are not illustrated. The nozzles are illustrated with reference numeral40inFIG.4.

Plane shapes of the nozzle surfaces37of the head modules38are parallelograms. Dummy plates39A are attached to both ends of the head frame39. The plane shapes of the nozzle surfaces37of the ink jet head30form an oblong shape as a whole together with the head modules38and the dummy plates39A.

Flexible substrates31are attached to the head modules38. The flexible substrates31are wiring members that transmit drive voltages to be supplied to the head modules38. One end of the flexible substrates31is electrically connected to the head modules38, and the other end of the flexible substrates31is electrically connected to a drive voltage supply circuit. The drive voltage supply circuit is not illustrated.

Each of the plurality of head modules38provided in the ink jet head30can be associated with module numbers indicating positions of the head modules38in an order from the head module38disposed at one end of the ink jet head30.

FIG.4is a plan view illustrating a nozzle disposition example of the ink jet head illustrated inFIG.3. A center part of the nozzle surface37of each head module38comprises a nozzle disposition portion38C having a strip shape. The nozzle disposition portion38C actually functions as the nozzle surface37.

A plurality of nozzles40are disposed in the nozzle disposition portion38C. The nozzles40include nozzle openings42formed on the nozzle surface37. A structure example of the nozzles40will be described later. In the following description, disposition of the nozzles40may be replaced with disposition of the nozzle openings42.

The head module38illustrated inFIG.4has a plane shape of a parallelogram having an edge surface on a long edge side along a direction V having an inclination of an angle β with respect to the substrate width direction illustrated with reference numeral X and an edge surface on a short edge side along a direction W having an inclination of an angle a with respect to the substrate transport direction illustrated with reference numeral Y.

In the head module38, the plurality of nozzles40are disposed in a matrix in a row direction along the direction V and a column direction along the direction W. The nozzles40may be disposed along a row direction along the substrate width direction and a column direction that obliquely intersects with the substrate width direction.

In the case of the ink jet head30in which the plurality of nozzles40are disposed in a matrix, a projected nozzle column obtained by projecting each nozzle40in the matrix disposition along the column direction of the nozzles can be considered to be equivalent to one nozzle column in which each nozzle40is arranged at an almost equal interval in the column direction of the nozzles with a density for achieving a maximum recording resolution. The projected nozzle column is a nozzle column obtained by orthogonally projecting each nozzle40in the matrix disposition along the column direction of the nozzles.

The almost equal interval means an actually equal interval as a jetting point recordable in a printing apparatus. For example, a concept of an equal interval also includes a case where an interval is slightly varied by taking into consideration at least one of manufacturing error or moving of a liquid droplet on the substrate caused by landing interference. The projected nozzle column corresponds to an actual nozzle column. In a case where the projected nozzle column is taken into consideration, each nozzle40can be associated with a nozzle number indicating a nozzle position in an arrangement order of projected nozzles arranged along the column direction of the nozzles.

While the ink jet head30in which the plurality of nozzles are disposed in a matrix is illustrated inFIG.4, one column disposition may be applied, or zigzag disposition of two columns may be applied to the plurality of nozzles.

An actual density of the nozzles40in the substrate width direction corresponds to a printing resolution in the substrate width direction. Examples of the printing resolution in the substrate width direction include1200dots per inch. Dots per inch indicating the number of dots per inch may be referred to as dpi using the abbreviation for Dot Per Inch.

Configuration Example of Test Apparatus

FIG.5is a schematic diagram illustrating a configuration example of hardware of the test apparatus. Reference numeral Z illustrated inFIG.5indicates the height direction that is orthogonal to the substrate transport direction and the substrate width direction. The test apparatus20illustrated inFIG.5generates the captured data of the printed image by capturing the printed image printed on the film substrate1supported using a transport roller54and a transport roller56.

The test apparatus20comprises a scanner unit50and an illumination unit52. The scanner unit50is disposed on the side of the film substrate1closer to the printing surface1A and has a posture in which a light-receiving surface of an image sensor58faces the printing surface1A of the film substrate1. The scanner unit50images the printing surface1A of the film substrate1.

The illumination unit52is disposed on the side of the film substrate1closer to the substrate support surface1B and has a posture in which an emission surface of illumination light faces the substrate support surface1B of the film substrate1. The illumination unit52irradiates the film substrate1with illumination light I from the side closer to the substrate support surface1B.

A configuration in which a plurality of LEDs are comprised and the plurality of LEDs are two-dimensionally disposed may be applied to the illumination unit52. The plurality of LEDs may be disposed along the overall length of the film substrate1in the substrate width direction. The plurality of LEDs may be disposed along an overall length of an irradiation region of the illumination light in the substrate transport direction. LED is the abbreviation for Light Emitting Diode.

The scanner unit50comprises the image sensor58as an imaging device. The image sensor58has an imaging region having a length that exceeds the overall length of the film substrate1in the substrate width direction. The image sensor58receives the illumination light I transmitted through the film substrate1, generates captured data by converting an optical image formed by the received illumination light I into an electric signal, and outputs the captured data.

The scanner unit50comprises an image forming lens60. The image forming lens60causes the optical image of the image printed on the film substrate1to be formed on the image sensor58by condensing the illumination light I transmitted through the film substrate1. A lens group including a plurality of lenses may be applied as the image forming lens60. The scanner unit50may comprise two or more types of optical elements such as lenses.

FIG.5illustrates a configuration of the test apparatus20that performs transmitted light imaging with respect to the transparent film substrate1. However, in a case where an opaque substrate such as paper is applied, the illumination unit52may be disposed on the same side as the scanner unit50for the opaque substrate, and reflected light imaging of receiving reflected light that is reflected from the opaque substrate may be performed. The scanner unit50of the embodiment is an example of an imaging apparatus.

Electric Configuration of Ink Jet Printing System

FIG.6is a functional block diagram illustrating an electric configuration of the ink jet printing system illustrated inFIG.1. The ink jet printing system10comprises a system control portion100, a transport control portion102, a precoating control portion104, a jetting control portion106, a drying control portion108, a maintenance control portion110, a scanner control portion112, and a test control portion114. In addition, the ink jet printing system10comprises a memory120and a sensor122.

The system control portion100controls an overall operation of the ink jet printing system10in an integrated manner. The system control portion100transmits instruction signals to various control portions. The system control portion100functions as a memory controller that controls storage of data in the memory120and readout of data from the memory120.

The system control portion100acquires a sensor signal transmitted from the sensor122and transmits the instruction signals based on the sensor signal to various control portions. The sensor122illustrated inFIG.6includes the tension pickup36illustrated inFIG.1. In addition, the sensor122includes various sensors such as a position detection sensor and a temperature sensor provided in each part of the ink jet printing system10.

The transport control portion102sets a transport condition based on the instruction signal transmitted from the system control portion100and controls an operation of the transport apparatus24based on the set transport condition. For example, the transport control portion102controls an operation of a motor connected to a drive roller or the like provided in the transport apparatus24, by applying the transport condition applied to the transport apparatus24.

In addition, the transport control portion102individually controls transport tension to be applied to the film substrate1in each section such as the precoating apparatus14and the jetting apparatus16provided in the ink jet printing system10. That is, the transport control portion102controls the transport tension of the film substrate1in each section from the substrate supply apparatus12to the collecting apparatus22.

The precoating control portion104sets a processing condition for precoating processing based on the instruction signal transmitted from the system control portion100and controls an operation of the precoating apparatus14based on the set processing condition.

The jetting control portion106sets a printing condition based on the instruction signal transmitted from the system control portion100and controls an operation of the jetting apparatus16based on the set printing condition.

The jetting control portion106comprises an image processing portion that generates halftone data based on printing data by performing color separation processing, color conversion processing, correction processing for each processing, and halftone processing on the printing data.

The jetting control portion106comprises a drive voltage generation portion that generates a drive voltage to be supplied to the ink jet head30. The jetting control portion106comprises a drive voltage output portion that supplies the drive voltage to the ink jet head30.

The jetting control portion106performs the jetting correction of the ink jet head30. For example, the jetting control portion106performs printing on a printing position of an unused nozzle without using the unused nozzle stored in advance, by using a normal nozzle positioned adjacent to the unused nozzle.

The drying control portion108sets a processing condition for drying processing applied to the drying apparatus18based on the instruction signal transmitted from the system control portion100and controls an operation of the drying apparatus18based on the set processing condition.

The maintenance control portion110sets a maintenance condition applied to the maintenance apparatus70based on the instruction signal transmitted from the system control portion100and controls an operation of the maintenance apparatus70based on the set maintenance condition.

The scanner control portion112sets a reading condition applied to the scanner32based on the instruction signal transmitted from the system control portion100and controls an operation of the scanner32based on the set reading condition.

The scanner control portion112acquires the read data of the test pattern image transmitted from the scanner32and transmits the acquired read data of the test pattern image to a read data processing portion130.

The test control portion114sets a test condition applied to the test apparatus20based on the instruction signal transmitted from the system control portion100and controls an operation of the test apparatus20based on the set test condition.

The test control portion114acquires the captured data of the printed image transmitted from the test apparatus20as test data and transmits the acquired test data to a test data processing portion132.

The memory120stores various programs, various parameters, and various types of data used in the ink jet printing system10. The memory120includes regions for various operations performed by the system control portion100and the like.

The ink jet printing system10comprises the read data processing portion130. The read data processing portion130detects a defective nozzle by analyzing the read data of the test pattern image generated using the scanner32. The defective nozzle may include a non-jetting nozzle that does not jet the ink, and an abnormal nozzle of which a jetting position and a jetting amount do not fall within a defined range.

The defective nozzle is specified using the nozzle number indicating the nozzle position in the substrate width direction. The test pattern image is generated for each ink color, the read data of the test pattern image is analyzed for each ink color, and the defective nozzle is specified for each ink color. Here, each ink color is synonymous with each ink jet head30.

The ink jet printing system10comprises the test data processing portion132. The test data processing portion132tests the printed image of the film substrate1on which the drying processing is performed using the drying apparatus18. That is, the test data processing portion132detects a defect such as a scratch and a streak in the printed image by analyzing the test data which is the captured data of the printed image. The test data processing portion132outputs a test result of the printed image.

The test data processing portion132estimates a defective nozzle candidate using an analysis result of the test data. That is, the test data processing portion132specifies a position of the defect in the test data and estimates one or more defective nozzle candidates using a correspondence relationship between the test data and the nozzles.

The test data processing portion132stores defective nozzle candidate information including a probability that the defective nozzle candidate actually causes occurrence of the image defect, a defect occurrence count, a defect occurrence frequency, and the like in the memory120. Details of the estimation of the defective nozzle candidate to which the test data processing portion132is applied will be described later. The defective nozzle candidate according to the embodiment is an example of a defective printing element candidate.

The ink jet printing system10comprises a nozzle information notification portion134. The nozzle information notification portion134acquires the defective nozzle candidate information and provides notification of the defective nozzle candidate information. An aspect of providing notification of displaying test information indicating the defective nozzle candidate information using a display apparatus may be applied to the nozzle information notification portion134.

The ink jet printing system10comprises a user input information acquisition portion136. The user input information acquisition portion136acquires various types of information input by a user using a keyboard or the like. Examples of the various types of information input by the user include information that provides an instruction to perform the maintenance of the ink jet head30and that is input by the user who visually recognizes the defective nozzle candidate information.

Configuration Example of Read Data Processing Portion

FIG.7is a functional block diagram illustrating a configuration example of the read data processing portion illustrated inFIG.6. The read data processing portion130comprises a read data acquisition portion150, a read data analysis portion152, a defective nozzle information storage portion154, and a defective nozzle information output portion156.

The read data acquisition portion150acquires the read data of the test pattern image generated using the scanner32illustrated inFIG.6. The read data acquisition portion150transmits the acquired read data of the test pattern image to the read data analysis portion152.

The read data analysis portion152specifies the defective nozzle by analyzing the read data of the test pattern image acquired using the read data acquisition portion150. The read data analysis portion152specifies the defective nozzle based on a missing part of the pattern, misregistration of the pattern, and a shape of the pattern in the test pattern image.

The read data analysis portion152stores the defective nozzle information including position information of the defective nozzle in the defective nozzle information storage portion154. In addition, the read data analysis portion152transmits the defective nozzle information to the defective nozzle information output portion156.

The defective nozzle information output portion156outputs the defective nozzle information. For example, the jetting control portion106acquires the defective nozzle information, performs masking processing on the defective nozzle, and performs the jetting correction on the defective nozzle. The defective nozzle information according to the embodiment is an example of defective printing element information.

Configuration Example of Test Data Processing Portion

FIG.8is a functional block diagram illustrating a configuration example of the test data processing portion illustrated inFIG.6. The test data processing portion132comprises a test data acquisition portion160, a test data analysis portion162, a defective nozzle probability calculation portion164, a defective nozzle candidate information storage portion166, and a defective nozzle candidate information output portion168.

The test data acquisition portion160acquires the test data generated using the test apparatus20illustrated inFIG.6. The test data acquisition portion160transmits the acquired test data to the test data analysis portion162.

The test data analysis portion162estimates the defective nozzle candidate by analyzing the test data acquired using the test data acquisition portion160. The test data analysis portion162transmits the defective nozzle candidate information including information about the estimation of the defective nozzle candidate to the defective nozzle probability calculation portion164.

The test data analysis portion162comprises a reference data acquisition portion170, a data comparing portion172, a defect position specifying portion174, a nozzle mapping information acquisition portion176, and a defective nozzle candidate estimation portion178.

The reference data acquisition portion170acquires reference data to be compared with the test data. The printing data in printing the printed image may be applied as the reference data, or captured data of a good printed image in which a defect has not occurred, such as the first printed image of each printing job, may be applied as the reference data.

The data comparing portion172specifies whether or not there is a defect in the test data by comparing the test data with the reference data. For example, the data comparing portion172specifies whether or not there is a defect from a difference between the test data and the reference data, by performing registration between the test data and the reference data and subtracting the reference data from the test data. In a preferable aspect, the data comparing portion172performs processing of matching resolutions between the test data and the reference data.

The data comparing portion172classifies the printed image into a good printed image and a defective printed image in accordance with a degree of the defect. The data comparing portion172stores and outputs classification information of the printed image. The user is notified of the classification information of the printed image output from the data comparing portion172. For example, a stamp is assigned to the printed image classified as the defective printed image.

The defect position specifying portion174specifies the position of the defect in the test data. Here, the position of the defect in the test data includes the position of the defect in the substrate width direction. A pixel position of the image sensor58corresponding to the defect may be specified from the position of the defect in the substrate width direction.

The nozzle mapping information acquisition portion176acquires nozzle mapping information. The nozzle mapping information is information indicating a correspondence relationship between nozzle positions of the ink jet head30and pixel positions of the image sensor58.

The nozzle mapping information acquisition portion176may read out the nozzle mapping information stored in advance. In addition, the nozzle mapping information acquisition portion176may acquire nozzle mapping correction information used in correcting the nozzle mapping information. The correction of the nozzle mapping information may suppress an effect of misregistration, rotation, skewing, and the like of the film substrate1in estimating the defective nozzle.

The defective nozzle candidate estimation portion178estimates positions of one or more defective nozzle candidates using the nozzle mapping information. In a case where an imaging resolution of the image sensor58is lower than the printing resolution, one pixel of the image sensor58includes a plurality of pixels of the printed image. In this case, a plurality of defective nozzle candidates are estimated for one defect.

In a case where the imaging resolution of the image sensor58is lower than the printing resolution, a region of the printed image corresponding to one pixel of the image sensor58is printed using a plurality of nozzles. In a case where the defective nozzle is one nozzle and one pixel of the printed image corresponding to the defective nozzle is missing, a feature corresponding to the defective nozzle appears in a specific pixel in the captured data of the image sensor58which is the test data.

Meanwhile, the feature corresponding to the defective nozzle may appear across multiple pixels in the captured data of the image sensor58because of an effect of reflection or the like of light. Therefore, the plurality of defective nozzle candidates can be further narrowed down by calculating a peak position of the feature corresponding to the defective nozzle as a centroid position approximated using a two-dimensional function or the like.

A trained learning model may be applied to the defective nozzle candidate estimation portion178. For example, a trained learning model that has learned a set of the test data and the position of the defect as correct answer data may be applied to the defective nozzle candidate estimation portion178. The defective nozzle candidate estimation portion178to which the trained learning model is applied may assign a score indicating likelihood of the defective nozzle for each of the plurality of defective nozzle candidates. The score indicating the likelihood of the defective nozzle may be handled as the probability of actually causing the occurrence of the image defect.

The defective nozzle candidate estimation portion178specifies a color of the defective nozzle candidate. The defective nozzle candidate estimation portion178calculates an amount of variation between a pixel value of the captured data of the image sensor58at a defect position and a pixel value of the reference data at a position corresponding to the defect position.

The defective nozzle candidate estimation portion178estimates a color of the defect using the calculated amount of variation. That is, the defective nozzle candidate estimation portion178derives a combination of the position and the color for the defective nozzle candidate.

The defective nozzle probability calculation portion164calculates the probability of actually causing the occurrence of the defect in the printed image for one or more defective nozzle candidates. In a case where there are a plurality of defective nozzle candidates, the defective nozzle probability calculation portion164may calculate the probability of actually causing the occurrence of the defect in the printed image for each defective nozzle candidate.

Specifically, the defective nozzle candidate estimation portion178creates a profile in the substrate width direction for the defect specified by the defect position specifying portion174, by averaging pixel values in the substrate transport direction for each pixel position in the substrate width direction.

The defective nozzle candidate estimation portion178may estimate one or more defective nozzles by calculating a centroid position of a peak portion of the profile and calculating a peak position of the defect in pixel units of the printed image having a higher resolution than the original imaging resolution of the image sensor58.

The defective nozzle probability calculation portion164may set the probability of actually causing the occurrence of the defect in the printed image to be relatively high for the defective nozzle candidate at a position relatively close from the peak portion of the profile. In addition, the defective nozzle probability calculation portion164may set the probability of actually causing the occurrence of the defect in the printed image to be relatively low for the defective nozzle candidate at a position relatively far from the peak portion of the profile.

For example, a distance between the centroid position of the peak portion and an ideal position of the defective nozzle candidate may be calculated for each defective nozzle candidate, and a ratio of the distance calculated for each defective nozzle candidate may be used as the probability of actually causing the occurrence of the defect in the printed image for each defective nozzle candidate.

The defective nozzle probability calculation portion164may calculate a probability of having a color that actually causes the occurrence of the defect in the printed image, for the color of the defective nozzle candidate. The defective nozzle probability calculation portion164may calculate the probability of actually causing the occurrence of the defect in the printed image and the probability of having the color that actually causes the occurrence of the defect in the printed image, for the defective nozzle candidate by applying the trained learning model.

The defective nozzle probability calculation portion164stores the defective nozzle candidate information including the probability of actually causing the occurrence of the defect in the printed image and the probability of having the color that actually causes the occurrence of the defect in the printed image, in the defective nozzle candidate information storage portion166for each defective nozzle candidate. In addition, the defective nozzle probability calculation portion164transmits the defective nozzle candidate information to the defective nozzle candidate information output portion168.

The defective nozzle candidate information output portion168transmits the defective nozzle candidate information to the nozzle information notification portion134illustrated inFIG.3. The nozzle information notification portion134provides notification of the defective nozzle candidate information transmitted from the defective nozzle candidate information output portion168.

The defective nozzle candidate information may include the defect occurrence count for each defective nozzle candidate and the defect occurrence frequency for each defective nozzle candidate. That is, the test data processing portion132may comprise a defect occurrence count derivation portion that derives the defect occurrence count for each defective nozzle candidate, and a defect occurrence frequency derivation portion that derives the defect occurrence frequency for each defective nozzle candidate. The defective nozzle candidate information according to the embodiment is an example of defective printing clement candidate information. Each defective nozzle candidate according to the embodiment is an example of each defective printing element candidate.

FIG.9is a block diagram schematically illustrating an example of a hardware configuration of the electric configuration illustrated inFIGS.6to8. A control apparatus200provided in the ink jet printing system10comprises a processor202, a non-transitory tangible computer-readable medium204, a communication interface206, and an input-output interface208.

A computer is applied as the control apparatus200. The computer may be in a form of a server, a personal computer, a workstation, a tablet terminal, or the like.

The processor202includes a central processing unit (CPU). The processor202may include a graphics processing unit (GPU). The processor202is connected to the computer-readable medium204, the communication interface206, and the input-output interface208through a bus210. An input apparatus214and a display apparatus216arc connected to the bus210through the input-output interface208.

The computer-readable medium204includes a memory that is a main memory, and a storage that is an auxiliary memory. A semiconductor memory, a hard disk apparatus, a solid state drive apparatus, and the like may be applied as the computer-readable medium204. Any combination of a plurality of devices may be applied as the computer-readable medium204.

The hard disk apparatus may be referred to as an HDD which is the abbreviation for Hard Disk Drive in English. The solid state drive apparatus may be referred to as an SSD which is the abbreviation for Solid State Drive in English.

The control apparatus200is connected to a network through the communication interface206and is connected to be capable of communicating with an external apparatus. A local area network (LAN) or the like may be applied as the network. The network is not illustrated.

The computer-readable medium204stores a transport control program220, a precoating control program222, a jetting control program224, a drying control program226, and a maintenance control program228.

The transport control program220corresponds to a transport control applied to the transport apparatus24illustrated inFIG.6. The precoating control program222corresponds to a precoating control applied to the precoating apparatus14.

The jetting control program224corresponds to a printing control applied to the jetting apparatus16. The jetting control program224includes a jetting correction program for performing the jetting correction of the ink jet head30. The jetting correction program according to the embodiment is an example of a third program.

The drying control program226corresponds to a drying control applied to the drying apparatus18. The maintenance control program228corresponds to a maintenance control of the ink jet head30applied to the maintenance apparatus70. The maintenance control program228according to the embodiment is an example of a second program.

In addition, the computer-readable medium204stores a scanner control program230, a test pattern image analysis program232, and a test program234. The scanner control program230corresponds to a reading control of the scanner32applied to the scanner control portion112.

The test pattern image analysis program232corresponds to analysis processing of the test pattern image applied to the read data processing portion130. The test program234corresponds to testing of the printed image applied to the test apparatus20.

The test program234includes a test control program240, a printed image determination program242, and a defective nozzle candidate estimation program244. The test control program240is applied to the testing of the printed image to which the test apparatus20is applied.

The printed image determination program242is applied to determination as to whether the printed image is a good printed image or a defective printed image based on the test data acquired from the test apparatus20in the test data processing portion132. The defective nozzle candidate estimation program244is applied to estimation processing of the defective nozzle candidate and output of the notification of the defective nozzle candidate information in the test data analysis portion162illustrated inFIG.8.

The test program234according to the embodiment is an example of a first program.

Various programs stored in the computer-readable medium204include one or more instructions. The computer-readable medium204stores various types of data, various parameters, and the like. The memory120illustrated inFIG.6is included in the computer-readable medium204illustrated inFIG.9.

The ink jet printing system10implements various functions of the ink jet printing system10by executing the various programs stored in the computer-readable medium204via the processor202. The term program is synonymous with the term software.

The control apparatus200performs data communication with the external apparatus through the communication interface206. Various standards such as universal serial bus (USB) may be applied to the communication interface206. Any of wired communication and wireless communication may be applied to a communication form of the communication interface206.

A liquid crystal display, an organic EL display, a projector, and the like may be applied as the display apparatus216. Any combination of a plurality of devices may be applied as the display apparatus216. For example, the display apparatus216of a touch panel method may be used as both of the input apparatus214and the display apparatus216. EL in the organic EL display is the abbreviation for Electro-Luminescence.

Here, examples of a hardware structure of the processor202include a CPU, a GPU, a programmable logic device (PLD), and an application specific integrated circuit (ASIC). The CPU is a general-purpose processor that acts as various functional portions by executing a program. The GPU is a processor specialized for image processing.

The PLD is a processor of which a configuration of an electric circuit can be changed after the device is manufactured. Examples of the PLD include a field programmable gate array (FPGA). The ASIC is a processor comprising a dedicated electric circuit that is dedicatedly designed to execute specific processing.

One processing portion may be composed of one of the various processors or may be composed of two or more processors of the same type or different types. Examples of a combination of various processors include a combination of one or more FPGAs and one or more CPUs and a combination of one or more FPGAs and one or more GPUs. Other examples of the combination of various processors include a combination of one or more CPUs and one or more GPUs.

A plurality of functional portions may be configured using one processor. Examples of the plurality of functional portions configured using one processor include, as represented by a computer such as a client or a server, an aspect in which one processor is configured by applying a combination of one or more CPUs and software such as a system on a chip (SoC) and this processor acts as the plurality of functional portions.

Other examples of the plurality of functional portions configured using one processor include an aspect of using a processor that implements functions of the entire system including the plurality of functional potions using one IC chip. IC is the abbreviation for Integrated Circuit.

As described above, various functional portions are configured using one or more of the various processors as a hardware structure. Furthermore, the hardware structure of the various processors is more specifically an electric circuit (circuitry) in which circuit elements such as semiconductor elements are combined.

The computer-readable medium204may include a semiconductor element such as a read only memory (ROM) and a random access memory (RAM). The computer-readable medium204may include a magnetic storage medium such as a hard disk. The computer-readable medium204may be provided with a plurality of types of storage media.

The processor202according to the embodiment is an example of a first processor, a second processor, and a third processor. The computer-readable medium204according to the embodiment is an example of a first memory, a second memory, and a third memory.

Data Processing Method According to Embodiment

Summary

In the ink jet printing system10that performs single pass printing as described usingFIGS.1to9, there is an issue of a defect having a streak shape caused by curved jetting and non-jetting in the defective nozzle occurring in the ink jet head30. A case where the defect occurs at all times, and a case where the defect occurs under a specific printing condition such as a specific gradation are present for the defective nozzle.

The defective nozzle in which the defect occurs at all times can be specified using the test pattern image, and the occurrence of the defect having a streak shape may be suppressed by performing the jetting correction. Meanwhile, it is difficult to specify the defective nozzle in which the defect occurs under a specific printing condition using the test pattern image.

The defect having a streak shape caused by the defective nozzle in which the defect occurs under a specific printing condition can be detected using the test apparatus20. While it is difficult to specify the defective nozzle that causes the defect having a streak shape, one or more defective nozzle candidates can be estimated.

The defect having a streak shape that cannot be specified using the test pattern image has variation in appearance frequency. For example, the defect may appear with relatively high frequency or may appear with relatively low frequency such as the defect that appears in one printed image among hundreds of printed images. In addition, intensity of the defect having a streak shape also varies. The defect having a streak shape that is relatively easily visible has relatively high intensity. Meanwhile, the defect having a streak shape that is relatively not easily visible has relatively low intensity.

Even in a case where the defect having a streak shape is detected in the printed image, it may not be required to perform the jetting correction and the maintenance of the ink jet head30, and the user may be caused to determine whether or not to perform the jetting correction and the like.

A data processing method described below enables the ink jet printing system10to efficiently operate by notifying the user of the defective nozzle candidate estimated using the test data of the printed image and causing the user to determine processing with respect to the defective nozzle candidate.

For example, in a case where the defect having a streak shape of which streak intensity is relatively low has occurred in the printed image, the user may choose to continue the printing job without performing processing such as the maintenance of the ink jet head30.

Procedure of Data Processing Method

FIG.10is a flowchart illustrating a procedure of the data processing method according to the embodiment. In defect information acquisition step S10, the test data analysis portion162illustrated inFIG.8acquires defect information of the printed image from the test data of the printed image. A transition is made to defective nozzle candidate estimation step S12after defect information acquisition step S10.

In defective nozzle candidate estimation step S12, the test data analysis portion162specifies the position of the defect from the defect information of the printed image acquired in defect information acquisition step S10and estimates one or more defective nozzle candidates corresponding to the position of the defect. A transition is made to defective nozzle candidate count determination step S14after defective nozzle candidate estimation step S12.

In defective nozzle candidate count determination step S14, the test data analysis portion162determines whether or not there are a plurality of defective nozzle candidates. In defective nozzle candidate count determination step S14, a No determination is made in a case where it is determined that there is one defective nozzle candidate. In a case where a No determination is made, a transition is made to defective nozzle candidate information output step S16.

In defective nozzle candidate information output step S16, the defective nozzle candidate information output portion168outputs the position and the color of the defective nozzle candidate estimated in defective nozzle candidate estimation step S12as the defective nozzle candidate information. The defective nozzle candidate information is displayed on the display apparatus216illustrated inFIG.9. After defective nozzle candidate information output step S16, the procedure of the data processing method is finished.

Meanwhile, in defective nozzle candidate count determination step S14, a Yes determination is made in a case where it is determined that there are a plurality of defective nozzle candidates. In a case where a Yes determination is made, a transition is made to probability calculation step S18.

In probability calculation step S18, the test data analysis portion162calculates a probability of causing the defect having a streak shape for each of the plurality of defective nozzle candidates. The probability of causing the defect having a streak shape means a probability that the defective nozzle candidate actually causes the occurrence of the defect having a streak shape. After probability calculation step S18, a transition is made to defective nozzle probability information output step S20.

In defective nozzle probability information output step S20, the defective nozzle candidate information output portion168outputs a probability that the defective nozzle candidate is the defective nozzle for each of the plurality of defective nozzle candidates. The defective nozzle candidate information is displayed on the display apparatus216illustrated inFIG.9. After defective nozzle probability information output step S20, the procedure of the data processing method is finished.

The user of the ink jet printing system10may perceive the probability that the defective nozzle candidate causes the defect having a streak shape for each of the plurality of defective nozzle candidates, and determine a priority for executing the recovery processing and the like of the ink jet head30.

Notification of Defective Nozzle Candidate Information

The position of the defective nozzle candidate may be applied as the defective nozzle candidate information provided by notification. For example, the nozzle number for each ink jet head30may be applied. In a case where the plurality of head modules38are comprised, the module numbers assigned to the head modules38may be applied as the defective nozzle candidate information provided by notification.

In a case where the ink jet head30is comprised for each ink color, information about a color of the ink jet head30may be applied as the defective nozzle candidate information provided by notification. The defective nozzle candidate information provided by notification may be a combination of the color of the ink jet head30and the nozzle number or the module number.

The defective nozzle candidate information provided by notification may be information in maintenance units. For example, in a case where the recovery processing of recovering the defective nozzle is the maintenance of the ink jet head30, the ink jet head30including the defective nozzle candidate may be applied as the defective nozzle candidate information provided by notification.

The defective nozzle candidate information may include information about the occurrence frequency indicating a degree to which the defect occurs for the defective nozzle candidate. For example, in a case where defective nozzle candidates that are only a few increase to a few tens of defective nozzle candidates in one printing job and the notification of the occurrence frequency of the defective nozzle is provided, the user may determine whether or not to perform processing of correcting the defect having a streak shape.

In addition, in a case where the defect occurrence frequency of the defective nozzle of which jetting performance is recovered by performing the recovery processing of the ink jet head30is increased, the user may determine to replace the head module38.

Performance Recovery Processing of Defective Nozzle

By presenting the defective nozzle candidate to the user, the user may determine to perform the maintenance of the ink jet head30, replace the head module38, and the like. In addition, the ink jet printing system10preferably performs performance recovery processing of recovering the performance of the defective nozzle.

Examples of the performance recovery processing of recovering the performance of the defective nozzle include the jetting correction performed by masking the defective nozzle as the unused nozzle and changing a jetting condition for the normal nozzle positioned adjacent to the defective nozzle. The user may set the unused nozzle from the defective nozzle candidates provided by notification and perform the jetting correction of suppressing the occurrence of the defect having a streak shape. The unused nozzle according to the embodiment is an example of an unused printing element.

Examples of the performance recovery processing of recovering the performance of the defective nozzle include the maintenance of the ink jet head30. In a case where the notification of the defective nozzle candidate is provided, the user may instruct the ink jet printing system10to perform the maintenance of the ink jet head30.

Effects of Embodiment

According to the ink jet printing system10and the data processing method according to the embodiment, the following effects can be obtained.

In a case where a defect in the printed image is detected, one or more defective nozzle candidates that may actually cause the occurrence of the defect are estimated, the notification of the estimated defective nozzle candidate is provided, and the notification of the probability of actually causing the occurrence of the defect in the printed image is provided for each defective nozzle candidate. Accordingly, the user may determine whether or not to perform the processing of correcting the defect in the printed image.

The probability of actually causing the occurrence of the defect in the printed image for each defective nozzle candidate is derived by calculating the peak position of the defect at the position of the defect in the printed image. Accordingly, the probability of actually causing the occurrence of the defect in the printed image may be set to be relatively high for the nozzle positioned relatively close to the peak position of the defect, and the probability of actually causing the occurrence of the defect in the printed image may be set to be relatively low for the nozzle positioned relatively far from the peak position of the defect.

The probability of actually causing the occurrence of the defect in the printed image for each defective nozzle candidate may be derived using the trained learning model. Accordingly, the probability of actually causing the occurrence of the defect in the printed image for each defective nozzle candidate may be derived with high accuracy.

Information indicating the position of the nozzle in the ink jet head30is applied as the defective nozzle candidate provided by notification. Accordingly, the position of the nozzle as the defective nozzle candidate in the ink jet head30may be specified.

The nozzle numbers assigned to all nozzles provided in the ink jet head30are applied as the information indicating the position of the nozzle in the ink jet head30. Accordingly, the defective nozzle candidate may be specified using the nozzle numbers.

The notification of the color of the defective nozzle candidate provided by notification is provided. Accordingly, the ink jet head30corresponding to the color for which the defective nozzle candidate is present may be specified.

The notification of the defect occurrence frequency in the defective nozzle candidate is provided. Accordingly, the user may determine whether or not to perform the processing of correcting the defect in the printed image in accordance with the defect occurrence frequency in the defective nozzle candidate.

The notification of the defect occurrence count in the defective nozzle candidate is provided. Accordingly, the user may determine whether or not to perform the processing of correcting the defect in the printed image in accordance with the defect occurrence count in the defective nozzle candidate.

The jetting correction is performed as the processing of correcting the defect in the printed image. Accordingly, the processing of correcting the defect in the printed image may be performed in printing.

The maintenance of the ink jet head30is performed as the processing of correcting the defect in the printed image. Accordingly, the occurrence of the defect in the printed image may be suppressed by performing the maintenance of the ink jet head30.

The ink jet head30is replaced as the processing of correcting the defect in the printed image. Accordingly, the occurrence of the defect in the printed image may be suppressed by replacing the ink jet head30. The head module38may be replaced in the ink jet head30comprising the plurality of head modules38.

Application to Data Processing Apparatus and Test Apparatus

The test data processing portion132illustrated inFIGS.6and7may be formed as a data processing apparatus that acquires the test data from the test apparatus20and that processes the acquired test data, using a computer. A test apparatus comprising the test apparatus20and the test data processing portion132may also be configured.

Application to Printing System of Other than Ink Jet Method

While the ink jet printing system10to which an ink jet method is applied is illustrated in the present embodiment, data processing according to the present embodiment may also be performed for a printing system of, for example, an electrophotographic method other than the ink jet method.

In a case where the electrophotographic method is used, the nozzle in the ink jet method corresponds to an exposure element. In addition, in a case where the electrophotographic method is used, the ink color is replaced with a color of a coloring material such as toner. Furthermore, in a case where the electrophotographic method is used, the maintenance of the ink jet head30is replaced with cleaning of a printing head.

Terms

The term printing apparatus is synonymous with terms such as a printing machine, a printer, a typing apparatus, an image recording apparatus, an image forming apparatus, an image output apparatus, and a drawing apparatus. An image is interpreted in a broad sense and also includes a color image, a monochrome image, a single color image, a gradation image, a uniform density image, and the like.

The term printing includes concepts of terms such as recording of an image, forming of an image, typing, drawing, and making a print. The term apparatus may include a concept of a system.

An image is not limited to a photographic image and is used as a comprehensive term including a design, a test, a symbol, a line drawing, a mosaic pattern, a color-coding pattern, other various patterns, and the like, and an appropriate combination thereof. In addition, the term image may include meanings of an image signal and image data indicating an image.

Configuration requirements of the embodiment of the present invention described above can be changed, added, or deleted, as appropriate, without departing from the gist of the present invention. The present invention is not limited to the embodiment described above, and many modifications can be made by those having ordinary knowledge in the field within the technical idea of the present invention. In addition, the embodiment, modification examples, and application examples may be combined, as appropriate.

Explanation of References

1: film substrate

1A: printing surface

1B: substrate support surface

10: ink jet printing system

12: substrate supply apparatus

20: test apparatus

30: ink jet head

30C: ink jet head

30K: ink jet head

30M: ink jet head

30Y: ink jet head

34: pass roller

38: head module

38C: nozzle disposition portion

39: head frame

50: scanner unit

54: transport roller

56: transport roller

58: image sensor

60: image forming lens

72: head moving apparatus

86: discharge flow channel

100: system control portion

102: transport control portion

106: jetting control portion

108: drying control portion

110: maintenance control portion

112: scanner control portion

114: test control portion

130: read data processing portion

132: test data processing portion

134: nozzle information notification portion

136: user input information acquisition portion

150: read data acquisition portion

152: read data analysis portion

154: defective nozzle information storage portion

156: defective nozzle information output portion

160: test data acquisition portion

162: test data analysis portion

164: defective nozzle probability calculation portion

166: defective nozzle candidate information storage portion

168: defective nozzle candidate information output portion

170: reference data acquisition portion

172: data comparing portion

174: defect position specifying portion

176: nozzle mapping information acquisition portion

178: defective nozzle candidate estimation portion

200: control apparatus

206: communication interface

214: input apparatus

216: display apparatus

220: transport control program

224: jetting control program

226: drying control program

228: maintenance control program

230: scanner control program

232: test pattern image analysis program

234: test program

240: test control program

242: printed image determination program

244: defective nozzle candidate estimation program

S10to S20: each step of data processing method