Patent ID: 12190000

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to specific embodiments of the present invention. Examples of these embodiments are illustrated in the accompanying drawings. Numerous specific details are set forth in order to provide a thorough understanding of the present invention. While the embodiments will be described in conjunction with the drawings, it will be understood that the following description is not intended to limit the present invention to any one embodiment. On the contrary, the following description is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the appended claims.

The disclosed embodiments provide an enhanced job resumption system that improves the usability of recovering from errors detected by inline inspection systems. A printing device may include an inline inspection system that performs inline image inspection in a normal manner. The inline inspection system scans printed sheets at the specified intervals. The inline inspection system evaluates the scanned image to look for print defects. When a defect is found, the inline inspection system either compensates or stops printing operations, based on the inspection system configuration.

If the inspection system is configured to stop printing, then the printing device will pause printing after it finds a defect in a scanned sheet. The printing device will then return as status letting the operator know that he/she needs to inspect the output. This message may be shown in the printing device panel on in the digital front end (DFE) user interface (UI). Alternatively, it may be sent to any clients displaying printing device status. The printing device then will stop feeding and clears out the paper path by sending all sheets to the stacker. For sheets that have been fed but not printed, the printing device optionally may send these to the output bin without printing on them.

Once the paper path is cleared, the printing device will report job cost information. Sheets before the defective sheet will be reported as good, or acceptable. Sheets after the defective sheet will be reported as waste. The printing device will report relevant job cost information at any time that job cost information is reported. This job cost information may include the sheets used, impressions printed, and consumables used. Sheets that were fed but do not have anything printed thereon will be reported as “blank impressions.” Consumables may refer to ink or toner usage.

The printing device also may lower the output bin so that the operator can quickly remove the paper stack from the printing device. The printing device also lets the DFE know the impression on which the defect is found. The DFE, will do the following actions. The DFE will suspend the active job and flag it as requiring input from the operator before printing resumes. The DFE also adjusts the page range for the print job so that it resumes printing from the impression on which the defect is found.

Once the printing device stops printing, the operator may perform maintenance routine to unclog the printhead. The printing device will report job cost information for printing done to unclog print heads, such as sheets, impressions, and ink or toner. The printing device also will report print head cleaning, usually a consumable such as ink or toner. The above actions may be taken multiple times until the head is cleared. Once the printing device exits maintenance, the DFE will aggregate job cost information from the maintenance operations and track that as separate job cost data. This feature may be implemented and performed within the printing device.

After successful maintenance, the printing device will resume normal printing operations. The suspended job will resume printing. The print job, however, will not automatically start printing. Instead, the DFE will show a user interface where the operator can review and adjust the resumption point. This will be set to the page where the defect was detected. The user interface also will prompt the operator to review the output stack to determine the last good sheet. This sheet may be different versus the page on which the defect was detected because the inspection system does not check every page.

Once the operator inspects the stack and determines the last good sheet, the operator can adjust the resume point via one of the following methods. For example, the user interface will show the operator a preview of the page that will print next and of the pages before and after this page. The operator may scroll back to previous pages until he/she finds the first bad page. The operator can select the preview to adjust the page from which to resume printing. The operator also may specify the number of bad sets in the stack. This method is best for print jobs with a small number of pages, such as printing 100 copies of a 40 pages brochure.

Another method for adjusting the resume point includes the user interface allowing the operator to specify the number of bad sheets on the stack. The user interface will adjust the previews to show the impression on the front of the first bad sheet. Because this feature may take some time for long print jobs, the operator optionally may suspend printing operations for the print job so that other print jobs are processed while one determines the page from which to resume printing. This feature may be best for transactional jobs for which integrity is critical and for which minimizing waste sheets is important, such as printing credit card statements.

If either jogging or slip sheets are enabled for the print job, then the user interface also may allow the operator to specify the number of bad segments. Jogging may refer to the shift offset of papers. The user interface will adjust the previews to show the front of the first sheet on the first bad segment. A segment may be defined as all the sheets within an offset block or all the sheets between two slip sheets. Because the operator need only count segments, he/she quickly can find the resumption point. This feature may be best for long jobs for which the amount of waste is not critical, such as printing personalized marketing mailers. In all cases, the operator may use the sheet preview to validate that he/she are resuming the print job at the expected location.

Once the operator adjusts the resumption point, the print job will resume printing normally. The DFE will adjust the good versus the waste job cost information based on how the resume page is adjusted. Once the print job completes, the printing device will report job cost information for the resumed portion of the print job. The DFE will aggregate this information with the previous job cost information and store the combined information for the print job.

The disclosed embodiments alleviate the need to inspect every sheet that is printed at the printing device, which, in turn lowers costs for printing operations. When defects do occur, the disclosed embodiments provide methods to identify when the defect occurred and resume printing operations. As defects should occur rarely, the time and additional costs associated with correcting the defect will be offset by the increase in print production and less resources used to perform constant inspections.

FIG.1Adepicts a printing system100for printing documents using printing device104according to the disclosed embodiments. Printing system100may be located in a print shop or other environment suitable for production printing operations. Printing system100includes one or more printing devices104that receive print jobs from one or more client terminals102.

Printing device104receives print jobs through printing system100, such as print job103. After processing print job103, printing device104prints or produces document105in a paper or media specified by the print job. Printing device104is disclosed in greater detail inFIG.2. Printing device104also includes digital front end (DFE)106, which facilitates processing print job103. DFE106may be disclosed in greater detail inFIG.1B. In addition to the components of DFE106disclosed inFIG.1B, it also includes various settings that may be of use for consumable use estimation, such as ink or toner use. This information includes job settings126, DFE configuration settings128, and printing device configuration settings130. DFE106also includes RIP firmware290, disclosed in greater detail below.

Printing device104also includes consumables132. Consumables132may relate to items at or within printing device104but are not actually part of the printing device itself. Consumables132, however, are used in printing operations. Consumables132include ink134and toner136. Ink134and toner136further may be broken into different colorant inks. For example, ink134may include cyan ink, magenta ink, yellow ink, and black ink. If printing device104is not capable of color printing, then ink134may include only black ink. Printing device104may include other consumables132, such as sheets, that are not disclosed in detail herein.

Print job103, when printed on printing device104, uses an amount of consumables132to produce document105. In some embodiments, print job103produces thousands or more of a document. Thus, the amount of consumables used for print job103may be considerable. As disclosed above, printing system100may need to provide an estimate for the use of consumable132. The estimate determined for print job103may depend on various settings of printing device104. The settings as well as print ticket settings138associated with print job103impact the amount of consumables132used to generate document105.

For example, DFE106may use RIP firmware290to convert bitmap images, vector graphics, fonts, and the like associated with pages in print job103to bitmap/rasterized representations of the pages, such as C, M, Y, and K pixels. The sum of the values of pixels of a particular color in the rasterized pages can be proportional to the amount of consumables132used by printing device104to print that color. RIP firmware290may rasterize pages of print job103according to various image rasterization settings, as captured by DFE configuration settings128. For example, these image rasterization parameters may include calibration curves, paper definitions, ICC profiles, spot color definitions, TRCs, color conversion settings, colorant limits for ink or toner, rendering intent, K preservation, CGR level, max colorant densities, print margins, halftones, and the like.

Print engine260also is included with printing device104. Printing device104may correspond to an industrial printing device capable of printing thousands of pages in an hour. Printing device104may be ink-based, toner-based, or both. Print engine260may include various parameters, shown as printing device configuration settings130, that can control the operation of printing device104, which impacts the amount of consumables132required by the printing device. For example, these settings may include printing device maintenance settings that control or effect head cleaning intervals, head clogging prevention intervals, and the like of printing device104. Printing device configuration settings130also may include spitting, or printing spray pattern over all content, the printing of purge sheets, the printing of spit lines, or lines printed between page frames in a roll-fed printing device to ensure that all jets of the print head fire when instructed.

To lower printing device consumable usage, RIP firmware290may be configured via image rasterization parameters of DFE configuration settings128to reduce the density for each colorant, convert color images to black and white, and adjust tone reproduction curves (TRCs) to lower printing device use of consumables132. Gray component replacement levels may be adjusted via DFE configuration settings128.

The disclosed embodiments also include an estimation system108that includes estimation logic to facilitate performance of ink use estimation. Estimation system108may include estimation logic118having a DFE emulator120and a print engine emulator122configured to emulate operations performed by DFE106and print engine260of printing device104. Print engine260is disclosed in greater detail below. DFE, emulator120and print engine emulator122may be configured with job settings126, DFE configuration settings128, and printing device configuration settings130to match settings associated with printing device104. Estimation logic118also may be configured to estimate the amount of consumables132to process print job103and produce document105.

In operation, estimation logic118may monitor information and settings of printing device104to determine any differences from previous estimates. This feature facilitates real-time configuration information for DFE106, RIP firmware290, or print engine260with the corresponding settings utilized by printing device104.

Estimation system108may be any device within system100and connected to network190to receive and send data to printing device104. Estimation system108also may be connected to other printing devices within system100. Preferably, estimation system108is a server. It also may be another device, such as a computer. Estimation system108includes a memory114and a processor112. Estimation system108also includes an input/output (I/O) subsystem110and a quote database116.

Estimation system108also may refer to consumable estimation software that executes on a device. As disclosed below, “offline estimation device” may refer to this software. The term “offline” may refer to the fact that estimation system108is not part of printing device104, or an “inline” component of the printing process.

Processor112is in communication with memory114. Processor112is configured to execute instruction code in memory114. The instruction code controls offline estimation device108to perform various operations for estimating consumables132that may be used by printing device104. Processor112may be a computer processing unit that executes the instruction code in memory114.

I/O subsystem110may include one or more input, output, or input/output interfaces that are configured to facilitate communications with other devices within system100, such as client terminal102and printing device104. An example of I/O subsystem110may be configured to dynamically determine the communication methodology utilized by entities of system100to communication information thereto. For example, I/O subsystem110may determine that a first entity utilizes a RESTful API and can, as a result, communicate with the entity using an interface that uses a RESTful communication methodology.

Estimation logic118is implemented within offline estimation device108to estimate the amount of consumables132to be used by printing device104for printing document105of print job103. Estimation logic118includes DFE emulator120and print engine emulator122, as disclosed above. DFE emulator120and print engine emulator122are configured with configuration setting information to match the settings and parameters of printing device104.

DFE emulator120may be configured to emulate operations performed by DFE106of printing device104. The emulation depends on various settings specified for printing device104. For example, DFE emulator120may be configured to convert bitmap images, vector graphics, fonts, and the like specified in sample pages of print job103to bitmap/rasterized representations of the pages using C, M, Y, and K pixels. The manner in which DFE emulator120performs the conversion may depend on various image rasterization settings of the DFE emulator, which correspond to the image rasterization settings of DFE106.

In some embodiments, DFE emulator120retrieves a RIP of the plurality of Rips124available at estimation system108. Selection of the appropriate RIP provides a better basis to estimate ink use. For example, estimation logic118may determine the DFE, software version for DFE,106to select a RIP that has the same version. Estimation system108includes many different RIPs124. Preferably, it includes one for each software version that has been released. DFE emulator120may automatically configure the selected RIP using configuration settings from information retrieved from DFE106.

Print engine emulator122may be configured to emulate operations performed by print engine260or printing device104. The emulation may depend on various printing device configuration settings130for printing device104.

Estimates provided using estimation logic118of estimation system108may be stored as a record or entry in quote database116. Each entry to quote database116may specify aspects associated with an estimate provided to a customer for processing a particular print job103. Each entry may include field for job settings126, DFE configuration settings128, and printing device configuration settings130used to provide the estimate as well as a consumables estimate field and a cost field. Other information may be provided such as a client information field, a job information field, or a unique identification (ID) field. Preferably, print job103is a recurring printing operation in that multiple instances will occur that involves the printing of document105.

FIG.1Bdepicts a block diagram of DFE106according to the disclosed embodiments. DFE106includes a receiver181, an RIP firmware290, a CMYK data storage184, an input/output connector185, and a correcting unit186. RIP firmware290also is disclosed inFIG.2and in greater detail inFIG.3. Additional components within DFE106may be implemented, including those disclosed inFIG.1A. DFE106, therefore, includes data for job settings126, DFE configuration settings128, and, optionally, printing device configuration settings130, even though these are not shown inFIG.1B.

Receiver181receives print job103received within system100and outputs the print job to RIP firmware290. Receiver181also may receive color information for the document or documents within the print job. It may output the color information to correcting unit186. The print job received by receiver181is associated with image data to be printed on print media. It also may include print condition information including information for indicating single-sided printing or two-sided printing or print medium-type information along with other data associated with the print job.

RIP firmware290converts image data associated with the print job into raster data to thereby generate rendering data, and outputs the generated rendering data. RIP firmware290also converts the rendering data into rendering data in a CMYK format. When the rendering data is originally in the CMYK format, or CMYK rendering data, the conversion may not be performed. RIP firmware290may perform gradation conversion of the CMYK rendering data, with reference to one or more tone reproduction curves (TRCs). A TRC refers to data indicating the relationship between a colored gradation value for rendering data and print color, or print density, on a given print medium.

When print color provided by printing device104alters over time, the TRCs stored in CMYK data storage184may be each deviated from an actually measured relationship between a colored value and print color. When the TRC is shifted from the actual relationship, gradation conversion for each colored gradation value cannot match a desired print color. In this regard, correcting unit186corrects the deviation, from the actual relationship, of the TRC stored in CMYK data storage184in order to allow each colored gradation value to match a desired print color. Correcting unit186converts RGB color information obtained through receiver181into CMYK color information. Correcting unit186may use the converted CMYK color information to generate the TRC. The TRC stored in CMYK data storage184is replaced with the generated TRC. Correcting unit186may correct the TRC. Correcting unit186may rewrite a part of the TRC stored in CMYK data storage184to thereby correct the TRC.

The rendering data generated by RIP firmware290is transmitted within printing device104via input/output connector185. The print condition information and the print medium type, as well as the rendering data, may be transmitted to engine260found in printing device104disclosed inFIG.2.

DFE106also includes web user interface188that may communicate with other printing devices or estimation system108, if it is located at a separate device, using, for example, input/output connector185. Web user interface188, or web application, allows a user of the DFEs of other printing devices to interact with content or software running on DFE106.

FIG.2depicts a block diagram of components of printing device104according to the disclosed embodiments. The architecture shown inFIG.2may apply to any multi-functional printing device or image forming apparatus that performs various functions, such as printing, scanning, storing, copying, and the like within system100. As disclosed above, printing device104may send and receive data from estimation system108, if a separate device, and other devices within system100.

Printing device104includes a computing platform201that performs operations to support these functions. Computing platform201includes a computer processing unit (CPU)202, an image forming unit204, a memory unit206, and a network communication interface210. Other components may be included but are not shown for brevity. Printing device104, using computing platform201, may be configured to perform various operations, such as scanning, copying, printing, receiving or sending a facsimile, or document processing. As such, printing device104may be a printing device or a multi-function peripheral including a scanner, and one or more functions of a copier, a facsimile device, and a printer. To provide these functions, printing device104includes printer components220to perform printing operations, copier components222to perform copying operations, scanner components224to perform scanning operations, and facsimile components226to receive and send facsimile documents. CPU202may issue instructions to these components to perform the desired operations.

Printing device104also includes a finisher211and one or more paper cassettes212. Finisher211includes rotatable downstream rollers to move papers with an image formed surface after the desired operation to a tray. Finisher211also may perform additional actions, such as sorting the finished papers, binding sheets of papers with staples, doubling, creasing, punching holes, folding, and the like.

Paper cassettes212supply paper to various components220,222,224, and226to create the image formed surfaces on the papers. Paper cassettes212also may be known as paper trays. Paper cassettes212may include papers having various sizes, colors, composition, and the like. Papers or media within paper cassettes212may be considered “loaded” onto printing device104. The information for printing these papers may be captured in a paper catalog stored at DFE106. Paper cassettes212may be removed to refill as needed. The printed papers from components220,222,224, and226are placed within one or more output bins227. One or more output bins227may have an associated capacity to receive finished print jobs before it must be emptied or printing paused. The output bins may include one or more output trays.

Document processor input feeder tray230may include the physical components of printing device104to receive papers and documents to be processed. Feeder tray also may refer to one or more input trays for printing device104. A document is placed on or in document processor input feeder tray230, which moves the document to other components within printing device104. The movement of the document from document processor input feeder tray230may be controlled by the instructions input by the user. For example, the document may move to a scanner flatbed for scanning operations. Thus, document processor input feeder tray230provides the document to scanner components224. As shown inFIG.2, document processor input feeder tray230may interact with print engine260to perform the desired operations.

Memory unit206includes memory storage locations214to store instructions215. Instructions215are executable on CPU202or other processors associated with printing device104, such as any processors within components220,222,224, or226. Memory unit206also may store information for various programs and applications, as well as data specific to printing device104. For example, a storage location214may include data for running an operating system executed by computing platform201to support the components within printing device104. According to the disclosed embodiments, memory unit206may store the tokens and codes used in performing the deferral operations for printing device104.

Memory unit206may comprise volatile and non-volatile memory. Volatile memory may include random access memory (RAM). Examples of non-volatile memory may include read-only memory (ROM), flash memory, electrically erasable programmable read-only memory (EEPROM), digital tape, a hard disk drive (HDD), or a solid-state drive (SSD). Memory unit206also includes any combination of readable or writable volatile memories or non-volatile memories, along with other possible memory devices.

Computing platform201may host one or more processors, such as CPU202. These processors are capable of executing instructions215stored at one or more storage locations214. By executing these instructions, the processors cause printing device104to perform various operations. The processors also may incorporate processing units for specific purposes, such as application-specific integrated circuits (ASICs) and field programmable gate arrays (FPGAs). Other processors may be included for executing operations particular to components220,222,224, and226. In other words, the particular processors may cause printing device104to act as a printer, copier, scanner, and a facsimile device.

Printing device104also includes an operations panel208, which may be connected to computing platform201. Operations panel208may include a display unit216and an input unit217for facilitating interaction with a user to provide commands to printing device104. Display unit216may be any electronic video display, such as a liquid crystal display (LCD). Input unit217may include any combination of devices that allow users to input information into operations panel208, such as buttons, a touch screen, a keyboard or keypad, switches, dials, and the like. Preferably, input unit217includes a touch-screen digitizer overlaid onto display unit216that senses touch to receive inputs from the user. By this manner, the user interacts with display unit216. Using these components, one may enter codes or other information into printing device104.

Display unit216also may serve as to display results from offline estimation device108, if applicable. Estimation system108may send ink use estimation data to printing device104for display. For example, the operator at printing device104may request an estimate for a received print job103. Printing device104requests an estimate for consumables132according to the disclosed embodiments.

Printing device104also includes network communication processing unit218. Network communication processing unit218may establish a network communication using network communication interface210, such as a wireless or wired connection with one or more other image forming apparatuses or a network service. CPU202may instruct network communication processing unit218to transmit or retrieve information over a network using network communication interface210. As data is received at computing platform201over a network, network communication processing unit218decodes the incoming packets and delivers them to CPU202. CPU202may act accordingly by causing operations to occur on printing device104. CPU202also may retrieve information stored in memory unit206, such as settings for printing device104.

Printing device104also includes print engine260, as disclosed above. Engine260may be a combination of hardware, firmware, or software components that act accordingly to accomplish a task. For example, engine260is comprised of the components and software to print a document. It may receive instructions from computing platform201after user input via operations panel208. Alternatively, engine260may receive instructions from other attached or linked devices.

Engine260manages and operates the low-level mechanism of the printing device engine, such as hardware components that actuate placement of ink or toner onto paper. Engine260may manage and coordinate the half-toner, toner cartridges, rollers, schedulers, storage, input/output operations, and the like. Raster image processor (RIP) firmware290that interprets the page description languages (PDLs) would transmit and send instructions down to the lower-level engine260for actual rendering of an image and application of the ink onto paper during operations on printing device104. RIP firmware290may be located in DFE106, as disclosed above.

Printing device104may include one or more sensors262that collect data and information to provide to computing platform201or CPU202. Each sensor262may be used to monitor certain operating conditions of printing device104. Sensors262may be used to indicate a location of a paper jam, failure of hardware or software components, broken parts, operating system problems, document miss-feed, toner level, as well as other operating conditions. Sensors262also may detect the number of pages printed or processed by printing device104. When a sensor262detects an operational issue or failure event, it may send a signal to CPU202. CPU202may generate an error alert associated with the problem. The error alert may include an error code.

Some errors have hardware-related causes. For example, if a failure occurred in finisher211, such as a paper jam, display unit216may display information about the error and the location of the failure event, or the finisher. In the instance when the paper jam occurs in paper cassettes212, display unit216displays the information about the jam error as located in one of the paper cassettes.

Some errors have a type of firmware-related cause. For example, network communication processing unit218may cause a firmware or software error. Display unit216may display the firmware-related error, any applicable error codes, and provide recommendations to address the error, such as reboot the device.

Memory unit206may store the history of failure events and occurred errors with a timestamp of each error. Printing device104communicates with other devices within system100via network communication interface210by utilizing a network protocol, such as the ones listed above. In some embodiments, printing device104communicates with other devices within system100through REST API, which allows the server to collect data from multiple devices within system100. REST API and SOAP are application protocols used to submit data in different formats, such as files, XML messages, JSON messages, and the like. By utilizing applicable network communication protocols and application protocols, printing device104submits and receives data from estimation system108as well as other printing devices within system100.

FIG.3depicts a schematic partial side view of printing device104equipped with an inline inspection system350according to the disclosed embodiments. Various components and features of printing device104not disclosed inFIG.2are illustrated inFIG.3.FIG.3shows an impression cylinder310as well as an upper portion of printing cylinder311and inking system, or color-selector cylinders313.

Sheets are fed in succession to impression cylinder310. Impression cylinder310may rotate in the clockwise direction inFIG.3and transports each sheet in succession past the printing nip formed between impression cylinder310and printing cylinder311. Once printed, the sheets are taken away from impression cylinder310by a suitable sheet conveyor system303for delivery to a sheet delivery station having multiple delivery piles. Sheet conveyor system303includes a chain gripper system having, for example, two endless chains supporting a plurality of spaced-apart gripper bars for holding the printed sheets by a leading edge thereof, which endless chains are driven along a delivery path between two pairs of chain wheels, including chain wheel331.

Inspection system350provides inline inspection of the sheets being processed in printing device104. Inspection system350includes an optical quality control apparatus for performing inspection of a printed area on a printed side of the sheets. The optical quality control apparatus may be coupled to an image processing unit, such as housed within DFE106for processing the images captured by the optical quality control apparatus.FIG.3shows an example inspection system350.

The optical quality control apparatus includes camera system355with one or more camera units, each comprising at least one line-scan camera356for scanning and capturing an image of the printed area while the sheet is being transported in printing device104past camera system355. Preferably, camera system355includes a single camera unit that is disposed transversely to the path of the sheets for scanning an entire width of the printed area of the sheets. Such camera unit may include one or more line-scan cameras356aligned transversely to the path of the sheets. A single line-scan camera356may be used as long as it can see the whole width of the printed area to be inspected. Depending on practical constraints, it may be desirable to provide two or more cameras356for scanning the entire width of the printed area, each camera scanning a corresponding section of the width of the printed area.

An illumination unit358is provided to suitably illuminate the portion of the printed area that is inspected by means of camera system355. In this example, two lighting sources may be provided on each side of the optical path of camera system355in order to illuminate the desired portion of the printed areas along two different angles. An adjustable blowing device372, such as a blowing pipe, may be provided at the inspection location C inFIG.3in order to blow air against the portion of the printed sheet being inspected.

The location of the one or more line-scan cameras356in printing device104press along the delivery path of the sheets, such as the path of the sheets running from the printing group to the delivery station, is selected in such a way that cyclical vibrations that spread periodically throughout printing device104during printing operations do not occur while camera system355is scanning the printed area of the sheet and capturing a complete image of the printed area. Vibrations may occur as a result of the passage of cylinder pits310aand311aof impression cylinder310and printing cylinder311. Vibrations, therefore, should not interfere with the image capturing process of the camera system.

In other embodiments, inspection system350may include contact image sensors (CISs) for inline inspection. These sensors may help in alerting inspection system350when a sheet is moving through the paper path in order to capture an image for inspection.

An intermediate transfer unit351is provided for guiding or transporting the sheets away from impression cylinder310to the circumference of a downstream located inspection cylinder or drum352. Inspection cylinder or drum352guides or transports the printed sheets in succession in front of and past the camera unit. Intermediate transfer unit351preferably designed to guide the sheets along a curved trajectory forming an arc of a circle and is configured as a rotating gripper system having at least one gripper bar for holding a leading edge of the sheet and transporting the sheet along the curved trajectory. As a rotating gripper system, intermediate transfer unit351is designed to take each successive sheet away from impression cylinder310and transfers it to the circumference of inspection cylinder or drum352, where the leading edge of a sheet is being held by the gripper bar of the rotating gripper system.

FIGS.4A and4Bdepict variable intervals402,403, and422being used in detecting a defect406during printing operations according to the disclosed embodiments. Printing device104may incorporate variable intervals402and403in performing inline inspections using inspection system350. During printing operations, printing device104performs inline image inspection using inspection system350. Inspection system350scans printed sheets400as disclosed above. It may scan one of sheets400at specified intervals. These intervals are variable.

For example, sheets400may include sheet1, sheet2, sheet3, sheet4, sheet5, sheet6, sheet7, sheet8, sheet9, sheet10, sheet11, and sheet12, shown for illustrative purposes. Additional sheets may be used within printing device104. Sheets400may be for printing document105of print job103. Inline inspection points occur according to variable intervals using inspection system350. As shown, first inspection point404and second inspection point405correspond to inspection operations to evaluate a scanned sheet from sheets400. Inspection points occur at the completion of a variable interval within printing device104.

Using the above example, printing device104begins printing print job103and sheet1of sheets400passes through the paper path. First variable interval402elapses and first inspection point404occurs by scanning sheet4. In this example, sheet4is determined to be acceptable so no action is taken. Sheet5is fed into the paper path and second variable interval elapses. Second inspection point405occurs by scanning sheet9. At this point, defect406is detected and printing operations are paused.

According to the disclosed embodiments, first variable interval402and second variable interval403do not scan the same number of sheets400. First variable interval402encompasses sheets1-4while second variable interval403encompasses sheets5-9. Thus, the number of sheets400within first variable interval402is 4 sheets while the number of sheets400within second variable interval403is 5 sheets. Preferably, variable intervals are time-based as opposed to the number of sheets processed. Thus, first variable interval402and second variable interval403both may be 5 seconds in that inspection system350is not counting the number of sheets400processed but scanning sheets according to a set period of time.

This feature may reduce requirements on DFE106to count the number of sheets400between inspections points. Instead, inspection system350is instructed to scan a sheet at the set time for the variable intervals. The term “variable” refers to the number of sheets processed between inspection points. As it is not static, the disclosed embodiments account for job costs caused by the defect as well as provide the disclosed features in addressing defect406that may occur.

When defect406is found, inspection system350may instruct printing device104to stop printing at stop point408. As shown, sheets10,11, and12already may be fed into the paper path to cylinders10and11before stop point408occurs. Printing device104may return a status410to let the operator know that he/she needs to inspect the output. Status410may be shown in operations panel208or the user interface for DFE106. Status410also may be sent to any clients displaying printing device status.

Printing device104will stop feeding sheets400and will clear all sheets within the paper path to the stacker. For sheets400that have been fed but not printed on, printing device104may send these to an output bin227without printing on them. For example, stop point408may occur between sheet12and sheet13of sheets400. Yet, the number of impacted sheets include all sheets processed within second variable interval403. Further, sheets8and9may still be in the paper path when stop point408occurs. Sheets13and14also may be within the paper path. Thus, sheets8-14are cleared from the paper path.

FIG.4Cdepicts a block diagram of separated cleared sheets450from inspection recovery according to the disclosed embodiments. Printing device104clears cleared sheets450from the paper path. As disclosed above byFIGS.4A and4B, sheets8-14are cleared. Further, some of the sheets may be acceptable, such as sheets8and9printed before defect406is detected. The possibly acceptable sheets are placed in a set of sheets, or good sheets452. Good sheets452may be sent to first output bin227A, if more than one output bin227is available at printing device104. If not, then good sheets452may be sent to output bin227.

Cleared sheets450also may be split into a set of defective sheets454. These are sheets within the paper path after the detected defective sheet, shown as sheet10. Defective sheets454most likely have a problem associated with the equipment malfunction that caused defect406, such as misfiring of an inkjet of inking system313. Defective sheets454include sheets10-14. From defective sheets, blank sheets456may be separated from cleared sheets450or defective sheets454. Blank sheets456are those that have no ink or toner on them and may be reused in printing operations. For example, sheets13and14may be within the paper path but not printed on as sheet12was the last printed sheet before stop point408. Preferably, these sets of sheets are sent to separate output bins from good sheets452. Thus, defective sheets454may be sent to second output bin227B and blank sheets456to third output bin227C.

Once the paper path is cleared, printing device104, using DFE106, reports relevant job cost information460to the operator. Sheets before the detected defective sheet may be reported as good. Thus, sheets8and9may be initially reported as good. Sheets after the defective sheet may be reported as waste. Thus, sheets11-14as well as defective sheet10may be reported as waste. These designations may be adjusted, as disclosed below. Printing device104may generate job cost information460and send it to user interface462. User interface462preferably is connected to DFE106to communicate directly with the DFE. It may be at DFE106or connected to a client device, such as client terminal102that allows the operator to directly view information from the DFE as opposed to operations panel208.

Job cost information460may include the number of sheets used. Preferably, the number of sheets is the number of defective sheets454but may include good sheets452and blank sheets456for reference. Job cost information460also may include impressions printed. For example, although sheets8-14are cleared from printing device104, only one or two impressions were used for processing these sheets. In other embodiments, a distinct impression may have been used for each sheet. Job cost information460also includes consumable use for processing and printing defective sheets454. Consumable use may include ink use or toner use.

Other actions that printing device104may take is lowering one or more output bins227A,227B, and227C. This may allow the operator to quickly remove the paper stacks from the respective output bin. Printing device104also may let DFE106know the impression on which defect406was found. DFE106may suspend the active print job and flag it as requiring input from the operator before printing operations continue, such as through user interface462. DFE106also may adjust the page range from print job103so that it resumes printing from the impression on which defect406was found.

Once printing device104stops printing, the operator may perform maintenance or other actions to repair the equipment malfunction. For example, the operator may perform actions to unclog the printhead or repair a clogged inkjet in inking system313. After performing the maintenance, printing device104may report with job cost information460the printing done to unclog the print heads, such as sheets, impressions, ink or toner. Further, it may account for any ink used in printhead cleaning. The actions may be taken multiple times until the problem is resolved. Once printing device104exits maintenance, DFE106will aggregate job cost information from the maintenance operations and track that is separate job cost information460.

After curing defect406, printing device104will resume printing operations. Print job103, currently, suspended, will resume printing, but, however, not automatically. Instead, DFE106will show in user interface462where the operator can review and adjust the resumption point. User interface462may initially be set to where defect406was detected. Using the above examples, resume point420may initially be set for sheet10, or where second inspection point405occurred. User interface462will prompt the operator to review the output stacks of good sheets452and defective sheets454to determine the last good sheet. The last good sheet may differ from the sheet on which defect406was detected because inspection system350does not check every sheet.

Once the operator inspects good sheets452and defective sheets454, the operator determines the last good sheet and may adjust resume point420accordingly. Thus, adjustments464may be made to resume point420as well as the number of good sheets452and defective sheets454. Adjustments464may be made a few different ways. One is where user interface462shows the operator a preview of the page that will print next and the pages before and after this page. The operator may scroll back to previous pages until he/she finds the first defective page. The operator may select the preview to adjust the page from which to resume printing. The operator may additionally specify the number of bad sets or sheets in the stack of defective sheets454. This method may be best for print jobs with a small number of pages, such as printing 100 copies of a 40 page brochure.

Another method for making adjustments464to resume point420is using user interface462to allow the operator to specify the number of defective sheets454on the stack. User interface462may adjust the previews to show the impression on the front of the first defective sheet. Because this may take some time for large print jobs, the operator may suspend the print job so that other print jobs print while the operator determines the page from which to resume printing. This method may be best for transactional jobs for which integrity is critical and for which minimizing waste sheets is important, such as printing credit card statements.

If either jogging or slip sheets are enabled for print job103, then user interface462may allow the operator to specify the number of defective segments. Referring toFIGS.4A and4B, sheets400may be known as segments400in that defective segments are detected by inspection system350. User interface462will adjust the previews to show the front of the first sheet on the first defective segment. A segment may be defined as all the sheets or pages within an offset block or all the sheets or pages between two slip sheets. Because the operator only needs to count segments, he/she can quickly find resume point420. This method may be preferable for large print jobs for which the amount of waste is not critical, such as printing personalized marketing mailers.

In all cases, the operator may use the sheet preview to validate that resume point420is at the expected location. Once the operator adjusts resume point420, print job103will resume printing normally. DFE106will adjust the good versus defective job cost information based on how resume point420is adjusted.

For example, using the disclosure above, user interface462sets resume point420to begin printing at sheet10, which corresponds to the first defective sheet detected by inspection system350. The operator, however, inspects good sheets452and finds that sheets8and9also are defective. The defect began to occur before sheet10. The operator makes adjustments464using user interface462to move resume point420to start with sheet8. Alternatively, resume point420is moved to start with the impression associated with the original sheet8.

After resuming printing operations, third variable interval422is used to determine third inspection point424to resume inspection of sheets are they are printed. Third variable422is based on the time period for inspections, and not tied to the number of sheets processed. Thus, third inspection point424may occur to scan sheet11after printing operations resume. Once print job103completes by printing one or more documents105, printing device104will report job cost information460for the resumed portion of the print job. DFE106may aggregate this information with the previous job cost information and stores the combined information for print job103. This information may be provided to estimation system108for verification and updating estimation processes.

FIG.5depicts a flowchart500for enhanced print inspection recovery according to the disclosed embodiments. Flowchart500may refer toFIGS.1A to4Cfor illustrative purposes. Flowchart500, however, is not limited to the embodiments disclosed byFIGS.1A to4C.

Step502executes by performing printing operations at printing device104. Sheets400may be fed through a paper path created by cylinders10and11. Sheets are printed and finished for print job103. Step504executes by executing a variable interval for inspection operations. Referring toFIGS.4A and4B, multiple variable intervals may be used to initiate inspection points. For example, the variable intervals may correspond to a period of time between inspection points, in which a sheet is scanned by inspection system350. The variable interval, for example, may occur every 5 or 10 seconds and is not tied to the number of sheets processed. Alternatively, the variable interval may be set by the number of sheets processed. The disclosed embodiments do not scan every sheet printed for inspection.

Step505executes by inspecting a printed sheet for defects at an inspection point by inspection system350. For example, after first variable interval402elapses, first inspection point404causes inspection system350to capture an image of the last printed sheet, or sheet4. Inspection system350then reviews sheet4for any possible defects. If no defects are found, then flowchart500returns to step504to execute the next variable interval. If defects are found, then step506executes by analyzing defect406within the inspected sheet.

Step508executes by determining the number of sheets400currently in the paper path of printing device104based on the scanned defective sheet and the variable interval. The number of sheets includes the defective sheet plus any sheets within the processed within the variable interval. It also may include sheets from another variable interval but still within the paper path. Step510executes by removing the number of sheets, or cleared sheets450, from the paper path in printing device104. Further, printing operations may be stopped.

Step512executes by determining a set of good sheets452from cleared sheets450. Good sheets452may include those sheets printed before the detected defective sheet, at least initially. Using the example above, if the detected defective sheet is sheet10, then sheets8and9, which are still in the paper path, may be placed in good sheets452. Step514executes by determining a set of defective sheets454. Initially, defective sheets454includes the sheets in the paper path including all sheets printed since within the variable interval and from when the defective sheet was printed. Step516executes by determining a set of blank sheets456from cleared sheets450. Blank sheets456may be those sheets in the paper path, but not yet printed on.

Step518executes by generating job cost information460from defective sheets454for waste in performing printing operations on sheets that will not be used. As disclosed above, job cost information460may include sheets used, impressions printed, and any ink or toner used by printing device104. Step520executes by sending the sets of sheets to any applicable output bin. For example, good sheets452may be sent to first output bin227A, defective sheets454to second output bin227B, and blank sheets456to third output bin227C. The different output bins allow the operator to review the sheets for adjusting the number of defective sheets. It also allows more than one operator to start on inspection recovery for large print jobs on production printing devices.

FIG.6depicts a flowchart600for adjusting resume point420during inspection recovery operations according to the disclosed embodiments. Flowchart600may refer toFIGS.1A to5for illustrative purposes. Flowchart600, however, is not limited to the embodiments disclosed in flowchart600.

Step602executes by reviewing cleared sheets450. Preferably, the operator will review good sheets452and defective sheets454. As disclosed above, these may be sent to separate output bins at printing device104. In reviewing the sheets, the operator may determine when the equipment malfunction started and which sheet is actually printed correctly.

Step604executes by performing equipment maintenance at printing device104. In performing the maintenance, additional resources or consumables may be used. DFE106and printing device104accounts for these additional resources and consumables during the maintenance operations.

Step606executes by automatically displaying resume point420for print job103. DFE106will show in user interface462where in the printing operations that the last good sheet is located. The last good sheet may be set to the sheet on which defect406is detected. Step608executes by determining the actual last good sheet printed before defect406occurred. The operator, in step602, may determine that defect406occurred earlier than the displayed last good sheet. In this instance, the last good sheet should be adjusted.

Step610executes by adjusting the last good sheet using user interface462connected to DFE106. As disclosed above, the operator may adjust resume point420according to a few different methods. The operator may scroll or input information to adjust where the last good sheet occurred.

Step611executes by suspending print job103while steps602-610are being performed. Step611may execute at any time after printing operations are stopped due to detection of defect406. Step612executes by processing a subsequent print job at printing device104. As the operator is reviewing sheets and doing other tasks, a subsequent print job may be processed at printing device104so that the printing device is not sitting idle and time is not being wasted. Once the equipment malfunction is addressed, there is no need to continue to pause printing operations. Downtime also loses money for the print shop. When the operator determines and adjusts the last good sheet for resuming print job103, the subsequent print job may be paused until print job103is complete.

Step614executes by resuming printing operations of print job103at the last good sheet, as determined above. Step616executes by updating job cost information460for handling defect406with the resources and consumables used to resolved the equipment malfunction. DFE106may aggregate job cost information460with previous job cost information and store the combined information for print job103. Printing device104may report job cost information460for handling defect406to estimation system108.

As will be appreciated by one skilled in the art, the present invention may be embodied as a system, method or computer program product. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, the present invention may take the form of a computer program product embodied in any tangible medium of expression having computer-usable program code embodied in the medium.

Any combination of one or more computer usable or computer readable medium(s) may be utilized. The computer-usable or computer-readable medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. More specific examples (a non-exhaustive list) of the computer-readable medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a transmission media such as those supporting the Internet or an intranet, or a magnetic storage device. Note that the computer-usable or computer-readable medium could even be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via, for instance, optical scanning of the paper or other medium, then compiled, interpreted, or otherwise processed in a suitable manner, if necessary, and then stored in a computer memory.

Computer program code for carrying out operations of the present invention may be written in any combination of one or more programming languages, including an object-oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).

The present invention is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.

The flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams or flowchart illustration, and combinations of blocks in the block diagrams or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an” and “the” are intended to include plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Embodiments may be implemented as a computer process, a computing system or as an article of manufacture such as a computer program product of computer readable media. The computer program product may be a computer storage medium readable by a computer system and encoding computer program instructions for executing a computer process. When accessed, the instructions cause a processor to enable other components to perform the functions disclosed above.

The corresponding structures, material, acts, and equivalents of all means or steps plus function elements in the claims below are intended to include any structure, material or act for performing the function in combination with other claimed elements are specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for embodiments with various modifications as are suited to the particular use contemplated.

One or more portions of the disclosed networks or systems may be distributed across one or more printing systems coupled to a network capable of exchanging information and data. Various functions and components of the printing system may be distributed across multiple client computer platforms, or configured to perform tasks as part of a distributed system. These components may be executable, intermediate or interpreted code that communicates over the network using a protocol. The components may have specified addresses or other designators to identify the components within the network.

It will be apparent to those skilled in the art that various modifications to the disclosed may be made without departing from the spirit or scope of the invention. Thus, it is intended that the present invention covers the modifications and variations disclosed above provided that these changes come within the scope of the claims and their equivalents.