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Automatic Calibration of Gravure Systems

In cooperation with Hell Gravure Systems (Heidelberger Druckmaschinen AG) we developed an image processing system for automatic calibration of the gravure heads of a gravure machine. One of the key goals in the development of the system was to come up with a solution that was hardware independent, future proofed and could be constructed with standard components, not to mention easy to use. We also strived to ensure the integration into existing software through the use of a simple interface existed. We believe we met all of these goals.

System Components

Taking The Image

  • Industrial Camera.
  • LED Lighting.
  • Standard Framegrabber

Image Processing

  • Standard PC Hardware.
  • Modular image processing software.
  • Easy to use library to allow for integration into existing software.

Output

  • Displayed on a VGA monitor.
  • Transfer of measurement results to the main application.

Tasks of the Image Processing Software

  • Search for optimal measurement points and regulate their lighting.
  • Focusing of the camera.
  • Search for the beginning of the cylinder that's about to be engraved.
  • Search for a marking that sets the starting position for the gravure head.
  • Measurement of a test gravure for adaptive fine tuning of the gravure system.

Example: Measurement of a Test Gravure

Below there's a description of the configuration used to take the measurements of a test gravure. The main application of the machine regulation starts the measurement process after the test gravure has been localized. The image processing DLL links the modules necessary for this task, it then activates the camera and takes measurements on the acquired image. Normally a test gravure will contain three strains of different depths. Every strain consists of numerous bowls. Measurements are taken on every bowl within a given picture and the results are transferred to the main application. The main application passes these results on to the regulation of the gravure heads which leads to perpetual tuning of the heads until the results comply with the given tolerances. Normally this is achieved within a maximum of three steps.

software structure

Configuration of the Measurement Module

The measurement module contains a graphical dialog for easy configuration. The module is configured once and then is stored. The image processing modules (filters) are controlled by the image processing DLL through a COM interface. The dialog is also used for maintenance purposes.

dialogue of the filter

Graphical Output

Digitization of the Original Image

Image Displayed on the Monitor
(Including Measurement Lines)

Originalbild

measured image

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