胶印油墨预置机制与技术的研究
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摘要
油墨预置技术是在印刷前，通过提取版面图文面积覆盖率分布的数据化信息和墨层厚度的定量要求，按照一定的方式转化为输出墨量要求后，再依此设置输出墨量。相对于传统的凭经验预置墨量，该技术具有输出墨量预置的准确性较高、减少试印的时间和材料浪费等优点。本文通过对油墨转移过程的分布特征进行深入的研究，提出一种油墨预置的新方法，以进一步提高油墨预置的精度。本文的主要贡献和创新点如下：
1.利用输墨系统的计算机仿真方法，研究油墨转移过程中的分布规律，验证了只有一个墨区输出油墨时，输出的墨量值和承印物上各墨区的墨层厚度之间存在着正比例的关系；多个墨区分别输出油墨时，承印物上墨层厚度分布值是各墨区单独输出墨量时，承印物上墨层厚度分布值的线性相加等多项规律。
2.针对一个墨区输出单位量的油墨，本文利用BP神经网络建立一定范围内各墨区的图文覆盖率分布和承印物上墨量分布之间的映射关系;然后读入实际印刷的版面覆盖率分布，利用训练好的BP网络，获得该墨区输出的油墨在承印物上的墨量分布向量，以此作为矩阵的一列，构建一个能定量地表达当前的图文面积覆盖率分布条件下的油墨流布特征。首次研究解决了印刷过程油墨流布特征的定量描述方法。
3.利用油墨流布特征矩阵，从理论上证明由于输墨系统性能固有的局限性，在一定的图文覆盖率分布条件下，承印物上墨量可能无法达到均勻一致的要求。基于此，本文创新地使用矩阵的奇异值分解法，通过截断奇异值的方法，求取一种油墨预置值，在该设置条件下，能满足承印物上墨量与标准要求的误差均方根小于规定的要求。
4.在上述研究的基础上，本文给出一种实现胶印油墨预置新的、完整的方法。首先利用印前数字文件，计算各墨区的图文面积覆盖率，并对网点面积的几何扩大进行补偿。然后利用训练好的BP神经网络，产生一个可以反映油墨流布特征的矩阵，釆用矩阵奇异值分解的方法，求得承印物上墨量分布近似标准要求条件下的墨斗辊输出墨量要求，再利用该值计算各墨区的墨键设置值。本方法的创新性在于，输出墨量预置值是根据特定条件下的油墨流布特征而获得，包含了油墨的回流和横向流动等油墨传递与转移特征对油墨预置的重要影响。根据本方法开发的胶印油墨预置系统已在多家印刷企业实现产业化应用，并取得良好的效益。
Ink preset is a process to set the output ink by the digital information of the imagecoverage on plate and the quantitative requirements of the ink film thickness. Compared withthe traditional method which relies on expeirence，this technology is of significant value for itsmore precise preset to spare the time of pirnting and reduce the waste of material. This paperstudies ink distirbution characteristic in the ink transfer process and gives a new method torealize the ink preset which can further improve the preset accuracy. The main contirbutionsand innovation points of this paper are summarized as follows:
1. Based on the inking system computer simulation method，this paper have acomprehensively study on the laws of the ink transfer process. It's veirifed that when one inkzone output ink, a kind of direct proportion exists between the ink output value and ink layerthickness of each ink zone on the substrate; when a number of ink zones output ink respectively,the ink quantity distirbution on the substrate equals to the sum total of the ink quantity of eachink zone output separately; Etc.
2. When one zone output a unit quantity ink, this paper use BP neural network to create themapping relationship between the image coverage rate of ink zones within a certain range andthe ink distirbution on the substrate. Then atfer reading the image coverage rate distirbution ofdigital prepress ifle, using the trained BP neural network, we can get the ink quantitydistirbution vector on the substrate, which is to be a column of the matirx and construct a matirxto express the ink distirbution characteirstics quantitatively under the conditions of the currentimage coverage rate distirbution. It is the first time to solve the quantitative description methodof ink distirbution feature in the pirnting process.
3. By the ink distribution characteristics of the matirx, this paper theoretically proves thatfor the inherent limitation of the inking system，the ink quantity on the substrate can not achievethe desired uniform requirements under the condition of a given image coverage rate. Based onthis, this paper uses the matrix singular value decomposition method innovatively, by themethod of truncated singular value, obtain ink preset value which can meet the requirement thatthe root mean square errors of the ink quantity on the substrate and the standard is less than theprescirbed requirement.
4. On the basis of the above research, this paper gives a new and integral method to realizethe ink preset. Firstly, calculate the image coverage rates of each ink zone rfom digital prepressfile, and compensate for the geometric expansion of the dot area; then use the trained BP neuralnetwork to produce a matrix which can reflect the distirbution characteristics of the ink; byusing the matirx singular value decomposition method, get the output ink value require of thefountain roller under the condition of the ink quantity distirbution on the substrate is approximate to the standard; after that use the value to calculate the ink preset value of each inkzone. The innovation of this method is that the output ink preset value is obtained based on theink distirbution characteirstics under the specific conditions, including the important inlfuenceof ink transfer characteirstics because of the ink backflow and axial movement. The developedoffset press ink preset system has been equipped by several pirnting companies and producedgood benefits.
1.利用输墨系统的计算机仿真方法，研究油墨转移过程中的分布规律，验证了只有一个墨区输出油墨时，输出的墨量值和承印物上各墨区的墨层厚度之间存在着正比例的关系；多个墨区分别输出油墨时，承印物上墨层厚度分布值是各墨区单独输出墨量时，承印物上墨层厚度分布值的线性相加等多项规律。
2.针对一个墨区输出单位量的油墨，本文利用BP神经网络建立一定范围内各墨区的图文覆盖率分布和承印物上墨量分布之间的映射关系;然后读入实际印刷的版面覆盖率分布，利用训练好的BP网络，获得该墨区输出的油墨在承印物上的墨量分布向量，以此作为矩阵的一列，构建一个能定量地表达当前的图文面积覆盖率分布条件下的油墨流布特征。首次研究解决了印刷过程油墨流布特征的定量描述方法。
3.利用油墨流布特征矩阵，从理论上证明由于输墨系统性能固有的局限性，在一定的图文覆盖率分布条件下，承印物上墨量可能无法达到均勻一致的要求。基于此，本文创新地使用矩阵的奇异值分解法，通过截断奇异值的方法，求取一种油墨预置值，在该设置条件下，能满足承印物上墨量与标准要求的误差均方根小于规定的要求。
4.在上述研究的基础上，本文给出一种实现胶印油墨预置新的、完整的方法。首先利用印前数字文件，计算各墨区的图文面积覆盖率，并对网点面积的几何扩大进行补偿。然后利用训练好的BP神经网络，产生一个可以反映油墨流布特征的矩阵，釆用矩阵奇异值分解的方法，求得承印物上墨量分布近似标准要求条件下的墨斗辊输出墨量要求，再利用该值计算各墨区的墨键设置值。本方法的创新性在于，输出墨量预置值是根据特定条件下的油墨流布特征而获得，包含了油墨的回流和横向流动等油墨传递与转移特征对油墨预置的重要影响。根据本方法开发的胶印油墨预置系统已在多家印刷企业实现产业化应用，并取得良好的效益。
Ink preset is a process to set the output ink by the digital information of the imagecoverage on plate and the quantitative requirements of the ink film thickness. Compared withthe traditional method which relies on expeirence，this technology is of significant value for itsmore precise preset to spare the time of pirnting and reduce the waste of material. This paperstudies ink distirbution characteristic in the ink transfer process and gives a new method torealize the ink preset which can further improve the preset accuracy. The main contirbutionsand innovation points of this paper are summarized as follows:
1. Based on the inking system computer simulation method，this paper have acomprehensively study on the laws of the ink transfer process. It's veirifed that when one inkzone output ink, a kind of direct proportion exists between the ink output value and ink layerthickness of each ink zone on the substrate; when a number of ink zones output ink respectively,the ink quantity distirbution on the substrate equals to the sum total of the ink quantity of eachink zone output separately; Etc.
2. When one zone output a unit quantity ink, this paper use BP neural network to create themapping relationship between the image coverage rate of ink zones within a certain range andthe ink distirbution on the substrate. Then atfer reading the image coverage rate distirbution ofdigital prepress ifle, using the trained BP neural network, we can get the ink quantitydistirbution vector on the substrate, which is to be a column of the matirx and construct a matirxto express the ink distirbution characteirstics quantitatively under the conditions of the currentimage coverage rate distirbution. It is the first time to solve the quantitative description methodof ink distirbution feature in the pirnting process.
3. By the ink distribution characteristics of the matirx, this paper theoretically proves thatfor the inherent limitation of the inking system，the ink quantity on the substrate can not achievethe desired uniform requirements under the condition of a given image coverage rate. Based onthis, this paper uses the matrix singular value decomposition method innovatively, by themethod of truncated singular value, obtain ink preset value which can meet the requirement thatthe root mean square errors of the ink quantity on the substrate and the standard is less than theprescirbed requirement.
4. On the basis of the above research, this paper gives a new and integral method to realizethe ink preset. Firstly, calculate the image coverage rates of each ink zone rfom digital prepressfile, and compensate for the geometric expansion of the dot area; then use the trained BP neuralnetwork to produce a matrix which can reflect the distirbution characteristics of the ink; byusing the matirx singular value decomposition method, get the output ink value require of thefountain roller under the condition of the ink quantity distirbution on the substrate is approximate to the standard; after that use the value to calculate the ink preset value of each inkzone. The innovation of this method is that the output ink preset value is obtained based on theink distirbution characteirstics under the specific conditions, including the important inlfuenceof ink transfer characteirstics because of the ink backflow and axial movement. The developedoffset press ink preset system has been equipped by several pirnting companies and producedgood benefits.
引文
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