An industrial inkjet printer wireless connection system and algorithm based on starburst technology
By utilizing the wireless connection system and algorithms of StarFlash technology, the connection stability and synchronization accuracy issues of industrial inkjet printers have been resolved, enabling efficient and low-cost multi-printer collaborative printing. This meets the needs of industrial inkjet printers for flexible layout and high-precision printing in complex environments.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- WUHAN AGILE MICROELECTRONICS CO LTD
- Filing Date
- 2026-03-26
- Publication Date
- 2026-06-16
AI Technical Summary
Existing industrial inkjet printer connection methods suffer from problems such as high cost, easy damage, weak anti-interference ability, and poor synchronization accuracy, making it difficult to meet the needs of flexible layout of multiple printheads and rapid production changeover.
The system employs a wireless connection system and algorithm based on StarFlash technology. Through the low-latency transmission and high-concurrency connection capabilities of the StarFlash protocol, wireless communication between the host and the printhead is achieved. Combined with a centralized scheduling and management module and a StarFlash communication module, resources are dynamically allocated and clock synchronization is achieved to ensure printing accuracy and stability.
It achieves highly reliable and low-latency inkjet printing, with a single host unit capable of controlling hundreds or even thousands of printheads, improving system integration and layout flexibility, reducing costs, and meeting the needs of multi-printhead collaborative printing.
Smart Images
Figure CN122227211A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of inkjet printing technology, and in particular to a wireless connection system and algorithm for industrial inkjet printers based on star-flash technology. Background Technology
[0002] Currently, most industrial inkjet printers use wired connections, linking the controller to the printhead via industrial cables. With the development of smart manufacturing, the demand for production line flexibility is increasingly prominent, and traditional wired connections, due to physical limitations, cannot meet the needs of flexible multi-printhead layouts and rapid production changeovers. In recent years, some manufacturers have attempted to use Wi-Fi or Bluetooth technologies to replace wired solutions. However, the connection methods currently used in these industrial inkjet printers all have certain drawbacks, specifically:
[0003] Wired connection: Shielded twisted pair or coaxial cable is used to achieve physical connection through aviation plug. The disadvantages are high cable cost (up to thousands of yuan per cable), easy to be damaged by mechanical damage leading to disconnection, and a single host can only drive a single nozzle.
[0004] Wi-Fi solution: Based on the 802.11n protocol, the theoretical latency is 10-100ms. The disadvantages are weak anti-interference ability (the packet loss rate increases sharply when the signal-to-noise ratio decreases) and the need to configure additional QoS policies when multiple devices are connected concurrently.
[0005] Bluetooth solution: adopts BLE 5.0 protocol with a latency of 10-30ms. Its disadvantage is poor synchronization accuracy (>1ms), which cannot meet the timing requirements of multi-printhead collaborative printing. Summary of the Invention
[0006] To address the aforementioned technical issues, this invention proposes a wireless connection system and algorithm for industrial inkjet printers based on StarFlash technology. This system and algorithm leverage the physical layer advantages, low-latency transmission characteristics, and high-concurrency connection capabilities of the StarFlash protocol to achieve wireless connection of industrial inkjet printers while significantly improving the stability and accuracy of inkjet printing. Furthermore, a single host scheduling device can simultaneously control hundreds or even thousands of printhead terminal devices, greatly improving system integration and layout flexibility while reducing overall costs.
[0007] A wireless connection system for industrial inkjet printers based on StarFlash technology includes a StarFlash wireless communication link for data transmission between a host scheduling device and printhead terminal devices. The StarFlash wireless communication link is executed in cooperation with a centralized scheduling management module integrated on the host scheduling device and a StarFlash communication module integrated on the printhead terminal devices. The centralized scheduling management module is used to dynamically allocate wireless communication resources to each printhead terminal device and synchronize the clocks of each printhead terminal device to coordinate the printing actions of multiple printheads. The StarFlash communication module receives printing instructions from the host scheduling device and drives the printhead actuator to complete the printing action under precise timing.
[0008] As a preferred embodiment of the above technical solution, the process by which the centralized scheduling and management module cooperates with the star-flash communication module to achieve wireless printing of the printhead terminal device is as follows:
[0009] S1, Network Initialization and Synchronization, uses StarSpark's precision clock synchronization protocol to align the clocks of all nozzles with the host.
[0010] S2, Communication Resource Allocation and Printing Execution, specifically:
[0011] S21, the host runs a dynamic time slot allocation algorithm to generate a superframe structure based on the tasks of all current nozzles;
[0012] S22, the host broadcasts the time slot allocation table through the beacon time slot, and each nozzle receives and stores its own time slot information;
[0013] S23, In a fixed service time slot, the host sends a printing instruction data packet to the designated printhead. The printhead listens and receives the packet in its own time slot and immediately adds it to the execution queue after confirmation.
[0014] S24, the printhead MCU drives the printhead to perform printing at precise microsecond-level moments based on the timestamp in the instruction and the local synchronization clock;
[0015] S3, Dynamic Adaptive Adjustment: When the host detects that the queue latency exceeds the threshold or the packet loss rate increases, the algorithm triggers dynamic adjustment and reallocates dynamic service time slots.
[0016] As a preferred embodiment of the above technical solution, the specific process of step S1 is as follows:
[0017] S11, the host is powered on, the StarNet network is started, and beacon frames are sent periodically;
[0018] S12: After the nozzle is powered on, it scans the host beacon on the pre-configured channel, initiates an association request, and reports its own capabilities.
[0019] S13, the host accepts the association, assigns a unique logical address to each printhead, and uses the StarSpark precision clock synchronization protocol to complete the clock alignment between all printheads and the host.
[0020] As a preferred embodiment of the above technical solution, in step S1, the host generates a directed weighted graph G(V, E) based on the printing tasks reported by each responding printhead and gives higher priority to continuous printing services. Here, vertex V represents a device, and the weight of edge E represents the theoretical minimum latency and priority of communication between devices.
[0021] As a preferred embodiment of the above technical solution, a contention access time slot is added between the beacon time slot and the fixed service time slot. The contention access time slot is used for new equipment to enter the network and emergency status reporting.
[0022] As a preferred embodiment of the above technical solution, the specific process of step S3 is as follows:
[0023] S31, the host continuously monitors the end-to-end latency and packet loss rate of each nozzle command;
[0024] S32, if the packet loss rate of a certain nozzle is detected to increase due to environmental interference, the scheduling algorithm can be triggered immediately;
[0025] If the production line changes or the nozzle task changes, the host computer recalculates the time slot allocation table and smoothly switches in the next superframe cycle.
[0026] As a preferred embodiment of the above technical solution, the workflow after the scheduling algorithm is triggered is as follows:
[0027] Enable adaptive frequency hopping for star flash to avoid interference frequencies;
[0028] In the next superframe, allocate additional retransmission time slots for the nozzle in the dynamic pool or adjust its fixed time slot position.
[0029] The beneficial effects of this invention are as follows:
[0030] 1. High reliability and anti-interference: Utilizing the physical layer advantages of Starflash technology (such as Polar coding and dynamic frequency hopping), it achieves an extremely low bit error rate in complex industrial electromagnetic environments, and the connection stability far exceeds that of traditional wireless solutions.
[0031] 2. Low latency and high precision: By leveraging the low latency transmission characteristics of the StarFlash protocol, combined with the system's centralized scheduling and clock synchronization mechanism, the instant delivery and execution of printing commands are ensured, achieving sub-millimeter-level printing position accuracy and meeting the needs of high-speed dynamic printing.
[0032] 3. Powerful centralized control capability: Based on the high concurrency connection capability of StarFlash technology, a single host scheduling device can control hundreds or even thousands of nozzle terminal devices simultaneously, which greatly improves the system integration and layout flexibility and reduces the overall cost.
[0033] 4. Intelligent Collaboration: Through centralized dynamic resource scheduling and status management, high-precision collaborative operation of multiple nozzles is achieved, and intelligent maintenance functions based on equipment status data are supported. Attached Figure Description
[0034] Figure 1 This is a schematic diagram of the present invention. Detailed Implementation
[0035] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.
[0036] like Figure 1 The illustrated industrial inkjet printer wireless connection system based on StarFlash technology includes a StarFlash wireless communication link for data transmission between a host scheduling device and printhead terminal devices. The StarFlash wireless communication link is executed in conjunction with a centralized scheduling management module integrated on the host scheduling device and a StarFlash communication module integrated on the printhead terminal devices. The centralized scheduling management module dynamically allocates wireless communication resources to each printhead terminal device and synchronizes the clocks of each printhead terminal device to coordinate the printing actions of multiple printheads. The StarFlash communication module receives printing commands from the host scheduling device and drives the printhead actuator to complete the printing action under precise timing.
[0037] In this embodiment, the process by which the centralized scheduling and management module cooperates with the StarFlash communication module to achieve wireless printing of the printhead terminal device is as follows:
[0038] S1, Network Initialization and Synchronization, uses StarSpark's precision clock synchronization protocol to align the clocks of all nozzles with the host.
[0039] S2, Communication Resource Allocation and Printing Execution, specifically:
[0040] S21, the host runs a dynamic time slot allocation algorithm to generate a superframe structure based on the tasks of all current nozzles;
[0041] S22, the host broadcasts the time slot allocation table through the beacon time slot, and each nozzle receives and stores its own time slot information;
[0042] S23, In a fixed service time slot, the host sends a printing instruction data packet to the designated printhead. The printhead listens and receives the packet in its own time slot and immediately adds it to the execution queue after confirmation.
[0043] S24, the printhead MCU drives the printhead to perform printing at precise microsecond-level moments based on the timestamp in the instruction and the local synchronization clock;
[0044] S3, Dynamic Adaptive Adjustment: When the host detects that the queue latency exceeds the threshold or the packet loss rate increases, the algorithm triggers dynamic adjustment and reallocates dynamic service time slots.
[0045] In this embodiment, the specific process of step S1 is as follows:
[0046] S11, the host is powered on, the StarNet network is started, and beacon frames are sent periodically;
[0047] S12: After the nozzle is powered on, it scans the host beacon on the pre-configured channel, initiates an association request, and reports its own capabilities.
[0048] S13, the host accepts the association, assigns a unique logical address to each printhead, and uses the StarSpark precision clock synchronization protocol to complete the clock alignment between all printheads and the host.
[0049] In this embodiment, in step S1, the host generates a directed weighted graph G(V, E) based on the printing tasks reported by each responding printhead and gives higher priority to continuous printing services. Here, vertex V represents a device, and the weight of edge E represents the theoretical minimum latency and priority of communication between devices.
[0050] In this embodiment, a contention access time slot is added between the beacon time slot and the fixed service time slot. The contention access time slot is used for new equipment to enter the network and emergency status reporting.
[0051] In this embodiment, the specific process of step S3 is as follows:
[0052] S31, the host continuously monitors the end-to-end latency and packet loss rate of each nozzle command.
[0053] Specifically, when the number of printheads is small, monitoring metrics and frequency can be simplified, focusing on the communication status of key printheads. For example, only the queue latency and packet loss rate of printheads in continuous printing operations can be monitored;
[0054] S32, if the packet loss rate of a certain nozzle is detected to increase due to environmental interference, the scheduling algorithm can be triggered immediately;
[0055] If the production line changes or the nozzle task changes, the host computer recalculates the time slot allocation table and smoothly switches in the next superframe cycle.
[0056] In this embodiment, the workflow after the scheduling algorithm is triggered is as follows:
[0057] Enable adaptive frequency hopping for star flash to avoid interference frequencies;
[0058] In the next superframe, allocate an additional retransmission time slot for this nozzle in the dynamic pool or adjust its fixed time slot position.
[0059] Specifically, a lightweight deep Q-network (DQN) model can be used, with global network throughput and worst-case latency as reward functions, to learn online and output a reallocation strategy for dynamic service time slots. Due to the smaller system size, adjustments can be completed in a shorter time, ensuring a smooth transition. For example, adjustments can be completed within 1-2 superframe cycles.
[0060] Meanwhile, the algorithm for enabling wireless printing by printhead terminal devices through the collaboration between the centralized scheduling and management module and the StarFlash communication module can also be implemented in the following ways:
[0061] Option 1 employs a multi-head collaborative synchronization and bidirectional ranging optimization algorithm to achieve a clock synchronization error between printheads of <10ns, ensuring absolute alignment of multi-head printed patterns (accuracy ±0.05mm) on a high-speed moving (2m / s) platform.
[0062] The algorithm principle and steps are as follows:
[0063] 1. High-precision clock synchronization protocol:
[0064] Two-way ranging (TWR) and clock offset calculation: Within the allocated synchronization time slots, grouped two-way ranging is performed between the host and the nozzles, and between nozzles themselves. Each group exchanges data packets containing precise timestamps t1, t2, t3, and t4. A Kalman filter is used to optimally estimate the propagation time τ and clock offset θ for multiple measurements, filtering out random jitter introduced by the RF circuitry.
[0065] Hierarchical synchronization topology: Constructing a minimum spanning tree with the host as the root node. Synchronization information is transmitted hierarchically along the tree structure. Each node integrates the synchronization signals from its parent node and the bidirectional ranging results with its peer nodes, and locally adjusts its own clock through a consensus algorithm (such as the average consensus protocol), ultimately achieving high-precision synchronization across the entire network.
[0066] 2. Motion compensation prediction algorithm:
[0067] In dynamic inkjet printing scenarios, the printhead moves relative to the object being printed. The algorithm integrates the real-time position P(t) and velocity V(t) fed back from the encoder.
[0068] Each inkjet printing instruction includes not only the printed content but also a future trigger timestamp predicted based on a motion model: T_trigger = T_send + τ + (P_target - P(t)) / V(t) + ΔT_calib. Here, ΔT_calib is the system latency compensation amount learned online based on historical data.
[0069] The nozzle control unit (STM32H743) uses a timer to trigger the PWM output based on this high-precision T_trigger, rather than simply executing the command immediately upon receiving it.
[0070] Option 2 employs intelligent anti-interference and spectrum sensing algorithms to achieve a bit error rate of <10⁻ in the complex 2.4GHz industrial frequency band (which is subject to interference from Wi-Fi, Bluetooth, and motor inverters). 9 To ensure that "a stable connection is maintained even next to the welding equipment".
[0071] The algorithm principle and steps are as follows:
[0072] 1. Joint Spectrum Sensing (JSS):
[0073] During inactive time slots, the baseband processor switches to spectrum sensing mode and quickly scans the 80MHz bandwidth.
[0074] Compressed sensing technology is used to acquire sparse spectral signals at a sampling rate much lower than that of the Nyquist spectrum, and the center frequency and bandwidth of the interference source are identified by the reconstruction algorithm to generate a real-time spectrum map.
[0075] 2. Dynamic spectrum selection and adaptive frequency hopping:
[0076] The core is an interference avoidance decision tree model. The inputs are a spectrum map, current link quality (CQI), and service priority.
[0077] The model first determines the type of interference: if it is wideband continuous interference (such as frequency converter), it triggers frequency switching and jumps to the preset "clean" backup channel; if it is narrowband burst interference (such as instantaneous electric arc), it triggers time-domain avoidance and delays the transmission of critical data packets through a dynamic scheduling algorithm.
[0078] The frequency hopping pattern is centrally calculated and securely distributed by the host. The pattern generation uses a chaotic sequence, which has quasi-randomness and predictability (only for authorized devices), and strong anti-tracking capability.
[0079] 3. Adaptive Polar code encoding:
[0080] Based on the real-time feedback of channel state information, the code rate R and information bit set of the Polar code are dynamically adjusted.
[0081] When channel conditions are good, a higher code rate (e.g., R = 3 / 4) is used to improve efficiency; when interference is severe, a lower code rate (e.g., R = 1 / 2) or even an additional parity bit is introduced to sacrifice bandwidth for extremely high reliability.
[0082] Option 3 employs a large-scale network adaptive routing and load balancing algorithm to optimize data flow paths, balance network load, prevent single-point congestion, and guarantee an extended latency limit of 300μs in ultra-large production lines or hybrid networks with more than 4096 nozzles.
[0083] The algorithm principle and steps are as follows:
[0084] 1. Adaptive routing based on Ant Colony Optimization (ACO):
[0085] The network topology is abstracted as a graph. Each data packet is treated as an "ant".
[0086] As the "ants" move forward, they dynamically update the "pheromones" on their path based on information such as real-time latency, remaining time slot resources, and historical success rates.
[0087] Subsequent data packets will select paths with high pheromone concentrations with a high probability, forming an efficient and self-healing data flow backbone.
[0088] 2. Hybrid scheduling of centralized and distributed systems:
[0089] The host (or host cluster) is responsible for global topology management and flooding broadcast of critical commands (such as emergency stop and mode switching).
[0090] Printhead status synchronization and non-real-time data (ink volume) reporting are achieved through multi-hop transmission in the StarFlash Mesh network using a distributed routing algorithm, reducing the burden on the host.
[0091] The host scheduling device uses an industrial-grade embedded computer (such as one based on an ARM Cortex-A series processor) as its core and runs a real-time operating system (such as Linux with PREEMPT-RT patch). This device integrates a StarSpark main control chip (such as Hi3861V100) and expands necessary industrial interfaces (such as EtherCAT and PROFINET) for connection to the upper-level MES / PLC system. The device is equipped with a touchscreen for parameter configuration and status monitoring.
[0092] Sprayer terminal equipment: Each sprayer module integrates a StarSpark slave chip, a microcontroller (MCU, such as the STM32H7 series), a sprayer drive circuit, and necessary sensors (such as temperature sensors and negative pressure sensors). The StarSpark chip communicates with the MCU via a high-speed SPI or UART interface. The entire module adopts a compact, shielded design to adapt to industrial environments.
[0093] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.
Claims
1. A wireless connection system for industrial inkjet printers based on star-flash technology, characterized in that: The system includes a StarFlash wireless communication link for data transmission between the host scheduling device and the printhead terminal device. The StarFlash wireless communication link is executed in cooperation with a centralized scheduling management module integrated on the host scheduling device and a StarFlash communication module integrated on the printhead terminal device. The centralized scheduling management module is used to dynamically allocate wireless communication resources to each printhead terminal device and synchronize the clocks of each printhead terminal device to coordinate the printing actions of multiple printheads. The StarFlash communication module receives printing instructions from the host scheduling device and drives the printhead actuator to complete the printing action under precise timing.
2. The wireless connection system for industrial inkjet printers based on star-flash technology according to claim 1, characterized in that: The process by which the centralized scheduling and management module works in conjunction with the StarFlash communication module to enable wireless printing from the printhead terminal device is as follows: S1, Network Initialization and Synchronization, uses StarSpark's precision clock synchronization protocol to align the clocks of all nozzles with the host. S2, Communication Resource Allocation and Printing Execution, specifically: S21, the host runs a dynamic time slot allocation algorithm to generate a superframe structure based on the tasks of all current nozzles; S22, the host broadcasts the time slot allocation table through the beacon time slot, and each nozzle receives and stores its own time slot information; S23, In a fixed service time slot, the host sends a printing instruction data packet to the designated printhead. The printhead listens and receives the packet in its own time slot and immediately adds it to the execution queue after confirmation. S24, the printhead MCU drives the printhead to perform printing at precise microsecond-level moments based on the timestamp in the instruction and the local synchronization clock; S3, Dynamic Adaptive Adjustment: When the host detects that the queue latency exceeds the threshold or the packet loss rate increases, the algorithm triggers dynamic adjustment and reallocates dynamic service time slots.
3. The wireless connection system for an industrial inkjet printer based on star-flash technology according to claim 2, characterized in that: The specific process of step S1 is as follows: S11, the host is powered on, the StarNet network is started, and beacon frames are sent periodically; S12: After the nozzle is powered on, it scans the host beacon on the pre-configured channel, initiates an association request, and reports its own capabilities. S13, the host accepts the association, assigns a unique logical address to each printhead, and uses the StarSpark precision clock synchronization protocol to complete the clock alignment between all printheads and the host.
4. The wireless connection system for an industrial inkjet printer based on star-flash technology according to claim 2, characterized in that: In step S1, the host generates a directed weighted graph G(V, E) based on the printing tasks reported by each responding printhead and gives higher priority to continuous printing services. Here, vertex V represents a device, and the weight of edge E represents the theoretical minimum latency and priority of communication between devices.
5. The wireless connection system for an industrial inkjet printer based on star-flash technology according to claim 2, characterized in that: A contention access time slot is added between the beacon time slot and the fixed service time slot. The contention access time slot is used for new equipment to enter the network and emergency status reporting.
6. The wireless connection system for an industrial inkjet printer based on star-flash technology according to claim 2, characterized in that: The specific process of step S3 is as follows: S31, the host continuously monitors the end-to-end latency and packet loss rate of each nozzle command; S32, if the packet loss rate of a certain nozzle is detected to increase due to environmental interference, the scheduling algorithm can be triggered immediately; If the production line changes or the nozzle task changes, the host computer recalculates the time slot allocation table and smoothly switches in the next superframe cycle.
7. The wireless connection system for an industrial inkjet printer based on star-flash technology according to claim 6, characterized in that: The workflow after the scheduling algorithm is triggered is as follows: Enable adaptive frequency hopping for star flash to avoid interference frequencies; In the next superframe, allocate additional retransmission time slots for the nozzle in the dynamic pool or adjust its fixed time slot position.