Adaptive Exposure Printing System for Digital Print Non-Uniformity Correction
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Solution Overview
Problem
Digital printing systems face issues with one-dimensional macro non-uniformities such as streaking and banding, which are not effectively addressed by optimizing individual subsystems alone, as these optimizations do not account for interactions among subsystems, leading to accumulated errors and inconsistent image quality.
Innovation Solution
A method involving a scanning device and controller to detect non-uniformities in printed targets, generating correction profiles that compensate for these issues by modifying exposure levels during the printing process, ensuring improved image quality by addressing the interactions between subsystems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If each subsystem is optimized individually, then the performance of each subsystem is improved, but the overall system performance deteriorates due to accumulated errors and lack of interaction consideration
Solution Approach 1:
The patent merges the optimization of multiple subsystems into a unified system-level optimization process. By measuring the actual output of the entire printing system and generating a comprehensive correction profile that accounts for interactions among all subsystems (imaging, transfer, fusion), the system achieves coordinated optimization rather than isolated subsystem tuning, thereby improving overall reliability while maintaining manufacturing precision.
Solution Approach 2:
The patent implements a feedback mechanism where the actual printed output is measured by a scanner or sensor, and the measured data is used to generate correction profiles that are applied to subsequent printing operations. This closed-loop feedback system allows the system to detect and correct accumulated errors and interaction effects among subsystems, resolving the contradiction between individual subsystem optimization and overall system performance.
2Manufacturing precision
If subsystem optimization is performed, then image quality is improved, but the complexity of the optimization process increases due to stringent requirements and tolerance accumulation
Solution Approach 1:
The patent extracts the complexity of subsystem interaction analysis from the optimization process by directly measuring the final system output. Instead of analyzing and optimizing each subsystem separately with stringent tolerance requirements, the system measures the actual printed image quality and derives correction profiles directly from the measured data, thereby simplifying the optimization process while maintaining high image quality.
Solution Approach 2:
The patent changes the optimization approach from adjusting multiple subsystem parameters with stringent tolerances to applying a single comprehensive correction profile that adjusts the digital input data. This parameter transformation simplifies the optimization process by working at the data level rather than at the physical subsystem level, reducing complexity while achieving improved image quality.
3Manufacturing precision
If correction profiles are generated for each color module, then color accuracy is improved, but the printing time increases due to multiple printing and scanning operations
Solution Approach 1:
The patent performs preliminary correction profile generation by printing test targets and scanning them before actual production printing. The correction profiles are created in advance and stored for use during normal printing operations. This preliminary action separates the time-consuming measurement and correction profile generation from the production printing process, thereby maintaining color accuracy while minimizing impact on productivity during actual printing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively corrects for non-uniformities in digital prints by using correction profiles to adjust exposure levels, thereby enhancing image quality and consistency across the printing process, improving the overall performance of digital printing systems.
Implementation Method 1
an exposure device, and the printer including a process direction
Data Source
AI summary
One or more printers or printing systems are connected to a scanning device. Each printer includes one or more color modules that are used during a printing operation. A printer prints a target for each color module or color channel. The printed targets are then scanned by the scanning device. The printed targets may be rotated to any angle and then scanned by the scanning device. The scanned raster data is processed by a controller to detect non-uniformities in at least one density image and to generate one or more correction profiles for the printer. When an image is to be printed, one or more controllers receive the image data and use the one or more correction profiles to correct or compensate for the non-uniformities during the exposure process.