Adaptive Jetting Failure Detection in Inkjet Printheads
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Solution Overview
Problem
Conventional printing systems perform unnecessary jetting failure detection even if no failure occurs, leading to wasteful detection and inefficient operation due to fixed threshold settings for detecting defective nozzles in ink-jet printers.
Innovation Solution
A printing apparatus with a controller that adjusts detection condition values based on operation history, performing jetting failure detection and recovery only when specific conditions are met, thereby optimizing the interval for detection and reducing wasteful operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If jetting failure detection is performed every time the number of printed copies reaches the predetermined number Pth, then defective nozzles can be detected reliably, but unnecessary detection operations occur leading to reduced productivity
Solution Approach 1:
The patent applies dynamics by making the detection interval adaptive rather than fixed. The controller dynamically adjusts the detection threshold based on actual nozzle performance data collected during printing operations. When nozzles are functioning normally, the system extends the detection interval; when performance degradation is detected, the system shortens the interval to ensure timely detection of defective nozzles.
Solution Approach 2:
The patent changes the parameter of detection threshold from a fixed predetermined value to a variable value that adapts based on operational conditions and historical performance data. The system monitors printing quality metrics and adjusts the detection criterion accordingly, allowing the detection sensitivity and frequency to be optimized based on actual nozzle behavior patterns.
2Manufacturing precision
If jetting failure detection is performed frequently to ensure early detection of defective nozzles, then image quality can be maintained, but wasteful detection operations increase reducing overall efficiency
Solution Approach 1:
The patent implements feedback mechanisms where the system continuously monitors printing outcomes and nozzle performance, using this information to adjust future detection strategies. The controller analyzes detected patterns and adjusts detection timing and sensitivity based on actual performance data, creating a closed-loop system that optimizes both quality assurance and operational efficiency.
Solution Approach 2:
The system performs preliminary monitoring and assessment of nozzle performance during normal printing operations before actual failure occurs. By detecting early signs of degradation through continuous performance tracking, the system can prepare for potential failures without requiring frequent interruptive detection operations, thus maintaining quality while reducing wasted time.
Data Source
AI summary
There is provided a printing apparatus comprising: a printhead; a recovery mechanism for the printhead; a jetting failure detector; an operation history memory; a detection condition memory, the jetting failure detector; and a controller. The controller in configured to control the printing apparatus to: determine whether or not the operation history of the printhead conforms to the first condition value; determine whether or not the jetting failure is present, in a case that, the operation history conforms to the first condition value; cause the recovery mechanism to perform the recovery process, in a case that, the jetting failure is present; and cause the detection condition memory to store the second condition value smaller than the first condition value as a new first condition value, in a case that the jetting failure is present.