Alignment Error Detection via Variable Pitch Line Patterns
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Solution Overview
Problem
High-speed printing systems face challenges in detecting and correcting alignment errors between printheads, such as registration and stitching errors, which affect image quality and require manual intervention and complex processes.
Innovation Solution
A method and system that utilize an alignment pattern printed by printheads on a substrate, analyzed by a sensor to detect alignment errors, involving the imaging of parallel lines with varying distances, and subsequent data analysis to determine and correct errors, incorporating image processing techniques like binarization and feature extraction to enhance accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual detection and correction methods are used for alignment errors, then the process requires human intervention and complex procedures, but this increases the time consumption and reduces productivity
Solution Approach 1:
The system performs self-diagnosis by automatically detecting alignment errors through sensor data collection and image analysis, eliminating the need for manual inspection and correction procedures
Solution Approach 2:
The patent replaces manual mechanical adjustment processes with automated optical sensing and computational image analysis systems to detect and correct alignment errors
2Reliability
If complex manual correction procedures are implemented, then alignment errors can be corrected, but the process complexity and operational difficulty increase
Solution Approach 1:
The system continuously monitors alignment through sensor feedback and automatically adjusts printhead positions based on detected errors, creating a closed-loop control system that simplifies operation while maintaining high reliability
Solution Approach 2:
The alignment correction process is automated through self-adjusting mechanisms that respond to detected errors without requiring manual intervention or complex procedural steps
3Productivity
If traditional alignment detection methods are used, then the process can identify errors, but the detection precision and measurement accuracy are insufficient
Solution Approach 1:
The patent introduces alignment patterns as intermediary reference objects that facilitate precise measurement of printhead positions and alignment errors through structured light or visual markers
Solution Approach 2:
The system replaces traditional mechanical measurement tools with optical sensing and digital image analysis techniques to achieve higher measurement precision in alignment error detection
Data Source
AI summary
A method of detecting an alignment error includes the steps of controlling a first portion of one or more imaging units to image on a substrate a first plurality of substantially parallel lines extending along a first direction and a second plurality of substantially parallel lines extending along a second direction and controlling a second portion of one or more imaging units to image a third plurality of substantially parallel lines extending along the first direction and a fourth plurality of substantially parallel lines extending along the second direction. One or more distances between adjacent lines of the second plurality of lines are varied and one or more distances between adjacent lines of the fourth plurality of lines are varied. Further, the lines imaged by the first and second portions form an alignment pattern. The method further includes the steps of collecting data relating to the alignment pattern and analyzing the collected data to determine an alignment error between the first and second portions of the one or more imaging units.