Automatic Tuning Compensation for Defective Printhead Nozzles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current uniformity compensation methods for printhead nozzles in high-speed production printers require prior knowledge of ink spread and ink model simulation or manual tuning, which are time-consuming and inefficient, leading to undesired printing artifacts like voids and banding due to defective nozzles.
Innovation Solution
An automatic tuning mechanism for jet-out compensation using a compensation module that performs uniformity compensation by generating transfer and inverse transfer functions based on measurement data from a test chart, adjusting halftone threshold arrays to compensate for defective printhead nozzles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual tuning is performed to find optimal jet-out compensation strength, then compensation accuracy is improved, but time consumption increases
Solution Approach 1:
The system performs automatic tuning where the compensation module independently determines optimal jet-out compensation strength by analyzing measurement data from test charts, eliminating the need for manual operator intervention while maintaining high compensation accuracy
Solution Approach 2:
The system performs preliminary measurement and characterization of printhead nozzle defects using test charts before actual printing operations, establishing compensation parameters in advance to ensure uniformity compensation is ready when needed
2Measurement precision
If ink model simulation is used to determine compensation parameters, then theoretical accuracy is improved, but complexity and time requirements increase
Solution Approach 1:
The system replaces complex ink model simulation and theoretical calculations with direct empirical measurement using test charts and image analysis, substituting computational complexity with straightforward measurement and data processing
Solution Approach 2:
The system changes from using theoretical ink model parameters to using empirically measured parameters derived from actual test chart printing and image analysis, adapting to real-world variations in ink behavior and printhead performance
3Ease of manufacture
If uniformity compensation is performed without automatic tuning, then manufacturing simplicity is maintained, but productivity decreases due to manual intervention
Solution Approach 1:
The compensation module automatically performs all tuning operations independently, including measuring test charts, analyzing image data, and determining optimal compensation parameters, eliminating manual intervention while maintaining system simplicity
Solution Approach 2:
The system performs preliminary automatic characterization of printhead defects and determination of compensation parameters before production printing begins, enabling rapid deployment without manual tuning during operations
4Adaptability or versatility
If manual tuning is required for jet-out compensation, then adaptability to specific printhead conditions is improved, but ease of operation deteriorates
Solution Approach 1:
The system automatically adapts to specific printhead conditions by independently measuring test charts, analyzing the actual jet-out patterns, and determining optimal compensation parameters tailored to that specific printhead without requiring operator expertise or manual adjustment
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A printing system (130) includes at least one physical memory device (1425) to store compensation logic and one or more processors (1410) coupled with the at least one physical memory device to execute the compensation logic to receive measurement data corresponding to a print medium printed with a plurality of non-functioning pel forming elements, a plurality of functioning pel forming elements (165) and a plurality of tint levels; wherein adjacent ones of the plurality of functioning pel forming elements print with compensation transfer functions (230) applied and are located adjacent to the plurality of non-functioning pel forming elements, associate measurement data with the plurality of non-functioning pel forming elements, the compensation transfer functions and the plurality of tint levels and determine optimal compensation by selecting the compensation transfer functions that have corresponding measurement data values closest to compensation target values for each of the plurality of tint levels.