Base Material Edge Detection for Transport Error Calculation
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Solution Overview
Problem
Conventional image recording apparatuses face challenges in detecting transport errors of long band-like base materials with high precision due to skids and elongation, leading to misregistration issues, as they rely on fixed-time interval detection and register marks which limit precision and space for print images.
Innovation Solution
A base material processing apparatus with a transport mechanism and edge sensors that intermittently detect the edge position of the material at multiple points, allowing for time-series data comparison to calculate transport errors, and a timing adjuster that changes detection timing to enhance precision without relying on register marks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If detection is performed at fixed time intervals by an optical sensor, then the detection system is simple to operate, but the transport error detection precision is limited by the detection time intervals
Solution Approach 1:
The patent applies dynamics by making the detection timing variable rather than fixed. The controller dynamically adjusts the detection timing of the optical sensor based on the transport speed of the base material, allowing the detection intervals to adapt to changing transport conditions. This enables high-precision transport error detection without requiring an overly complex detection system, as the simplicity of optical sensor detection is maintained while achieving precision through adaptive timing.
2Measurement precision
If reference images (register marks) are formed on the surface of printing paper, then transport error detection is enabled, but the space for recording target print images is narrowed
Solution Approach 1:
The patent extracts the transport error detection function from the print area by using the edge of the base material itself as the detection reference instead of forming separate register marks on the print surface. The optical sensor detects the position of the leading edge or lateral edge of the base material, which serves as a natural reference that does not consume any printable area. This separates the detection function from the printing function, allowing full utilization of the base material surface for print images.
3Productivity
If the transport speed of printing paper differs from ideal speed due to skids or elongation, then the transport mechanism continues operating, but misregistration occurs in multicolor image recording
Solution Approach 1:
The patent implements feedback by continuously monitoring the actual position of the base material edge during transport and using this information to calculate transport errors. The controller receives detection results from the optical sensor, compares them with expected positions based on ideal transport speed, calculates the deviation, and then corrects the ejection timing of ink droplets accordingly. This closed-loop feedback system allows continuous transport operation while maintaining high image registration accuracy through real-time corrections.
4Measurement precision
If detection timing is changed dynamically by a timing adjuster, then transport error detection precision is improved beyond fixed time intervals, but the control system becomes more complex
Solution Approach 1:
The patent applies universality by making the controller perform multiple functions: it not only controls the transport mechanism and ink ejection but also dynamically adjusts the detection timing of the optical sensor. The single controller unit handles timing adjustment, error calculation, and correction application, eliminating the need for separate dedicated timing control hardware. This multi-functional approach improves detection precision while minimizing the increase in overall system complexity.
Data Source
AI summary
A base material processing apparatus includes a first detector, a second detector, and an arithmetic unit. The first detector intermittently detects the position of the edge of the base material in the width direction at a first detection position to acquire a first detection result (Ra). The second detector intermittently detects the position of the edge of the base material in the width direction at a second detection position located downstream of the first detection position to acquire a second detection result (Rb). The arithmetic unit calculates a transport error of the base material by comparison between the first detection result (Ra) and the second detection result (Rb). The controller changes detection timing of at least one of the first detector and the second detector.