CIJ Printer Optical Monitoring Stroke Segmentation
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Solution Overview
Problem
Continuous inkjet (CIJ) printers face challenges in quickly identifying and correcting misprints due to fluctuations in operating parameters, requiring complex commissioning procedures and not being true plug-and-play systems, especially in high-speed printing applications.
Innovation Solution
A method for operating CIJ printers with optical monitoring that involves generating a bitmap of the desired image, sequentially controlling charge and deflection electrodes to apply ink droplets, capturing the printed image, and automating the comparison of the desired and actual images stroke by stroke, allowing for immediate detection of errors and adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If camera monitoring is implemented to detect misprints, then printing quality control is improved, but the system complexity and commissioning time increase
Solution Approach 1:
The patent segments the bitmap into individual strokes and further divides each stroke into multiple partial strokes. This segmentation allows the monitoring system to verify printing quality stroke by stroke rather than requiring complete image capture and complex overall analysis, thereby improving reliability while reducing system complexity and commissioning requirements
Solution Approach 2:
The patent implements preliminary action by pre-defining the expected positions of ink droplets in each stroke before actual printing occurs. The system compares actual droplet positions against these pre-established reference positions, enabling quality control without requiring complex real-time analysis or extensive commissioning procedures
2Manufacturing precision
If complete bitmap verification is performed, then printing accuracy is improved, but verification time increases
Solution Approach 1:
The patent divides the complete bitmap verification into smaller stroke-level verifications. By checking each stroke independently as it is printed rather than waiting for the complete image, the system maintains printing accuracy through continuous monitoring while significantly reducing verification time and enabling faster error detection
Solution Approach 2:
The patent applies partial action by verifying only the current stroke being printed rather than requiring complete bitmap verification. This partial verification approach maintains sufficient printing accuracy for quality control while dramatically reducing the time required, allowing the system to operate in high-speed printing environments
3Measurement precision
If traditional teach-in procedures are used, then optical monitoring accuracy is improved, but commissioning complexity increases
Solution Approach 1:
The patent segments the teach-in process into stroke-level operations. Instead of requiring complex overall system calibration, the system performs simple teach-in procedures for individual strokes, recording expected droplet positions for each stroke separately. This segmentation maintains optical monitoring accuracy while dramatically simplifying commissioning procedures
Solution Approach 2:
The patent implements preliminary action by pre-recording the expected positions of ink droplets for each stroke during a simple teach-in process. These pre-recorded reference positions enable accurate optical monitoring without requiring complex commissioning, as the system compares actual printing against these pre-established benchmarks
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 simplifies pattern recognition, increases verification speed, and reduces hardware requirements, enabling quicker error detection and correction, thus improving the precision and sensitivity of the printing process while allowing for a more straightforward teach-in process.
Implementation Method 1
the droplets required for the actual printing process are produced from the ink jet according to the basic principle of Rayleigh's decay of laminar liquid jets
Implementation Method 2
The droplet formation and in particular the droplet size is controlled by a modulation, which is, for example, impressed on the inkjet by piezo elements excited in a suitable manner
Implementation Method 3
The droplets produced in this way are electrically charged in a suitable manner and guided by deflection electrodes to a desired trajectory
Data Source
AI summary
Provided are a method for operating a CIJ printer with an optical monitoring means (80) having the steps of generating a bitmap (90,180) of the printed image to be printed, sequential controlling of charge electrodes (25) and/or deflection electrodes (30) of the CIJ printer, in order to generate dots or groups of dots of the bitmap (90,190) by applying ink droplets (12) to a substrate (100) to be printed and thus to sequentially apply a real printed image (195) to the substrate (100), capturing the real printed image (195) applied to the substrate (100) with the optical monitoring means (80), and automated comparing of the bitmap (90,190) of the desired printed image and of the real printed image (195) which has been applied to the substrate (100) and has been captured with the optical monitoring means (80), wherein the bitmap (90,190) of the desired printed image and the real image applied to the substrate (100) are automatically compared either on the basis of rows or columns of the bitmap (90,190) or on the basis of components of rows or columns of the bitmap (90,190), a CIJ printer for carrying out such a method and a method for teaching-in an optical monitoring means (80) of such a CIJ printer.