Digital Printer Failure Compensation Through Dynamic Print Strategies
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Solution Overview
Problem
Existing digital printing technologies struggle to maintain print quality while adapting to print condition changes and nozzle failures during the printing process, leading to reduced productivity.
Innovation Solution
A method that dynamically switches between print strategies based on real-time print condition detection, allowing for seamless transitions between different print modes to compensate for nozzle failures and environmental changes, ensuring consistent print quality and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed print strategy is used from the beginning of a print job, then the initial print quality is maintained, but the print quality degrades when print condition changes occur during printing
Solution Approach 1:
The patent implements dynamic print strategy selection by continuously monitoring print conditions (temperature, humidity, media type) during the print job and switching between different print strategies based on detected changes. This allows the system to adapt to varying print conditions while maintaining consistent print quality throughout the entire print job.
Solution Approach 2:
The system incorporates feedback mechanisms by detecting print condition changes during printing and using this information to dynamically adjust the print strategy. The control unit receives feedback from sensors monitoring temperature, humidity, and media properties, then selects appropriate print strategies to compensate for detected changes.
2Reliability
If supplementary operations are executed to compensate for non-operational nozzles, then print quality is maintained, but printing productivity decreases
Solution Approach 1:
The system dynamically selects between different print strategies based on the detected nozzle failure patterns. When nozzles are malfunctioning, it chooses a compensation strategy that maintains print quality; when nozzles are operational, it switches to a faster print mode that prioritizes productivity. This dynamic adaptation optimizes both quality and speed based on real-time conditions.
Solution Approach 2:
The patent changes printing parameters (such as number of passes, dot placement patterns, and media feed rate) based on the detected print condition. When nozzle failures are detected, parameters are adjusted to compensate for missing nozzles while minimizing the impact on overall printing speed and productivity.
3Reliability
If the number of print passes per unit area is increased to maintain print quality, then print quality is preserved, but printing time increases
Solution Approach 1:
The system dynamically adjusts the number of print passes based on detected print conditions. When environmental changes or nozzle failures occur that threaten print quality, the system increases the number of passes in the affected areas. When conditions are stable and nozzles are operational, it reduces the number of passes to minimize printing time.
Solution Approach 2:
The patent applies different numbers of print passes to different regions of the print media based on local conditions. Areas affected by print condition changes receive additional passes for quality maintenance, while areas with stable conditions use fewer passes to reduce overall printing time.
Data Source
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AI summary
A digital printer and a method of controlling the digital printer having a print head with an array of printing elements and a failure detection system arranged to detect malfunctioning printing elements. When, during printing, a malfunctioning printing element is detected, a switch from the current print strategy to another print strategy is arranged during printing which leaves the number of passes per swatch constant, i.e. the print quality is not affected by the switch.