Distributed Control Architecture for Large Inkjet Printers
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Solution Overview
Problem
Large size ink jet printers face high data processing loads due to centralized control systems, leading to memory overflow, reduced processing capacity, slower printing speeds, and lower quality prints, as they are often upgraded from small size printers without optimizing data distribution.
Innovation Solution
A distributed control system is implemented, where a computer device and a large size ink jet printer communicate through a data path board, I/O controller board, and ink supply control board, using MCU analysis and signal transfer to manage printer head operations, ink levels, and carriage movements, reducing data processing load and enhancing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a centralized control system is used to manage all printer components, then the control structure is simple, but the data processing load becomes too high causing memory overflow and reduced processing capacity
Solution Approach 1:
The control system is divided into multiple independent control boards: a main control board for overall coordination, a data path board for image data processing, an ink supply control board for ink management, and a carriage control board for position control. Each board handles specific functions independently, distributing the data processing load and preventing memory overflow while maintaining system reliability.
2Device complexity
If all data processing is performed on a single processor, then data transmission is simple, but printing speed decreases due to insufficient processing capacity
Solution Approach 1:
The data processing function is segmented across multiple boards: the data path board receives and pre-processes image data, the main control board coordinates overall printing operations, and other specialized boards handle specific tasks. This segmentation enables parallel data processing and increases printing speed without excessive complexity.
Solution Approach 2:
The data path board acts as an intermediary between the computer and the printing system, buffering and pre-processing image data before it reaches the printer head. This intermediary structure enables faster data transmission and processing, improving printing speed while managing data flow efficiently.
3Manufacturing precision
If a RIP program is added for vector to raster conversion, then printing quality improves, but data processing requirements and system complexity increase
Solution Approach 1:
The RIP program is implemented as an intermediary software layer on the data path board, separating the complex vector-to-raster conversion process from the main printing control. This allows high-quality printing through proper image processing while managing data processing requirements through dedicated hardware resources on the data path board.
4Adaptability or versatility
If multiple ink tanks and pumps are used for industrial printing, then printing versatility improves, but control difficulty and data processing load increase
Solution Approach 1:
Each ink tank and pump is assigned to a dedicated ink supply control board that manages it independently. This segmentation allows the system to handle multiple ink types and printing configurations without overwhelming the main control processor, maintaining versatility while managing control difficulty through distributed architecture.
Data Source
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AI summary
A printing system formed of a computer device and a large size ink jet printer transmitting and receiving a data with the computer device is disclosed, which comprises said large size ink jet printer including a printer head injecting an ink on a printing object which is to be printed; an ink pump supplying an ink to the printer head; a head controller controlling the operation of the printer head; a carriage with the printer head; a carriage driving part moving the carriage in at least one direction; a data path board receiving and analyzing the data from the computer device and transferring a control signal to the head controller for controlling the printer head; an ink supply control board controlling the operation of the ink pump; and an I/O (Input and Output) controller board receiving the data from the computer device, the data path board and the ink supply control board and analyzing and transmitting the data, and the computer device including a RIP (Raster Image Process) program converting an image/text signal into an image/text raster (bit map) image data for printing; and a carriage driving part control program controlling the operation of the carriage driving part of the large size ink jet printer.