Droplet Ejection Control for Overlap Printing Nozzle Failure
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Solution Overview
Problem
Existing droplet ejection systems in printers face issues with obtaining a desired print result in overlap printing due to nozzles incapable of correctly ejecting droplets, leading to incomplete or inaccurate printing, especially when multiple nozzles are involved.
Innovation Solution
A droplet ejection control apparatus that utilizes a control unit to set the amount of droplets for overlap printing based on print control data, allowing a first nozzle row group and a second nozzle row group to perform superimposition printing, even when one or multiple nozzles in either group are incapable of normal ejection, ensuring that droplets are ejected accordingly to achieve the desired print result.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If overlap printing is performed using multiple nozzle row groups, then printing coverage and redundancy are improved, but print quality deteriorates when nozzles are incapable of normal ejection
Solution Approach 1:
The control unit dynamically adjusts the droplet ejection amount parameter based on the operational status of nozzles. When a nozzle is detected as incapable of normal ejection, the system modifies the droplet amount for remaining functional nozzles to compensate, thereby maintaining print quality while preserving overlap printing coverage
Solution Approach 2:
The system incorporates nozzle status detection feedback into the control loop. The control unit receives information about which nozzles are functioning properly and which are incapable of normal ejection, then uses this feedback to adjust droplet ejection amounts in real-time, ensuring consistent print quality across the entire printing area
2Reliability
If a nozzle incapable of normal ejection is replaced by another nozzle, then nozzle failure is compensated, but desired print result cannot be achieved because droplets are ejected through a single nozzle
Solution Approach 1:
Instead of relying on a single complementary nozzle to replace a failed nozzle, the system merges the ejection function across multiple nozzles in the first and second nozzle row groups. The control unit coordinates droplet ejection from multiple functional nozzles to collectively cover the area that would have been covered by the failed nozzle, maintaining both reliability and print accuracy
Solution Approach 2:
The system dynamically adjusts droplet ejection amounts based on real-time nozzle status. When a nozzle fails, the control unit dynamically redistributes the ejection load to other nozzles, varying droplet amounts to ensure that the combined output of multiple nozzles achieves the desired print result rather than relying on a static single-nozzle replacement
3Manufacturing precision
If droplet amount is adjusted based on nozzle ejection capability, then print quality is maintained, but control complexity increases
Solution Approach 1:
The control unit implements parameter changes by adjusting droplet ejection amounts based on predetermined nozzle status information. The system uses predefined adjustment rules and lookup tables that map nozzle failure patterns to appropriate droplet amount modifications, maintaining print quality while avoiding the need for complex real-time calculations
Solution Approach 2:
The control unit automatically detects nozzle status and self-adjusts droplet ejection amounts without requiring external intervention or complex processing. The system uses built-in detection mechanisms and predetermined control logic to autonomously compensate for nozzle failures, simplifying the overall control architecture while maintaining print quality
Data Source
AI summary
Provided is a droplet ejection control apparatus that causes a droplet ejection apparatus including a head in which a plurality of nozzles are disposed being aligned in a predetermined direction to perform overlap printing in which printing is duplicated in a predetermined region using a first nozzle row group and a second nozzle row group, and includes a control unit which sets an amount of droplets, when a predetermined condition is satisfied, to a value corresponding to the stated condition based on print control data according to which the first nozzle row group and the second nozzle row group perform superimposition printing.