Dual-Chamber Ink Level Sensor Detects Foam
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Solution Overview
Problem
Existing ink supply systems in industrial inkjet printing face challenges with foam formation, which can lead to measurement errors and are difficult to completely eliminate, necessitating a solution to accurately measure ink levels and detect foam presence without errors.
Innovation Solution
A device with two interconnected chambers, one for ink storage and another for measurement, equipped with sensors to determine the presence, height, and type of foam by processing level readings from both chambers, allowing for early detection and prevention of foam-related errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single chamber with ultrasonic sensor is used for ink level measurement, then the device structure is simple, but foam formation causes measurement errors
Solution Approach 1:
The ink supply system is divided into two separate chambers: a first chamber for ink storage and a second chamber for measurement. This segmentation allows the measurement chamber to provide accurate level readings free from foam interference, while the storage chamber can tolerate foam formation without affecting measurement precision.
Solution Approach 2:
A connection piece with an opening serves as an intermediary between the two chambers, allowing ink to flow between them while preventing foam from the first chamber from entering the second chamber. This intermediary structure protects the measurement chamber from foam contamination.
2Measurement precision
If foam formation is completely avoided or eliminated, then measurement accuracy is improved, but the technical complexity increases significantly
Solution Approach 1:
The system separates ink storage and measurement functions into different chambers, allowing foam to exist in the storage chamber without compromising measurement accuracy in the measurement chamber. This avoids the need for complex foam elimination systems.
Solution Approach 2:
Instead of trying to eliminate foam completely, the invention accepts foam formation in the storage chamber and uses the chamber separation to convert this potentially harmful effect into a non-issue for measurements, thereby simplifying the overall system.
3Device complexity
If only level measurement is provided, then the device is simple, but no information about foam presence is obtained
Solution Approach 1:
The measurement system in the second chamber serves multiple functions: it accurately measures ink level and simultaneously detects foam presence and characteristics. This multi-functionality is achieved through comparing the level reading from the measurement chamber with the actual ink level in the storage chamber.
Solution Approach 2:
The system uses feedback from the level measurement to detect foam. When the measured level in the second chamber differs from the expected level based on ink consumption, the system infers foam presence, providing valuable information without additional sensors.
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
Enables accurate measurement of ink levels and detection of foam, preventing errors in ink supply to print heads, allowing for timely actions such as draining or warning, thereby ensuring reliable printing operations.
Implementation Method 1
the secondary chamber is assigned a sensor, which measures a level of a foam-free surface of the ink in the secondary chamber
Implementation Method 2
the first chamber is either also assigned the sensor or another sensor, the sensor or the further sensor measures a further level of a potentially foam-bearing surface of the ink in the main chamber
Data Source
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AI summary
An inventive device for measuring the level of a foam-forming ink for an inkjet printing press, comprising two chambers (12, 13) that can be filled with the ink (30) and are connected to each other via an opening (14) for exchanging the ink, i.e., a first chamber (12) as the main chamber (12) and a second chamber (13) as the secondary chamber (13), wherein the main chamber holds an ink supply (30a) and the secondary chamber is assigned a sensor (40) which measures a level (32) of a foam-free surface (31, 31a) of the ink in the secondary chamber, i.e., a level measurement value (42), is characterized in that the first chamber (12) is also assigned either the sensor (40) or a further sensor (41), wherein the sensor or the further sensor measures a further level (33) of a potentially foam-bearing surface (31, 31b) of the ink in the main chamber, i.e.,a further level measurement (43); and that a computer (60) is provided which computationally processes the level measurement (42) and the further level measurement (43) to determine the presence of foam (50), the height (52) of any existing foam, and/or the type (51) of any existing foam. The invention advantageously makes it possible to measure the level of a foam-forming ink without errors and simultaneously obtain information about foam that has already formed.