Dual-Sensor Liquid Ejection Inspection for Nozzle Failure Detection
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Solution Overview
Problem
Inkjet printers face challenges with nozzle clogging, leading to ejection failures and dot omission in printed images, as existing inspection methods struggle to accurately detect and address issues with each nozzle, especially when dealing with overlapping color dots and reading errors.
Innovation Solution
A liquid ejection inspection device with a dual-sensor system, comprising a first sensor for reading printed images and a second sensor for detecting ink ejection status within the head, allowing for precise identification of nozzle failures and targeted recovery operations to prevent ink wastage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single sensor is used for ejection inspection, then the device complexity is reduced, but the measurement precision of nozzle ejection failure is insufficient
Solution Approach 1:
The patent combines two different sensing principles (optical sensor and piezoelectric sensor) into a unified inspection system. The optical sensor detects actual ink ejection on the medium, while the piezoelectric sensor detects nozzle vibration during ejection. By merging these complementary detection methods, the system achieves high measurement precision for ejection failure detection without requiring overly complex individual sensor systems.
Solution Approach 2:
The inspection device is designed to perform multiple inspection functions using different sensing principles. The system can detect both the physical ejection state (optical sensor) and the nozzle vibration characteristics (piezoelectric sensor), providing universal detection capability for various types of ejection failures including clogging, misalignment, and incomplete ejection.
2Reliability
If comprehensive inspection of all nozzles is performed, then the reliability of printed image quality is improved, but the loss of time for inspection increases
Solution Approach 1:
The system performs preliminary inspection during the printing process itself rather than after printing is complete. By continuously monitoring nozzle ejection in real-time using both optical and piezoelectric sensors, the system can detect ejection failures as they occur and trigger recovery operations immediately, maintaining high image quality reliability without requiring separate post-printing inspection time.
Solution Approach 2:
The dual-sensor system provides continuous feedback during the printing process. The optical sensor monitors actual ink deposition while the piezoelectric sensor monitors nozzle vibration, creating a feedback loop that enables real-time detection and correction of ejection failures. This allows comprehensive inspection without time loss because the inspection occurs concurrently with printing through automated feedback-driven recovery operations.
3Productivity
If ink ejection is inspected during printing, then the productivity is maintained, but the measurement precision of individual nozzle status is insufficient
Solution Approach 1:
The system segments the inspection process into two complementary measurement dimensions: optical detection of ink ejection patterns and piezoelectric detection of individual nozzle vibration. This segmentation allows simultaneous monitoring of overall printing progress (maintaining productivity) and individual nozzle status (achieving measurement precision) without requiring separate inspection passes that would reduce productivity.
4Ease of operation
If recovery operation is performed without precise detection, then the ease of operation is improved, but the loss of substance (ink wastage) increases
Solution Approach 1:
The system replaces simple mechanical recovery operations with sensor-driven intelligent recovery. The piezoelectric sensor detects specific vibration patterns that indicate clogged nozzles, and the optical sensor confirms actual ejection failure. This substitution enables precise identification of which nozzles require recovery, allowing the system to perform targeted recovery operations only on affected nozzles rather than blanket recovery of all nozzles, thereby reducing ink wastage while maintaining ease of operation through automated control.
Data Source
AI summary
A liquid ejection device includes a head, a first sensor, a second sensor, a recovery unit, and a controller. The head is configured to eject liquid on a medium. The first sensor is configured to detect liquid ejection of the head by using a first principle. The second sensor is configured to detect the liquid ejection by using a second principle being different from the first principle. The recovery unit is configured to recover the liquid ejection by the head. The controller is configured to control the first sensor and the second sensor, and control the recovery unit based on a first detection result by the first sensor and a second detection result by the second detector.