Edge Sensor Displacement Detection for Base Material Registration
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Solution Overview
Problem
Conventional image recording apparatuses face challenges in accurately detecting the displacement of long band-like base materials during transport, leading to misregistration of single-color images due to variations in transport speed, which is difficult to correct in real-time without relying on reference images.
Innovation Solution
A base material processing apparatus that includes a transport mechanism and edge sensors to detect the position of the base material's edge at upstream and downstream positions, calculating displacement and speed differences using a displacement amount calculation part to identify highly matched data sections, thereby correcting ink ejection timing without relying on register marks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If reference images such as register marks are formed on the surface of the printing paper to suppress mutual misregistration, then the misregistration problem is improved, but the space for recording an intended print image is narrowed and the detection complexity increases
Solution Approach 1:
The invention extracts the registration detection function from the printed surface by using edge sensors to detect the physical edges of the base material. This eliminates the need for register marks on the surface, preserving recording space while maintaining registration accuracy.
Solution Approach 2:
The invention introduces edge sensors as intermediary devices to detect base material displacement. These sensors act as mediators between the transport system and the recording system, enabling real-time displacement detection without modifying the base material surface.
2Measurement precision
If reference images are used to detect displacement, then registration accuracy is improved, but the detection speed decreases due to the need to process reference image data
Solution Approach 1:
The invention replaces the optical-based reference image detection system with an electrical sensing system using edge sensors. This substitution enables faster, real-time displacement detection without the computational overhead of processing reference image data.
3Productivity
If the transport speed is increased to improve productivity, then the output speed is improved, but the transport stability deteriorates due to skids and elongation
Solution Approach 1:
The invention implements a feedback control system where edge sensors continuously monitor base material displacement and the controller adjusts recording head ejection timing in real-time. This feedback mechanism compensates for transport speed variations and maintains registration accuracy even at high speeds.
Solution Approach 2:
The invention makes the ejection timing of the recording head dynamic by continuously adjusting it based on real-time displacement detection. This dynamic adjustment allows the system to adapt to transport speed variations and maintain precise registration without requiring perfectly stable transport.
Data Source
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AI summary
A displacement amount calculation part (41) in a base material processing apparatus calculates the degree of matching between an upstream data section (D1) included in a first detection result (R1), which indicates a time-varying change in the position of an edge (91) of a base material in the width direction at an upstream detection position (Pa), and a downstream data section (D2) included in a second detection result (R2), which indicates a time-varying change in the position of the edge (91) of the base material in the width direction at a downstream detection position (Pb). This calculation uses calculation results obtained by sequentially calculating the degrees of matching between sub-data sections in the upstream data section (D1) and downstream sub-data sections in the downstream data section (D2). This reduces the amount of computation and enables highly accurate detection of the amount of displacement of the base material in the transport direction on the basis of an identification result of the downstream data section (D2) that is highly matched with the upstream data section (D1).