Fluid Jetting Delays for Moving Substrate Alignment
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Solution Overview
Problem
Existing printing systems face challenges in synchronizing the fluid ejection of multiple print modules to accurately form images on moving substrates, particularly due to variations in substrate speed and nozzle alignment, leading to misalignment and quantization errors in droplet placement.
Innovation Solution
A system that dynamically calculates and implements a time delay between data packet deliveries to print modules, comprising an integer and fractional portion of the jetting cycle, to ensure precise alignment and placement of fluid droplets on the substrate, using a controller that processes image data and adjusts nozzle activation times based on substrate speed and distance between print modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple print modules eject fluid droplets simultaneously onto a moving substrate, then productivity is improved through parallel printing, but manufacturing precision deteriorates due to misalignment and quantization errors in droplet placement
Solution Approach 1:
The system calculates and applies time delays to data packets before they reach the print modules. The controller receives data packets at different times and deliberately introduces delays (including fractional jetting cycle delays) to ensure that droplets from multiple print modules arrive at the correct positions on the moving substrate simultaneously, compensating for substrate motion and quantization errors.
Solution Approach 2:
The system dynamically adjusts the time delay between data packet deliveries based on real-time substrate speed and position. The controller modifies the timing of droplet ejection from different print modules to account for variations in substrate motion, ensuring continuous precision despite changes in printing conditions.
2Ease of operation
If data packets are delivered to multiple print modules at the same time, then ease of operation is improved through simplified data transmission, but manufacturing precision deteriorates due to inability to correct for substrate speed variations and nozzle alignment differences
Solution Approach 1:
The controller pre-calculates the required time delays for each data packet based on the substrate motion profile and nozzle positions. Data packets are transmitted with embedded timing information that specifies when each print module should eject droplets, allowing the system to maintain operational simplicity while achieving precise image formation through advance timing adjustments.
Solution Approach 2:
The system uses feedback from substrate position sensing and speed measurement to dynamically adjust data packet timing. The controller continuously monitors substrate motion and modifies the time delays between data packet deliveries to compensate for speed variations and alignment differences, ensuring accurate image formation despite changing conditions.
3Device complexity
If the system uses fixed time delays between print module activations, then device complexity is reduced through simpler control logic, but adaptability deteriorates due to inability to respond to changes in substrate speed and nozzle alignment
Solution Approach 1:
The control system transitions from fixed time delays to dynamic, adjustable time delays. The controller calculates optimal delay values based on real-time substrate speed and position data, and adjusts the timing of data packet deliveries accordingly. This allows the system to adapt to varying printing conditions while maintaining manageable control complexity through algorithmic delay calculation.
Solution Approach 2:
The system changes the timing parameters of data packet deliveries dynamically. Instead of using constant time delays, the controller adjusts the delay duration between data packet transmissions to each print module based on measured substrate speed and position, enabling the system to adapt to different printing scenarios while using a unified control approach.
Data Source
Figure 1A~1B
Figure 1C
Figure 1D~1E
AI summary
Among other things, the disclosure features a system for use in fluid jetting. The system comprises a first print module comprising a first row of nozzles, a second print module comprising a second row of nozzles, and a controller to receive a first data packet from a remote device at a first moment and a second data packet from the remote device at a second moment after the first moment. Upon receipt of the first data packet, the controller is configured to cause at least some nozzles in the first row, at a third moment, to eject fluid droplets onto a line on a substrate. Upon receipt of the second data packet, the controller is configured to cause at least some nozzles in the second row, at a fourth moment separated from the third moment by a time delay, to eject fluid droplets onto the line on the substrate.