Fluid Pump Degradation Detection via Diagnostic Image Refill Timing
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Solution Overview
Problem
Current printing systems face issues with false out-of-ink signals and refill time-outs due to degradation of the fluid pump or other components, leading to potential misdiagnosis and unnecessary service engineer involvement.
Innovation Solution
A user-controlled diagnostic process is implemented in the printer, which includes printing a diagnostic image to monitor the fluid level and refill time, allowing users to assess the fluid pump's operation and differentiate between pump degradation and other potential issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fluid pump operates continuously to refill the intermediate tank, then the printing system maintains adequate fluid supply, but the pump degradation goes undetected causing false out-of-ink signals
Solution Approach 1:
The system performs preliminary diagnostic actions by printing a test image that consumes a known amount of fluid, then measures the actual refill time. This preliminary test allows detection of pump degradation before it causes false out-of-ink signals during normal operation, resolving the contradiction between maintaining reliable fluid supply and achieving accurate fluid level measurement.
2Measurement precision
If the system implements continuous monitoring of fluid levels, then pump degradation can be detected, but false out-of-ink signals and refill time-outs occur due to measurement inaccuracies
Solution Approach 1:
The system uses feedback by measuring the actual time taken to refill a known volume of fluid (determined by the test image printing) and comparing it against expected refill times. This feedback mechanism provides accurate pump performance data that distinguishes between normal fluid consumption and actual low-fluid conditions, eliminating false out-of-ink signals while maintaining reliable monitoring.
3Ease of operation
If users implement manual diagnostic procedures, then service engineer involvement is reduced, but the complexity of user operation increases
Solution Approach 1:
The system enables self-service diagnostics by automatically guiding users through a simplified process: printing a test image and allowing the system to automatically measure refill time. The controller handles the complex measurements and comparisons, while users only need to perform the simple action of printing the test image. This resolves the contradiction by making the diagnostic process easy for users while maintaining the sophistication needed for accurate pump degradation detection.
Data Source
AI summary
A method of monitoring a fluid supply is provided, the fluid supply including a supply tank, an intermediate tank and a fluid pump operatively coupled to the supply tank and the intermediate tank; the method comprising with the intermediate tank having a defined first fluid level, starting to feed fluid from the intermediate tank; when a defined amount of fluid has been fed from the intermediate tank, with the feeding of fluid from the intermediate tank proceeding, activating the fluid pump to supply fluid from the supply tank to the intermediate tank; monitoring the fluid level of the intermediate tank while the fluid pump remains activated; and diagnosing operation of the fluid pump as a function of the fluid level of the intermediate tank.