FPGA Phase Testing for Continuous Inkjet Printers
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Solution Overview
Problem
Continuous inkjet printers face challenges in synchronizing the charging of ink droplets at high speeds due to the need for phase testing, which requires a finite time and can compromise print quality on fast production lines with closely spaced products.
Innovation Solution
Incorporating a field-programmable gate array (FPGA) to control the switching of amplifiers and initiate phase tests based on a system clock, allowing for reduced inter-message gaps by eliminating the need for capacitor discharge and optimizing the phase testing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If phase testing is performed to synchronize droplet charging at high speeds, then charge synchronization accuracy is improved, but the time required for phase testing increases the inter-message gap between successive prints
Solution Approach 1:
The patent performs phase testing during the inter-message gap period between successive prints, rather than requiring a separate dedicated time period. The system uses the otherwise idle time between printing operations to conduct phase measurements and adjustments, thereby preparing the system in advance for the next print operation without extending the overall cycle time.
Solution Approach 2:
The patent implements periodic phase testing at predetermined intervals during the printing operation, rather than requiring continuous or extensive phase testing before each print. This periodic approach maintains adequate synchronization accuracy while minimizing the time consumed by phase testing activities.
2Measurement precision
If the system waits for capacitor discharge before phase testing, then measurement accuracy is improved, but the recovery period extends the inter-message gap
Solution Approach 1:
The patent maintains continuous operation by performing phase testing during the inter-message gap when the system is otherwise idle. Rather than stopping or waiting for capacitor discharge, the system continuously utilizes available time periods for productive phase measurement activities, eliminating wasted recovery periods.
Solution Approach 2:
The patent rushes through the phase testing process by utilizing the brief inter-message gap period efficiently. The system performs necessary phase measurements and adjustments quickly during the available time, rather than allowing the system to slow down or wait for capacitor discharge cycles.
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
This solution enables faster and more efficient phase testing, reducing the time between prints while maintaining accurate charge synchronization, thereby improving print quality on high-speed production lines.
Implementation Method 1
a vibration or perturbation is applied to the ink jet causing the jet to break into a stream of droplets
Implementation Method 2
the printer includes a charge electrode to charge selected droplets, and an electrostatic facility to deflect the charged droplets
Implementation Method 3
an electrostatic facility to deflect the charged droplets away from their original trajectory and onto a substrate
Data Source
Figure 1
Figure 2A~2B
Figure 3~4
AI summary
The invention describes a number of methods and apparatus for shortening the inter-message gap on a continuous inkjet printer. Included is a novel phase testing methodology.