Full Width Array Sensor Jet Monitoring
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Solution Overview
Problem
Continuous feed printers face delays and increased costs due to malfunctioning print head jets, which are difficult to detect efficiently, especially in continuous operations, as existing methods require extraneous test patterns and additional time and resources.
Innovation Solution
Implementing a full width array linear sensor system to monitor print head jets by detecting differences in image data before and after printing, using a monochrome or RGB sensor to identify pixels dominated by a single color, and tracking pixel column accumulations to quickly identify and flag abnormally performing jets without the need for test patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If extraneous test patterns are printed to detect malfunctioning jets, then jet detection capability is improved, but printing time and paper consumption increase
Solution Approach 1:
The patent combines the jet monitoring function with the normal printing operation by using the full-width array linear sensor to capture images of the printed medium during regular printing. This merging eliminates the need for separate test pattern printing, thereby maintaining jet detection capability while avoiding additional time and paper consumption.
Solution Approach 2:
The full-width array linear sensor serves multiple functions: it captures images for normal printing operations and simultaneously monitors jet performance by analyzing pixel density variations. This multi-functionality allows the system to detect malfunctioning jets without requiring dedicated test patterns or additional printing resources.
2Reliability
If test patterns are printed between customer images for jet detection, then jet malfunction detection is improved, but paper consumption and printing efficiency deteriorate
Solution Approach 1:
The system uses the normal printing process itself to generate the data needed for jet monitoring. The full-width array linear sensor captures images of the printed medium during regular operation, and the processor analyzes these images to detect jet malfunctions. This self-service approach eliminates the need for separate test patterns, maintaining reliability while preserving printing efficiency.
Solution Approach 2:
The monitoring system operates continuously during normal printing without interrupting the printing process or requiring pauses for test patterns. The full-width array linear sensor continuously captures images, and the processor continuously analyzes them for jet malfunctions, ensuring both reliable detection and uninterrupted printing efficiency.
3Device complexity
If single cutter equipment is used to remove test patterns, then equipment simplicity is maintained, but test pattern removal capability is lost
Solution Approach 1:
The patent extracts and eliminates the test pattern element from the system entirely. Instead of printing separate test patterns that need to be removed, the system uses the full-width array linear sensor to monitor jets during normal printing of customer images. This extraction removes the need for test pattern removal capability while maintaining equipment simplicity.
4Reliability
If purge operations are performed between jobs to recover missing jets, then jet reliability is improved, but printing continuity and productivity deteriorate
Solution Approach 1:
The system implements continuous feedback monitoring of jet performance using the full-width array linear sensor during normal printing operations. When jet malfunctions are detected through image analysis, the system can immediately identify and flag the problematic jets without interrupting the printing process, allowing for continuous operation while maintaining jet reliability through real-time monitoring and alerting.
Data Source
AI summary
Systems and methods are provided for monitoring jets of an image device. The detection is implemented using a data processor that monitors information sent to a jet and using an image sensor that monitors an image being printed or an image after being printed. A detector detects the difference between the image being printed and/or the image after printing to the information sent to the jet, and identifies a faulty jet based on the difference detected.