Illuminator Calibration for Media Edge Detection
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Solution Overview
Problem
Print apparatus face challenges in accurately detecting media edges due to noise from contaminants and ambient light, leading to misidentification and failure to print near the edge of media, especially in long print runs with infrequent calibrations.
Innovation Solution
A media edge calibration service that adjusts the brightness level of an illuminator and optical sensor system to improve edge detection, using a processor to determine optimal sensitivity and signal-to-noise ratio for accurate media edge detection during printing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If periodic calibration is performed during non-printing periods, then the calibration process is simple and does not interrupt printing operations, but misidentification of media size and failure to print near edges occur during long print runs
Solution Approach 1:
The calibration process is integrated into the printing operation itself, allowing continuous calibration during long print runs. The system performs calibration measurements without interrupting the printing workflow, maintaining both productivity and measurement precision by making the calibration action continuous rather than periodic.
Solution Approach 2:
The system performs preliminary calibration measurements at the beginning of long print runs and at scheduled intervals, preparing the illuminator and sensor system for accurate edge detection before potential drift occurs. This preliminary action prevents misidentification issues during the print run.
2Measurement precision
If calibration is performed frequently during printing operations, then media edge detection accuracy is maintained, but printing productivity decreases due to calibration interruptions
Solution Approach 1:
The calibration process is designed to run concurrently with printing operations, eliminating the need to stop printing for calibration. The system continuously monitors and adjusts illuminator brightness and sensor sensitivity during the print run, maintaining measurement precision without sacrificing productivity.
3Ease of operation
If standard periodic calibration is used, then the system is easy to operate, but noise from contaminants and ambient light causes erroneous edge detection
Solution Approach 1:
The system continuously monitors the optical sensor output and compares it against expected values, automatically adjusting the illuminator brightness and sensor sensitivity in real-time. This feedback mechanism compensates for noise from contaminants and ambient light, maintaining accurate edge detection without requiring manual recalibration or complex user intervention.
Solution Approach 2:
The system dynamically adjusts calibration parameters including illuminator brightness level and optical sensor sensitivity based on real-time measurements. By changing these parameters adaptively during operation, the system maintains measurement precision despite varying environmental conditions and contaminant accumulation.
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
Enhances the accuracy of media edge detection, reducing waste and improving print quality by automatically calibrating the illuminator and optical sensor system to minimize noise interference and ensure precise edge detection.
Implementation Method 1
The automatic detection may be carried out through measurements of reflectance values at an optical sensor with a light source to emit light onto the media
Implementation Method 2
a light source to emit light onto the media
Data Source
AI summary
An apparatus including an illuminator to emit light on a media to be printed on is provided. The apparatus also includes an optical sensor disposed proximate to the illuminator to detect an amount of reflected light. In addition, the apparatus includes a processor to control the illuminator and the optical sensor. The processor is to calibrate the illuminator to determine a first brightness level for high sensitivity at the optical sensor. The processor is to calibrate the illuminator to determine a second brightness level iteratively based on a signal to noise ratio. The processor is to compare the second brightness level with the first brightness level to determine whether to proceed with detection of an edge of the media using the second brightness level.