Multi-Head Imaging Calibration via Positional Interpolation
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Solution Overview
Problem
Existing imaging systems with multiple imaging heads face challenges in calibrating geometric distortions, which are complicated by the positioning and orientation errors induced by one imaging head on another, requiring costly specialized equipment and complex factory-based calibration processes.
Innovation Solution
A method that adjusts the imaging of one imaging head based on the position of another, using interpolation to determine necessary corrections and storing these in a lookup table, allowing for effective calibration of multiple-head imaging systems in the field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If factory-based calibration systems with specialized equipment are used, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The imaging system performs self-calibration using its own imaging heads and control mechanisms. The system captures test images, analyzes geometric distortions, and automatically generates correction values without requiring external specialized calibration equipment, enabling the system to service its own calibration needs
Solution Approach 2:
The patent uses test images that replicate the imaging process and geometric characteristics of actual production images. By analyzing distortions in these test images formed by the imaging heads, the system creates a simplified model of the calibration problem that can be solved using the imaging system's own resources rather than requiring complex external measurement equipment
2Manufacturing precision
If factory-based calibration is performed, then manufacturing precision is improved, but loss of time increases due to shipping test images
Solution Approach 1:
The calibration process is performed entirely on-site at the imaging system location. The system captures test images, processes them through the controller to determine geometric distortions, and generates correction values without requiring physical transport of test images to external calibration facilities, eliminating shipping time and enabling immediate calibration
Solution Approach 2:
The controller acts as an intermediary that processes test images locally and generates correction values. This intermediary function eliminates the need for external calibration equipment and the time-consuming process of shipping test images, as the controller performs all necessary analysis and generates corrections within the imaging system itself
3Productivity
If multiple imaging heads are used, then productivity is improved, but manufacturing precision deteriorates due to positioning errors between heads
Solution Approach 1:
The system captures test images using multiple imaging heads and analyzes the actual positions and geometric distortions of each head. The controller processes this feedback information to determine correction values that compensate for positioning errors and geometric variations between heads, enabling the system to maintain high alignment accuracy while utilizing multiple heads for increased productivity
Solution Approach 2:
The patent applies individual correction values to each imaging head based on its specific positioning errors and geometric distortions. Rather than treating all heads uniformly, the system tailors corrections to each head's local characteristics, ensuring that each head contributes to high-precision multi-color imaging while maintaining overall system productivity
Data Source
AI summary
An apparatus (10) for adjusting the calibration of an imaging system to correct for geometric distortion comprises a rotating drum for receiving recording media (17), a plurality of carriages (18) each having an imaging head (16) with a plurality of addressable imaging channels, and a controller programmed with a lookup table, analytical relationship or algorithm that relates corrective adjustments to be made to the imaging of a given imaging head based on the positions of others of the imaging heads. A method is described for obtaining the lookup table, analytical relationship or algorithm. The method has particular relevance to large imaging systems.