Ink Jet Card Printer Gantry Sensor Positioning
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Solution Overview
Problem
Ink jet card printers face challenges in accurately positioning cards for printing due to misregistration issues, which can lead to incomplete or contaminated images, and existing solutions do not effectively address the obstruction of printing operations by card feeders in their raised positions.
Innovation Solution
The ink jet card printer incorporates a transport belt system with a gantry that supports the ink jet print head and sensor, allowing for precise detection of card positions and movement relative to the processing axis, and includes a lift mechanism to move card feeders from raised to lowered positions during printing, ensuring the print head can operate without obstruction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If card feeders are positioned in raised positions for card loading, then card feeding capability is improved, but printing operations are obstructed and ink contamination occurs
Solution Approach 1:
The card feeder is designed with movable positioning capability, transitioning from a static raised position to a dynamic system that can lower the card feeder away from the print zone during printing operations. This dynamic adjustment eliminates ink contamination while preserving card feeding functionality.
Solution Approach 2:
The solution moves the card feeder along the vertical dimension (lowering it away from the print zone) rather than removing it entirely. This dimensional change allows the card feeder to be positioned out of the horizontal print path, preventing contamination while maintaining operational capability.
2Manufacturing precision
If card position detection is not implemented, then device complexity is reduced, but printing precision deteriorates due to misregistration
Solution Approach 1:
The patent replaces complex mechanical positioning systems with a sensor-based detection system. Instead of using mechanical mechanisms to ensure precise card positioning, optical or other sensors detect card position, and the system adjusts printing parameters accordingly, reducing mechanical complexity while maintaining precision.
Solution Approach 2:
A sensor system provides real-time feedback on card position to the control system. This feedback loop allows the system to detect card placement accuracy and adjust printing operations to compensate for misregistration, achieving high precision without complex mechanical positioning mechanisms.
3Productivity
If card feeders remain in raised positions during printing, then device complexity is reduced, but productivity decreases due to interrupted printing operations
Solution Approach 1:
The card feeder positioning system is made dynamic, automatically lowering during printing and raising for card loading. This dynamic behavior enables continuous printing operations without interruption, as the card feeder is out of the way during printing but readily accessible for loading, thereby improving productivity.
Solution Approach 2:
The card feeder undergoes periodic positioning changes - lowered during printing phases and raised during card loading phases. This periodic action coordinates with the printing cycle, ensuring the feeder is positioned appropriately for each operational phase without interrupting printing throughput.
Data Source
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AI summary
In a method of operating an ink jet card printer, which includes a transport belt, a print unit including an ink jet print head, a sensor and a gantry, a card is loaded onto the transport belt along a processing axis using an exposed surface of the transport belt. The sensor and the ink jet print head are moved relative to the card using the gantry. A current position of the card is detected using the sensor. An image is printed to the card using the ink jet print head when the detected current position of the card indicates that the card is supported on the transport belt in a print position. Printing is interrupted when the detected current position of the card indicates that the card is not in the print position.