Ink Jet Head Maintenance via Cumulative Chemical Liquid Counting
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Solution Overview
Problem
The existing methods for determining the replacement time of ink jet heads in manufacturing processes, such as for display devices, often result in premature replacement of functional heads and failure to replace deteriorated heads, leading to reduced economics, efficiency, and quality of the manufacturing apparatuses and the final products.
Innovation Solution
A method that calculates the cumulative discharging number of chemical liquid from the ink jet head's piezoelectric elements and compares it to a set limit, determining the replacement time based on this comparison, allowing for continuous use or replacement of the ink jet head, thereby optimizing maintenance and printing quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the ink jet head is replaced according to the manuals provided by manufacturers, then the replacement process is simple and standardized, but the replacement time is not precisely determined leading to premature replacement of functional heads and reduced economics and efficiency
Solution Approach 1:
The system implements a feedback mechanism by continuously monitoring the discharging number of the ink jet head and comparing it with a predetermined reference value. This feedback loop enables dynamic determination of replacement timing based on actual usage conditions, preventing both premature and delayed replacements, thereby optimizing manufacturing efficiency and economics.
2Ease of operation
If the ink jet head is replaced according to the manuals provided by manufacturers, then the replacement procedure is straightforward, but the performance deterioration is not detected leading to decreased quality and reliability of the display device
Solution Approach 1:
The system monitors the discharging number of the ink jet head in real-time and provides feedback by comparing it with a reference value. This enables timely detection of performance deterioration and triggers replacement only when necessary, ensuring display device quality and reliability while maintaining operational simplicity through automated monitoring.
3Productivity
If the ink jet head is not replaced when the manual-specified time is not reached, then the economics and efficiency are improved by avoiding premature replacement, but the performance deterioration goes undetected leading to decreased quality
Solution Approach 1:
The system uses feedback control by continuously monitoring the discharging number and comparing it with a reference value. This enables the system to extend the usage life of the ink jet head beyond manual specifications when performance is still adequate, while simultaneously ensuring printing quality by triggering replacement immediately when the discharging number reaches the reference value, thus resolving the contradiction between efficiency and precision.
4Device complexity
If the replacement time is determined by manual specifications, then the maintenance schedule is simple to follow, but the actual condition of the ink jet head is not monitored leading to suboptimal maintenance timing
Solution Approach 1:
The system implements feedback monitoring of the discharging number with comparison to a reference value, enabling condition-based maintenance timing that adapts to actual ink jet head performance. This approach maintains reliability by ensuring replacement occurs at the optimal moment while keeping the system relatively simple through automated counting and comparison operations.
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 approach ensures the ink jet head is replaced only when necessary, enhancing manufacturing line efficiency and maintaining the quality of the display device by precisely determining the replacement time and adjusting nozzle performance, thus improving the reliability and economics of the process.
Implementation Method 1
discharging numbers of the chemical liquid discharged from the ink jet head onto an object may be identified. A cumulative discharging number of the chemical liquid from the ink jet head may be calculated. In example embodiments, the discharging numbers of the chemical liquid may be obtained by counting operating numbers of piezoelectric elements of the ink jet head.
Data Source
AI summary
In a printing method using an ink jet head, a chemical liquid may be discharged onto a substrate from a plurality of nozzles of the ink jet head. Discharging numbers of the chemical liquid from the plurality of nozzles may be identified and a cumulative discharging number of the chemical liquid from the plurality of nozzles may be calculated. The cumulative discharging number of the chemical liquid may be compared with a previously set limit discharging number of the ink jet head. A replacement time of the ink jet head may be determined if the cumulative discharging number of the chemical liquid exceeds the previously set limit discharging number.