Inkjet Printer Belt Misalignment Correction via Test Image Analysis
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Solution Overview
Problem
Inkjet printers face challenges in maintaining image squareness due to misalignment between the printing belt and recording heads, requiring skilled technicians for adjustments and involving time-consuming processes, which is not efficient for achieving image quality comparable to offset printing.
Innovation Solution
An image forming apparatus with a belt member, image forming unit, reader, memory, and controller that forms test images to determine and correct misalignment between the nozzles and the printing belt, using data stored in memory and readings from the reader to adjust the position of the recording heads and printing belt for precise squareness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment by skilled technician is used, then image squareness is improved, but adjustment time and operation complexity increase
Solution Approach 1:
The system performs self-diagnosis and self-adjustment through automated measurement using the reader and calculation of misalignment amounts, eliminating the need for skilled technicians to manually measure and adjust recording head positions
Solution Approach 2:
Manual mechanical measurement and adjustment operations are replaced with an automated optical measurement system using a reader to capture test images and a controller to calculate and apply correction values
2Measurement precision
If manual measurement with scale is used, then misalignment can be detected, but measurement precision and repeatability are limited
Solution Approach 1:
Manual measurement using physical scales is replaced with an optical reading system that captures test images and automatically calculates misalignment amounts, providing higher precision and repeatability
Solution Approach 2:
The system creates a digital copy of the test image through the reader, allowing precise measurement of misalignment without physical contact or manual reading operations
3Manufacturing precision
If position sensor for each recording head is used, then positioning accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The complex positioning sensor systems are removed entirely, replacing them with a simpler test image-based measurement approach that achieves comparable positioning accuracy without additional sensors
Solution Approach 2:
Instead of using physical sensors to detect head positions, the system uses digital test images as proxies to infer misalignment, achieving positioning accuracy through image analysis rather than direct physical measurement
4Measurement precision
If scanner is used to read image, then misalignment can be measured, but misalignment between printing belt and scanner prevents accurate measurement
Solution Approach 1:
The test image serves as an intermediary reference that bridges the relationship between the printing belt and scanner, allowing misalignment measurement even when direct alignment between these components cannot be guaranteed
Data Source
AI summary
A belt member conveys a sheet while carrying a sheet. An image forming unit is provided with a plurality of nozzles for ejecting inks and forms an image on the sheet carried by the belt member using the ink ejected from the plurality of nozzles. A reader reads the sheet on which the image is formed by the image forming unit. A memory stores data regarding a tilt of the reader. A controller controls the image forming unit to form a test image on a sheet, and determines a misalignment of a first direction in which the plurality of nozzles are arranged with respect to a second direction based on the data stored in the memory and a result of reading the sheet read by the reader and on which the test image is formed.