Automated Inkjet Printer Calibration via Sample Substrate Imaging
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Solution Overview
Problem
Inkjet printing machines face challenges in maintaining serviceability due to ink drying in nozzles and the absence of a practical method for pre-production testing, leading to potential issues discovered only at the customer site, resulting in costly replacements and reduced manufacturer credibility.
Innovation Solution
An automated calibration method using a computer with an image capture system, where a printed sample substrate with defined deviations is used to simulate a real printing operation, allowing for the calculation and comparison of compensation values to assess and calibrate the printing machine's serviceability without actual printing, focusing on print head and software conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a functional test (proofing) is carried out in inkjet printing machines before delivery, then the serviceability can be checked, but ink dries out in the printing nozzles during the storage period, causing damage to the print heads
Solution Approach 1:
The patent uses a printed sample substrate that contains simulated fault patterns (ghosting, streaks, etc.) to create a copy of real printing defects. This allows the evaluation system to assess print head serviceability without actually printing with ink, thereby avoiding ink drying while still testing the detection and compensation algorithms.
Solution Approach 2:
The evaluation system acts as an intermediary between the print heads and the serviceability assessment. It captures images of the printed sample substrate and uses software algorithms to evaluate the print head condition, replacing the need for actual ink-based proofing that would cause drying.
2Object-affected harmful factors
If proofing is omitted in inkjet printing machines, then ink drying is avoided, but serviceability issues cannot be detected before delivery, leading to costly on-site repairs
Solution Approach 1:
The system performs preliminary evaluation of print head serviceability by capturing and analyzing images of a printed sample substrate before the machine is delivered to the customer. This allows detection of serviceability issues in advance, enabling corrective actions before actual printing operations begin.
Solution Approach 2:
The patent replaces the traditional mechanical/chemical proofing process (actual ink printing) with an optical/electronic evaluation system that uses image capture and digital analysis to assess serviceability, eliminating the harmful effects of ink drying while maintaining detection capability.
3Object-affected harmful factors
If a dummy ink supply unit is used for proofing, then ink drying is prevented, but the test results are less valuable due to differences from the actual ink supply system
Solution Approach 1:
Instead of using a dummy ink supply unit that creates unrealistic test conditions, the patent uses a printed sample substrate that contains copies of actual fault patterns. This allows evaluation of the image capture system and software algorithms under conditions that accurately reflect real printing scenarios without requiring actual ink flow.
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 method enables the detection and correction of malfunctions in inkjet printing machines during production, preventing on-site issues and reducing costs by simulating real printing scenarios, ensuring accurate calibration and maintaining machine reliability.
Implementation Method 1
generating a digital image of the printed sample substrate by using the image capture system
Data Source
AI summary
A method for the automated calibration of a printing machine with an image capture system by using a computer, includes putting at least one printed sample substrate with defined deviations into the printing machine, generating a digital image of the printed sample substrate by using the image capture system, calculating current compensation values including defined deviations for configuration parameters of the printing machine relating to optimizing the printing quality by using the computer, and comparing the current compensation values created with target compensation values known from the defined deviations of the printed sample substrate. Serviceability of the printing machine is checked by evaluating the comparison by the computer and/or calibrating the printing machine by using the evaluated comparison by the computer.