Inkjet Head Alignment Using Synchronized Image Sensors

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Solution Overview

Problem

Conventional head alignment processes for inkjet modules in printing equipment are time-consuming, prone to operator skill variations, and can lead to accumulated errors, affecting the quality and performance of the printing process.

Innovation Solution

A head alignment apparatus utilizing a reference position determining unit with synchronized image sensors to accurately align inkjet head modules, ensuring precise mounting positions through a structure with marked surfaces and visual display of alignment positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual head mounting and position checking is performed repeatedly, then head alignment can be achieved, but alignment time increases significantly

Engineering Contradiction:

Improvehead mounting precisionVSAvoidalignment time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical mounting and visual position checking with an automated optical measurement system. Image sensors capture head positions, and a control unit automatically calculates alignment status, eliminating the need for repeated manual mounting and checking operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-alignment through automated detection and calculation. The image sensors and control unit work autonomously to determine head positions and guide alignment, reducing dependency on operator skill and repeated manual adjustments.

Inventive Principle:

Principle #25Self-service

2Productivity

If manual head setting is performed by operators, then head alignment can be completed, but variations in mounting precision occur depending on operator skill level

Engineering Contradiction:

Improvealignment speedVSAvoidmounting precision consistency

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent replaces manual operator-based mounting with an automated optical measurement and control system. Image sensors objectively capture head positions, and the control unit calculates precise alignment status, eliminating variations caused by different operator skill levels.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system provides real-time feedback through the image sensors and control unit, which detect head positions and calculate alignment status. This feedback mechanism ensures consistent precision by objectively guiding alignment based on measured data rather than operator judgment.

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If multiple heads are mounted manually, then complete printing equipment can be assembled, but accumulated errors deteriorate printing quality

Engineering Contradiction:

Improveequipment functionalityVSAvoidprinting quality

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent replaces manual multi-head mounting with an automated system using image sensors to capture positions of multiple heads simultaneously. The control unit calculates relative positions and alignment status for all heads, preventing error accumulation by ensuring each head is precisely positioned relative to others.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The control unit acts as an intermediary that coordinates the positioning of multiple heads. It calculates the position of each head relative to a reference head and determines overall alignment status, ensuring that multiple heads are precisely aligned without accumulated errors.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Measurement precision

If repeated mounting and position checking is performed, then correct head position can be achieved, but the process becomes complex and time-consuming

Engineering Contradiction:

Improveposition accuracyVSAvoidalignment process complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex manual repeated mounting and checking with a streamlined automated system. Image sensors capture head positions in one or few operations, and the control unit automatically calculates alignment status, reducing both time and process complexity while maintaining high position accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11491781B2Apparatus for aligning head module and system for treating substrate with the apparatus

Publication Date: 2022.11.08 SYSTEM ENGINEERING MEGA SOLUTION CO LTD

AI summary

A head alignment apparatus for determining a reference position using position synchronization and aligning a plurality of head modules according to the reference position, and a substrate treating system including the same are provided. The head alignment apparatus may include, a reference position determining unit for determining a first reference position of a head transfer, in which a plurality of inkjet head modules are installed; and a mounting position determining unit for determining a second reference position of the inkjet head module based on the first reference position so that the inkjet head module can be moved from a current position to a second reference position, wherein the reference position determining unit determines a first reference position using a first image sensor installed on the same plane as the inkjet head module and a second image sensor installed facing the inkjet head module.