Inkjet Head Correction Modes for Malfunction Density
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Solution Overview
Problem
Inkjet-type image forming apparatuses face challenges in efficiently correcting multiple ink ejection malfunction positions within a short time, leading to high costs due to the need for high-speed hardware to perform correction processes.
Innovation Solution
The apparatus includes a recording head, control unit, and correction processing unit that prints test patterns to determine malfunction positions and sets correction modes based on ink ejection density, allowing for targeted correction processes, either including or excluding the malfunctioning nozzle, to reduce the number of nozzles requiring correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If high-speed hardware is used to perform correction process for multiple ink ejection malfunction positions, then the correction process can be completed within the short time, but the apparatus cost increases
Solution Approach 1:
The correction process is segmented into two distinct modes: first correction mode that corrects both the malfunction nozzle and adjacent nozzles, and second correction mode that corrects only adjacent nozzles. This segmentation allows selective application of correction intensity based on malfunction density, avoiding the need for high-speed hardware while maintaining correction effectiveness within the short time window between sheet position determination and ink ejection.
Solution Approach 2:
The patent applies partial action by selectively choosing between first and second correction modes based on malfunction density. For areas with lower malfunction density, the second correction mode (correcting only adjacent nozzles) is sufficient, reducing the overall correction workload. This partial approach to correction allows the system to complete corrections within the time constraint without requiring expensive high-speed hardware for all positions.
2Reliability
If correction process is performed for all malfunction positions, then complete correction is achieved, but the correction time exceeds the available short time window
Solution Approach 1:
The patent applies local quality by determining malfunction density at different positions and applying different correction modes locally. Areas with high malfunction density receive the first correction mode (correcting malfunction nozzle and adjacent nozzles), while areas with lower density receive the second correction mode (correcting only adjacent nozzles). This localized approach ensures complete correction where needed while maintaining productivity in other areas, achieving both reliability and speed within the short time window.
Data Source
AI summary
In an image forming apparatus, a correction processing unit prints a test pattern using a recording head, determines ink ejection malfunction positions on the basis of a scanned image of the test pattern, sets one of first and second correction modes for each of the ink ejection malfunction positions in accordance with a density of the ink ejection malfunction position on the basis of the scanned image, and performs the correction process for the ink ejection malfunction position in the set first or second correction mode. In the first correction mode, the correction process is performed for both a nozzle corresponding to the ink ejection malfunction position and an adjacent nozzle of the nozzle. In the second correction mode, the correction process is not performed for the nozzle corresponding to the ink ejection malfunction position but is performed for the adjacent nozzle.