Inkjet Head Unit Operation Count Control for Print Quality
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Solution Overview
Problem
Image forming devices, such as inkjet printers, face a significant reduction in print quality and eventual failure due to head unit deterioration, necessitating premature replacement, which limits continuous printing without significantly lowering quality.
Innovation Solution
An image forming device that includes a processor to monitor the head unit's operation count and control the printing process by either reducing pixel density or thinning images when approaching the life end point, allowing extended use without immediate replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the head unit is used until the life end point based on the number of ink discharges, then the productivity is improved by maximizing the utilization of the head unit, but the print quality deteriorates remarkably and the reliability decreases when the head unit is near its life end point
Solution Approach 1:
The system performs preliminary action by detecting the element operation count and determining whether it has reached or exceeded the warning threshold count before the life end point is reached. When the warning threshold is reached, the system proactively changes the image formation mode to suppress element operation count increment, preventing the head unit from operating in a deteriorated state and thus maintaining print quality while extending continuous printing time.
Solution Approach 2:
The system dynamically changes the image formation mode based on the element operation count. When the count is below the warning threshold, normal image formation is performed. When the count reaches or exceeds the warning threshold, the system switches to a mode that suppresses element operation count increment (such as skipping certain pixels or reducing print density), thereby adaptively managing the head unit's operational stress to extend its usable life without significantly compromising print quality.
2Reliability
If the head unit is replaced immediately when reaching the life end point, then the print quality is maintained at a high level, but the productivity decreases due to frequent replacement operations and downtime
Solution Approach 1:
The system sets a warning threshold count that is smaller by a predetermined count than the life threshold count (life end point). This preliminary warning mechanism allows the system to switch to a protective mode before the head unit actually reaches its life end point, extending the usable operational period while preventing quality deterioration. This resolves the contradiction by allowing continuous printing beyond the traditional replacement point without significant quality loss.
Solution Approach 2:
The system changes the operational parameters of the head unit by switching between different image formation modes. When the element operation count reaches the warning threshold, the system changes parameters such as pixel selection, print density, or element utilization pattern to suppress the increment of element operation count. This parameter change allows the head unit to continue operating in a modified capacity beyond the traditional life end point while maintaining acceptable print quality.
3Duration of action of stationary object
If the element operation count is suppressed by thinning pixels or reducing pixel density, then the head unit lifespan is extended, but the image quality may be reduced
Solution Approach 1:
The system applies partial action by selectively suppressing element operation count increment rather than completely disabling the head unit. When the warning threshold is reached, the system suppresses the increment of element operation count through techniques like thinning pixels or reducing pixel density, but only to the extent necessary to extend head unit lifespan. This partial suppression maintains a balance between extending lifespan and preserving acceptable image quality, avoiding excessive degradation.
Solution Approach 2:
The system changes image formation parameters dynamically based on the element operation count status. When the count is below the warning threshold, full-quality image formation is performed. When the count reaches or exceeds the warning threshold, the system changes parameters such as pixel density, pixel distribution, or element selection patterns to suppress element wear. These parameter changes are optimized to extend head unit lifespan while minimizing the impact on perceived image quality.
Data Source
AI summary
An image forming device includes an inkjet head unit, a count acquiring section, a determining section, and a head controlling section. The inkjet head unit includes an element. The count acquiring section acquires, based on job data, an element operation count of the element. The determining section determines whether the element operation count is equal to or greater than a warning threshold count that is smaller by a predetermined count than a life threshold count corresponding to a life end point of the element. The head controlling section controls, when the element operation count is equal to or greater than the warning threshold count, the inkjet head unit to form an image by suppressing the element operation count.