Inkjet Line Head Overlap Alignment Correction

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Solution Overview

Problem

Existing inkjet recording apparatuses face challenges in aligning printing positions of recording heads in the sub scanning direction, leading to color displacement and degraded image quality due to deviations in the fitting position of recording heads, which conventional technologies fail to address effectively.

Innovation Solution

The apparatus includes a sheet conveying unit, a storage unit, and a control unit that manages the ejection of ink from a line head with overlapping nozzles, allowing for the printing of adjustment charts to determine and correct deviations in the sub scanning direction by displacing the timing of ink ejection between upstream and downstream heads.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If multiple recording heads are arranged in a staggered formation to increase printable sheet width, then the printable area is improved, but the alignment precision in the sub scanning direction deteriorates due to fitting position deviations

Engineering Contradiction:
Improveprintable sheet widthVSAvoidalignment precision in sub scanning direction
Core Design Contradiction:
Area of stationary objectVSManufacturing precision

Solution Approach 1:

The patent divides the recording head into multiple independent recording heads (first recording head, second recording head, etc.) arranged in a staggered formation. Each recording head has its own nozzle array and can be independently adjusted in the sub scanning direction, allowing individual alignment correction while maintaining the expanded printable width.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent introduces adjustable timing parameters (timing advance amounts) for each recording head to correct alignment deviations. By changing the ejection timing of ink from each recording head relative to the sheet conveyance timing, the system compensates for fitting position deviations and achieves precise alignment in the sub scanning direction.

Inventive Principle:
Principle #35Parameter changes

2Ease of manufacture

If recording heads are fitted with standard tolerances during assembly, then the ease of manufacture is improved, but the printing position accuracy deteriorates due to cumulative fitting position deviations

Engineering Contradiction:
Improveassembly easeVSAvoidprinting position accuracy
Core Design Contradiction:
Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent performs preliminary measurement of the actual fitting positions of recording heads during assembly and stores this information. Based on these measurements, the system pre-calculates and sets appropriate timing advance amounts for each recording head before actual printing operations, thereby compensating for fitting deviations without requiring reassembly.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent implements a feedback mechanism where the actual printing positions are measured and compared against target positions. The timing advance amounts are then adjusted based on this feedback to minimize alignment deviations, creating a closed-loop system that continuously optimizes printing position accuracy.

Inventive Principle:
Principle #23Feedback

3Productivity

If the timing of ink ejection is synchronized based on specification-stated distances and speeds, then the productivity is improved, but the measurement precision of actual position deviations deteriorates due to ignoring real fitting variations

Engineering Contradiction:
Improveprinting speedVSAvoidposition deviation detection accuracy
Core Design Contradiction:
ProductivityVSMeasurement precision

Solution Approach 1:

The patent transitions from static timing synchronization based on specification values to dynamic timing adjustment based on actual measured positions. The system continuously adapts the ejection timing of each recording head according to real fitting position data, maintaining high productivity while achieving precise alignment through real-time parameter optimization.

Inventive Principle:
Principle #15Dynamics

Data Source

PatentUS10723126B2Inkjet recording apparatus and control method therefor
Publication Date: 2020.07.28 KYOCERA DOCUMENT SOLUTIONS INC
  • US10723126B2 patent drawing
  • US10723126B2 patent drawing
  • US10723126B2 patent drawing

AI summary

An inkjet recording apparatus includes a sheet conveying unit, a storage unit, a line head, and a control unit. The line head includes an upstream-side head and a downstream-side head. The upstream-side and downstream-side heads are fitted to have overlapping portions in which a plurality of nozzles arranged in respective end portions of the heads overlap as seen from the sub scanning direction. When an adjustment chart is printed, the control unit makes the nozzles in the overlapping portion of the upstream-side head print a first line. The control unit makes the nozzles in the overlapping portion of the downstream-side head print a second line.