Inkjet Nozzle Compensation via Deviating Adjacent Nozzles
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Solution Overview
Problem
Inkjet printing machines face challenges in compensating for failed nozzles, particularly when multiple adjacent nozzles fail, leading to distorted images and increased maintenance costs due to the need for redundant hardware and complex compensation processes.
Innovation Solution
A method using a computer to identify and group nozzles that deviate from their intended path, allowing these nozzles to compensate for adjacent failed nozzles, reducing the number of nozzles marked as defective and optimizing ink drop volume for improved image quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If redundant printing nozzles or multiple print heads are used to compensate for failed nozzles, then compensation reliability is improved, but device complexity and maintenance costs increase
Solution Approach 1:
The patent applies the self-service principle by enabling functional nozzles to compensate for failed nozzles through self-adjustment of ink drop volume. The system automatically identifies failed nozzles and redistributes their printing load to adjacent functional nozzles without requiring redundant hardware components, thereby maintaining compensation reliability while avoiding increased device complexity
Solution Approach 2:
The patent implements parameter changes by dynamically adjusting the ink drop volume parameter of functional nozzles to compensate for failed nozzles. The control unit modifies the ink drop volume of adjacent nozzles based on the failure pattern, allowing the system to adapt to different failure scenarios without changing the physical structure or adding redundant components
2Reliability
If ink drop volume of adjacent nozzles is increased to compensate for failed nozzles, then compensation effectiveness is improved, but risk of overcompensation and black line formation increases
Solution Approach 1:
The patent applies feedback by implementing a measurement and evaluation process that monitors the printing performance of each nozzle. The system measures actual ink drop placement and volume, compares it against target values, and uses this feedback information to calculate appropriate compensation amounts for adjacent nozzles, preventing overcompensation and black line formation
Solution Approach 2:
The patent implements partial action by applying compensation only to the extent necessary to cover the failed nozzle's printing area. The control unit calculates the precise ink drop volume needed based on the failed nozzle's characteristics and the adjacent nozzle's performance, avoiding excessive ink application that would cause black lines while ensuring sufficient coverage
3Manufacturing precision
If nozzles printing in a deviating way are deactivated to maintain print quality, then image quality is improved, but productivity decreases due to more failed nozzles
Solution Approach 1:
The patent converts the harmful effect of deviating nozzles into a beneficial compensation resource. Instead of deactivating nozzles that print with slight deviations, the system identifies them as potential compensation candidates and adjusts their ink drop volume to cover failed nozzles. This transforms what would be considered defective nozzles into useful compensation assets, maintaining image quality while preserving productivity
4Reliability
If multiple adjacent nozzles fail, then compensation difficulty increases, but traditional methods can only compensate for individual nozzles
Solution Approach 1:
The patent applies merging by combining the compensation capabilities of multiple adjacent functional nozzles to cover multiple failed nozzles. The control unit calculates a distributed compensation scheme where several functional nozzles work together, each contributing a portion of the total compensation needed, thereby handling multiple adjacent failures without requiring complex redundant hardware
Data Source
AI summary
A method for compensating for failed printing nozzles in an inkjet printing machine uses a computer to provide an increased ink drop volume of adjacent nozzles. All existing printing nozzles are measured regarding print failure and deviation of a printed dot beyond a specific threshold, so that the printing nozzles are marked either as functioning, failed, or printing a dot deviating in a direction transverse to the printing direction, and the results are saved on the computer. The computer hides all functioning printing nozzles and marks all remaining isolated printing nozzles as failed nozzles. The computer groups adjacent remaining printing nozzles by marking nozzles printing a dot deviating in a direction transverse to the printing direction as functioning printing nozzles contributing to the compensation or as failed printing nozzles in accordance with a rule, and the computer compensates for all printing nozzles having been marked as failed.