Inkjet Nozzle Correction Prioritizing Early Ejection Timing
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Solution Overview
Problem
Inkjet-type image forming apparatuses face challenges in correcting multiple ink ejection malfunction positions within a short time, leading to potential blank lines due to droplet coalescence and increased costs associated with high-speed hardware for correction processes.
Innovation Solution
An image forming apparatus with a recording head, control unit, and correction processing unit that detects malfunctioning nozzles and prioritizes early ejection nozzles for correction when the number of malfunctions exceeds a threshold, adjusting ink droplet amounts based on ejection order to minimize image quality degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the correction process is performed for all ejection malfunction nozzles, then the image quality is improved, but the processing time exceeds the short time available from sheet position determination to ink ejection
Solution Approach 1:
The patent applies partial action by selecting only a subset of malfunctioning nozzles for correction based on their ejection timing. Specifically, nozzles that eject ink droplets earlier than adjacent nozzles are prioritized for correction, while late-ejection nozzles are excluded. This selective approach allows the correction process to complete within the short available time while still addressing the most critical malfunctions that would cause blank lines.
Solution Approach 2:
The patent implements preliminary action by determining the ejection order of nozzles before the actual printing process and pre-identifying which malfunctioning nozzles require correction. The control unit calculates the ejection timing relationships between nozzles and pre-determines the correction targets based on this preliminary analysis, allowing the correction process to proceed efficiently without time-consuming real-time calculations during printing.
2Speed
If high-speed hardware is used to perform correction processing for multiple malfunction positions, then the processing speed is improved, but the apparatus cost increases
Solution Approach 1:
The patent replaces the need for high-speed hardware with a software-based correction approach. Instead of using expensive high-speed hardware to process all malfunctioning nozzles simultaneously, the system uses the existing hardware combined with intelligent software algorithms that selectively correct only the critical early-ejection nozzles. This substitution reduces hardware requirements while maintaining acceptable processing speeds through optimized control logic.
Solution Approach 2:
The patent changes the parameter of correction scope from all malfunctioning nozzles to only early-ejection nozzles. By modifying this parameter based on ejection timing analysis, the system reduces the processing load on hardware, allowing standard hardware to suffice rather than requiring high-speed hardware, thus reducing apparatus cost while maintaining sufficient correction capability.
3Manufacturing precision
If the supplementing process is performed for early ejection nozzles, then the ink ejection amount is corrected, but droplet coalescence occurs causing blank lines due to position deviation
Solution Approach 1:
The patent inverts the conventional approach by excluding early-ejection nozzles from correction rather than including them. Since early-ejection nozzles are more prone to causing droplet coalescence and blank lines when their ink is pulled by adjacent dots, the system chooses not to correct these nozzles. Instead, it focuses correction on late-ejection nozzles, which do not have the same coalescence problem, thereby avoiding the generation of blank lines while still correcting harmful malfunctions.
Data Source
AI summary
An image forming apparatus includes a recording head, a control unit, and a correction processing unit. The recording head is configured to eject ink corresponding to an image to be printed, using arranged nozzles. The control unit is configured to determine nozzles corresponding to the image to be printed, correspondingly to a position of a print sheet, and cause the recording head to eject ink from the nozzles. The correction processing unit is configured to detect an ejection malfunction nozzle and perform a correction process corresponding to the ejection malfunction nozzles. Further, if the number of the detected ejection malfunction nozzles exceeds a predetermined upperlimit value, the correction processing unit preferentially sets as a target of the correction process an ejection malfunction nozzle that ejects an ink droplet earlier than nozzles corresponding to two adjacent dots of a dot corresponding to the ejection malfunction nozzle.


