Inkjet Nozzle Defect Avoidance via Printing Position Shift
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Solution Overview
Problem
In single-pass inkjet printing, nozzle defects lead to streak-like defects in images due to air bubbles or clogging, necessitating frequent nozzle recovery operations, which reduce productivity.
Innovation Solution
An image processing technique that determines whether moving the printing position can avoid conspicuous defects by analyzing density unevenness images and feature amounts, allowing for reduced nozzle recovery operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If single-pass printing method is used to increase printing speed, then productivity is improved, but nozzle discharge defects become more visible causing frequent recovery operations
Solution Approach 1:
The system performs preliminary detection of defective nozzles before printing, and pre-calculates alternative printing positions that can avoid the defects. By preparing the avoidance strategy in advance, the system can immediately adjust printing positions without interrupting the printing process for recovery operations.
Solution Approach 2:
The printing position is made dynamic and adjustable based on detected nozzle conditions. Instead of fixed printing positions, the system dynamically shifts printing positions to areas not affected by defective nozzles, allowing continuous printing without recovery operations.
2Manufacturing precision
If nozzle recovery operations are performed frequently to maintain print quality, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The system extracts and identifies the specific regions affected by nozzle defects, then separates the printing process into affected and non-affected areas. Printing is redirected to non-affected areas, effectively taking the defective nozzle regions out of the printing process without stopping production.
Solution Approach 2:
The system changes the printing position parameter dynamically based on nozzle condition data. By adjusting the printing position parameter to avoid defective nozzles, the system maintains print quality without requiring physical recovery operations that would interrupt production.
3Productivity
If image position is moved to avoid defective nozzles, then productivity is improved by reducing recovery operations, but image density unevenness may become more conspicuous
Solution Approach 1:
The system applies different processing to different regions of the image based on nozzle defect locations. Areas that will be printed by defective nozzles receive special handling or are shifted to regions covered by functional nozzles, while other areas maintain normal printing parameters.
Solution Approach 2:
The system creates a virtual model of the nozzle conditions and uses this to predict and avoid defect areas. By copying the nozzle status information into the printing position calculation, the system can pre-determine optimal printing positions that avoid defects without trial and error.
Data Source
AI summary
An image processing apparatus comprises an obtainment unit configured to obtain a density unevenness image in which uneven density caused by a nozzle in a nozzle row for discharging ink occurs in an image for printing, and a determination unit configured to determine whether a printing position of the image for printing needs to be moved based on a feature amount in each of the image for printing and the density unevenness image.