Inkjet Printer Nozzle Dot Position Correction via Scanner Image Analysis
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Solution Overview
Problem
Existing inkjet printers face challenges in maintaining high-quality printing due to the need for precise adjustments of the inkjet heads, which can be time-consuming and prone to variations based on individual adjusters.
Innovation Solution
A method for adjusting an inkjet printer that involves printing a test pattern, reading it with a scanner, and analyzing it using image processing to calculate correction values for the printer's operation, allowing for automatic storage and application of these values to improve printing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual adjustment methods are used for inkjet heads, then adjustment flexibility is maintained, but adjustment time increases and consistency deteriorates due to individual differences
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated image processing system. A scanner captures test patterns, and image processing software automatically analyzes the captured images to calculate correction values for nozzle position misalignment, eliminating the need for manual measurement and adjustment by individuals.
Solution Approach 2:
The system enables self-service adjustment where the inkjet printer itself performs the adjustment through automated feedback. The printer prints test patterns, the scanner reads them, the image processing calculates corrections, and the system automatically adjusts the inkjet head positions based on the calculated correction values, making the adjustment process independent of skilled manual operators.
2Reliability
If manual adjustment is performed, then adaptability to different printers is maintained, but consistency and reliability of adjustment results deteriorate due to individual differences
Solution Approach 1:
The patent implements a closed-loop feedback system. The inkjet printer prints test patterns with known geometric features, the scanner captures these patterns, the image processing software analyzes the captured images to determine actual nozzle positions, calculates correction values, and feeds back control signals to adjust the inkjet head positions. This automated feedback loop ensures consistent and reliable adjustment results free from individual operator variations.
Solution Approach 2:
The manual mechanical adjustment process is replaced with an automated optical-mechanical system. Instead of relying on human eyes and hands to measure and adjust, the system uses a scanner to capture images, image processing algorithms to automatically measure positions, and electronic control to execute adjustments, thereby ensuring uniformity and reliability across different printers and operators.
3Measurement precision
If image processing analysis is performed, then adjustment precision is improved, but device complexity increases
Solution Approach 1:
The patent introduces a scanner as an intermediary device between the inkjet printer and the adjustment system. The scanner captures test patterns and converts them into digital images that can be processed by software. This intermediary enables precise measurement of dot positions through image analysis without requiring complex direct sensing mechanisms in the printer itself, thus achieving high measurement precision while managing system complexity.
Solution Approach 2:
Direct mechanical measurement of nozzle positions is replaced with optical measurement through image processing. Instead of using complex mechanical sensors or direct position detection mechanisms, the system uses a simple scanner to capture test patterns and employs image processing algorithms to calculate precise dot positions and misalignment values, thereby achieving high measurement precision with relatively simple hardware.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables efficient and consistent adjustment of inkjet printers, reducing the number of manual adjustment hours and minimizing variations in image quality across different printers.
Implementation Method 1
reading, with a scanner, the medium on which the test pattern is printed
Data Source
AI summary
A method for adjusting a printing apparatus includes an analyzing stage of performing, by an image analysis apparatus, analysis on a pattern image generated by reading a test pattern by a scanner, and a setting value updating stage of updating a control setting value stored in a database, in which the printing apparatus is caused to print a test pattern including a pattern for ejecting ink from a plurality of nozzle rows to the same position in a main scanning direction, in the analyzing stage, a dot position misalignment amount occurring in each nozzle row is detected by image processing based on the pattern image, a dot position correction value corresponding to the dot position misalignment amount is calculated by calculation, and in the setting value updating stage, the database is caused to store the dot position correction value as at least a part of the control setting value.