Inkjet Recording Apparatus Nozzle Failure Compensation
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Solution Overview
Problem
Inkjet recording apparatuses face issues with image quality degradation due to nozzle blockages, which cause deviated ink droplet discharge and white lines in printed images, especially in high-precision applications like barcode printing, and existing solutions require costly detection systems and are not versatile across different printing systems.
Innovation Solution
An inkjet recording apparatus with an ink head, region detector, and drop amount controller that adjusts ink droplet amounts based on pixel attributes without needing nozzle detection, allowing for image quality improvement by increasing or decreasing ink droplets across neighboring pixels to fill gaps and maintain image integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If nozzle detection systems are added to detect and compensate for failing nozzles, then image quality degradation is reduced, but equipment cost increases
Solution Approach 1:
The inkjet recording apparatus compensates for failing nozzles using its own existing nozzle structure without requiring external detection systems. The control unit adjusts ink discharge amounts based on predetermined failure patterns, allowing the system to self-correct without additional hardware
Solution Approach 2:
Instead of detecting actual nozzle failures, the system uses predetermined failure pattern data as a copy or model to compensate for potential or actual nozzle issues. This abstract representation replaces the need for physical detection systems
2Measurement precision
If optical sensor arrays are added to detect failing nozzles across the entire printing width, then nozzle detection accuracy is improved, but production cost increases significantly
Solution Approach 1:
The invention extracts only the essential compensation function from the complex detection system. Instead of using full-width optical sensors to detect every nozzle failure, the system extracts predetermined failure patterns and applies compensation only where needed, eliminating the need for expensive detection hardware
Solution Approach 2:
The system uses inexpensive predetermined failure pattern data instead of expensive optical sensor arrays. The compensation is based on pre-stored information about common nozzle failure patterns rather than real-time detection hardware
3Productivity
If single pass systems use a line head longer than the printing range to cover all regions in one pass, then printing speed is improved, but the ability to compensate for failing nozzles is lost
Solution Approach 1:
The system dynamically adjusts ink discharge amounts for different nozzles based on their operational status and failure patterns. Even in single-pass systems, the control unit can vary the discharge amount of each nozzle individually, enabling compensation without requiring multi-pass operation
Solution Approach 2:
The invention applies local compensation by adjusting the ink discharge amount of specific nozzles based on their individual failure patterns. Each nozzle can have its discharge amount independently controlled to compensate for its specific performance characteristics, allowing compensation within a single pass
4Manufacturing precision
If multi-pass systems are used to compensate for failing nozzles by passing the printing medium multiple times, then image quality is improved, but printing time increases
Solution Approach 1:
The system performs preliminary compensation by adjusting ink discharge amounts based on predetermined failure patterns before the actual printing occurs. The control unit pre-calculates compensation values for each nozzle based on stored failure data, eliminating the need for time-consuming multi-pass operations
Data Source
AI summary
An inkjet recording apparatus is adapted to form an image on a printing medium 10, and recognize an image forming region as a region of pixels having drop amounts unequal to zero in the image. A drop amount increase/decrease controller 342 executes an increase/decrease process of drop amount at a current pixel as a target of the process, in accordance with an attribute of the current pixel when the current pixel is included in the image forming region. Pixels are made of ink discharged from nozzles arrayed in a scan direction perpendicular to a transfer direction of the recording medium 10. The drop amount increase/decrease controller 342 executes the increase/decrease process of drop amount in a reverse increase/decrease pattern to ink to be discharged from a neighboring nozzle.