Inkjet Head Obstruction Detection via Image Sensor
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Solution Overview
Problem
Conventional inkjet recording apparatuses fail to accurately determine and address the cause of improper ink deposition on a recording medium, leading to insufficient solutions for issues like nozzle misfiring or obstruction, as they only assess whether nozzles are misfiring without identifying the underlying cause.
Innovation Solution
An inkjet recording apparatus equipped with an image sensor to capture images of the ejection surface and recording medium, a blocking object determining unit to identify obstructions affecting multiple neighboring ejection outlets, and a blocking object dealing unit to perform appropriate recovery operations such as removal or notification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional nozzle misfiring detection is used, then it is possible to identify whether each nozzle is misfiring, but it is not possible to determine the underlying cause (obstruction vs. nozzle failure) or take appropriate remedial action
Solution Approach 1:
The patent segments the problem of ink deposition failure into two distinct causes: nozzle misfiring and obstruction of ink flight. By using an image sensor to capture images of the recording medium and analyzing the captured images, the system can identify patterns that indicate obstruction (affecting multiple neighboring nozzles) versus isolated nozzle failure. This segmentation enables targeted remedial actions for each cause.
Solution Approach 2:
The patent introduces an image sensor as an intermediary device between the inkjet head and the analysis system. The image sensor captures images of the recording medium, and the controller analyzes these images to determine whether ink deposition failure is caused by obstruction or nozzle misfiring. This intermediary enables non-contact, automated detection and cause identification without requiring physical inspection of the inkjet head.
2Reliability
If automated obstruction detection and remediation is implemented, then print quality and reliability are improved, but device complexity increases due to additional image sensor and control logic
Solution Approach 1:
The patent makes the image sensor serve multiple functions: it captures images for quality verification, identifies obstructions, determines affected nozzle regions, and triggers appropriate remedial actions. The controller also performs multiple functions including image analysis, cause determination, and control of remedial operations. This multi-functionality reduces the need for separate dedicated components for each function.
Solution Approach 2:
The system implements self-service by automatically detecting obstructions, identifying affected nozzles, and executing remedial actions without human intervention. The controller continuously monitors ink deposition quality through image capture and analysis, and automatically triggers cleaning operations or adjusts ejection control when obstructions are detected, enabling the system to maintain itself.
Data Source
AI summary
The present invention provides an inkjet recording apparatus includes an inkjet head, a conveyor, a printing controller, an image sensor, a blocking object determining unit, and a blocking object dealing unit. The inkjet head has an ejection surface in which plural ejection outlets ejecting ink are formed. The conveyor has a placing member on which a recording medium is placed and conveys the placing member to a position opposing the ejection surface. The printing controller causes the conveyor to convey the placing member to the opposing position and causes the inkjet head to eject the ink towards the opposing position. The image sensor captures an image of at least one of (i) a surface of the recording medium placed on the placing member, (ii) a surface of the placing member, and (iii) the ejection surface. The blocking object determining unit determines, based on the image captured by the image sensor, whether an object which blocks the flight of the ink exists between the ejection outlets and the opposing position so as to obstruct at least two neighboring ejection outlets among the ejection outlets. The blocking object dealing unit carries out a predetermined blocking object dealing operation when the blocking object determining unit determines that the object blocking the flight of the ink obstructs at least two neighboring ejection outlets among the ejection outlets.