Inkjet Printer Head Gap Control for Corrugated Sheets
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Solution Overview
Problem
Inkjet printers face challenges in maintaining image quality when recording sheets are corrugated by the corrugating mechanism, leading to variations in the gap between the recording head and the sheet, which affects ink discharge precision.
Innovation Solution
An inkjet printer system with a conveyer roller unit, a recording head, and a corrugation mechanism that alternately adjusts the gap between the recording head and the sheet, using a controller to execute conveying and recording steps, including corrected discharging positions to account for sheet nipping and non-nipping conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the recording sheet is corrugated by the corrugating mechanism, then the sheet can be conveyed in a rippled shape, but the gap between the recording head and the sheet varies, causing image quality degradation
Solution Approach 1:
The controller performs preliminary actions by storing reference timing information for ink discharge and pre-calculating corrected discharging positions based on the corrugated sheet's position. This allows the system to anticipate and compensate for gap variations before they affect image quality, ensuring precise ink discharge despite the varying gap caused by corrugation.
Solution Approach 2:
The system implements feedback by detecting the actual position of the corrugated sheet using sensors and comparing it with expected positions. Based on this feedback, the controller dynamically adjusts the discharging position and timing of the recording head, creating a closed-loop control system that maintains image quality despite sheet deformation.
2Ease of operation
If the recording head discharges ink at a fixed position, then the operation is simple, but the ink discharge precision deteriorates when the sheet is corrugated
Solution Approach 1:
The system transitions from a static, fixed discharge position to a dynamic discharge position that automatically adjusts based on the corrugated sheet's actual position. The controller calculates and applies corrected discharging positions in real-time, making the discharge operation adaptive rather than rigid, thereby maintaining precision without significantly complicating the overall operation.
3Productivity
If the conveyer roller unit nips the sheet, then the sheet conveyance is controlled, but the sheet position varies, affecting ink discharge accuracy
Solution Approach 1:
The system uses feedback mechanisms where sensors detect the actual position of the sheet after it passes through the conveyer roller unit. This position information is fed back to the controller, which then calculates corrected discharging positions to compensate for any deviations caused by the nipping action, ensuring accurate ink discharge while maintaining controlled sheet conveyance.
Solution Approach 2:
The controller dynamically changes the discharge timing and position parameters based on the sheet's actual position detected after conveyance. By adjusting these parameters in real-time according to the varying sheet position caused by nipping, the system maintains ink discharge accuracy while preserving the benefits of controlled sheet conveyance.
Data Source
AI summary
An inkjet printer having a conveyer, a recording head, a carriage, a corrugation mechanism, and a controller is provided. The controller executes an operation including a conveying step to convey a sheet and a recording step to discharge ink through the recording head toward the sheet. The recording step includes a discharging step, in which the recording head is manipulated to discharge the ink toward the sheet in response to the carriage being placed in a discharging position when the sheet is in a nipped condition, in which the sheet is nipped by the conveyer roller unit; and a corrected discharging step, in which the recording head is manipulated to discharge the ink toward the sheet in response to the carriage being placed in a corrected discharging position, when the sheet is in a non-nipped condition, in which the sheet is not nipped by the conveyer roller unit.