LED Module Calibration for UV Curing Consistency
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Solution Overview
Problem
Variations in manufacturing processes and age of radiant energy sources in curing modules lead to inconsistent radiant energy output in printing devices, resulting in inconsistencies in image characteristics such as sheen, color density, and hue in printed images.
Innovation Solution
A calibration system that uses visual inspection of calibration images to adjust power level settings for each LED module, ensuring consistent radiant energy output across modules, with user input guiding adjustments to achieve uniform image characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple curing modules are used to cover larger printing areas, then the printing capacity and coverage are improved, but variations in manufacturing processes and age of radiant energy sources lead to inconsistent radiant energy output across modules
Solution Approach 1:
The patent applies local quality by making each curing module individually adjustable through separate power level settings. This allows each module to be calibrated independently to compensate for manufacturing variations and aging effects, ensuring that despite being different physical units, each module delivers consistent radiant energy output tailored to its specific characteristics.
Solution Approach 2:
The patent utilizes parameter changes by adjusting the power level settings of each curing module's radiant energy sources. By varying the operational parameters (power levels) of individual modules, the system compensates for inconsistencies in radiant energy output, maintaining uniform curing quality across all modules regardless of their manufacturing variations or age.
2Manufacturing precision
If power level settings are adjusted to compensate for variations in radiant energy output, then image characteristic consistency is improved, but additional calibration time and user input requirements increase
Solution Approach 1:
The patent implements feedback by using calibration images that visually display the radiant energy output of each curing module. Users inspect these images and provide input about observed variations, which feeds back into adjusting the power level settings. This feedback loop enables systematic calibration that improves image consistency while structuring the process to be as efficient as possible.
Solution Approach 2:
The patent applies preliminary action by performing calibration using visual inspection of calibration images before actual printing operations. This allows power level settings to be pre-adjusted based on observed variations, ensuring that when printing begins, the modules are already optimized for consistent output, thereby reducing time loss during production.
3Ease of operation
If visual inspection methods are used to detect variations in cured images, then measurement of image characteristics is simplified, but detection precision and objectivity are reduced compared to automated sensing
Solution Approach 1:
The patent uses calibration images as an intermediary between the curing modules and the user's assessment. These specially designed calibration images amplify and make visible the variations in radiant energy output, serving as a mediator that translates subtle physical differences into observable visual patterns that users can systematically evaluate.
Solution Approach 2:
The patent exploits color changes and visual characteristics in the calibration images that result from differential curing. Variations in radiant energy output produce detectable differences in color, sheen, or other visual properties of the cured calibration image, making the otherwise imperceptible variations observable and assessable by users.
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
The calibration system effectively reduces inconsistencies in image characteristics by ensuring each LED module emits a similar spectral profile and intensity, resulting in more consistent and durable printed images.
Implementation Method 1
curing modules that include various types of the radiant energy sources. The radiant energy sources can be in the form of lamps or light emitting diodes (LEDs)
Implementation Method 2
curing of the printing material may take the form of air curing, heat curing, or curing by exposure to radiant energy, such as infrared (IR) and ultraviolet (UV) radiation
Data Source
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AI summary
Examples described herein include method for calibrating LED modules (125-1 ... 125-N) in a curing engine. The method of calibrating UV curing modules includes receiving an uncured calibration image and initiating a curing operation that includes operating the curing modules according to a plurality of corresponding initial power level settings to apply radiant energy to the uncured calibration image to generate a cured calibration image. The method further includes receiving user input or information about an image characteristic of the cured calibration image from a user. The method then includes analyzing the user input to generate adjustments to the corresponding initial power level settings, and then applying the adjustments to the corresponding initial power level settings to generate a plurality of corresponding adjusted power level settings.