Liquid Discharge Apparatus Deviation Correction
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Solution Overview
Problem
Existing liquid discharge apparatuses face challenges in accurately adjusting the discharge timing of ink from multiple head units, leading to deviations in ink placement on the conveyance medium.
Innovation Solution
A liquid discharge apparatus comprising multiple liquid discharge head units, an image sensor, and processing circuitry that detects deviations in ink placement, corrects discharge timing, and switches between different conveyance speeds and image sizes to maintain accurate ink placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the image sensor images the object with a large image size (first image size) to detect deviation accurately, then the measurement precision is improved, but the productivity decreases due to slower conveyance speed
Solution Approach 1:
The system dynamically switches between two operational modes: a first control mode for high-precision deviation detection using a large image size and slow conveyance speed, and a second control mode for high-speed processing using a smaller image size and fast conveyance speed. This dynamic adaptation allows the system to optimize between measurement precision and productivity based on operational requirements.
Solution Approach 2:
The system performs preliminary deviation detection using the first control (large image size, slow speed) to establish accurate reference measurements. Based on these preliminary results, it then applies correction values to the discharge timing of liquid discharge head units, allowing subsequent operations to proceed at higher speeds with pre-corrected parameters.
2Productivity
If the conveyance speed is increased to improve productivity, then the output is improved, but the manufacturing precision of ink placement deteriorates
Solution Approach 1:
The system uses the image sensor to detect actual ink placement positions and compares them with target positions, generating feedback signals. Based on this feedback, the processing circuitry calculates correction values and adjusts the discharge timing of liquid discharge head units, enabling the system to maintain manufacturing precision even at high conveyance speeds.
Solution Approach 2:
The system changes operational parameters by switching between different conveyance speeds and image sizes. When high productivity is required, it increases conveyance speed while using a smaller image size for detection. Correction values are applied to maintain precision, effectively decoupling the trade-off between speed and accuracy through parameter adaptation.
3Productivity
If multiple liquid discharge head units operate simultaneously to improve productivity, then the output is improved, but the manufacturing precision deteriorates due to timing synchronization difficulties
Solution Approach 1:
The image sensor detects the actual discharge positions of multiple liquid discharge head units, and the processing circuitry calculates individual correction values for each head unit based on detected deviations. These correction values are applied to adjust the discharge timing of each head unit, ensuring that even when multiple heads operate simultaneously, each maintains accurate placement precision.
Solution Approach 2:
The system applies individualized correction values to each liquid discharge head unit based on its specific deviation characteristics. Rather than using a uniform correction approach, the processing circuitry tailors the timing adjustment for each head unit, ensuring that local variations in discharge position are corrected appropriately for each component.
Data Source
AI summary
A liquid discharge apparatus includes liquid discharge head units, an image sensor, and processing circuitry. The circuitry detects, based on image data detected by the sensor, an amount of deviation between positions on an object onto which liquid has been discharged by the head units; corrects a timing of discharging the liquid, based on the amount of deviation; switches between first control of conveying the object at a first speed while the sensor images the object with a first image size and second control of conveying the object at a second speed faster than the first speed while the sensor images the object with a second image size having a smaller number of pixels; and sets pixel positions of the sensor used for imaging during the second control, according to the amount of deviation detected based on the image data imaged with the first image size by the first control.