Substrate Media Registration via Image Inversion

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Solution Overview

Problem

Higher end xerographic and direct marking media registration systems are inefficient, complex, and costly due to their reliance on measuring average paper position for image alignment, which does not correct lateral errors on an individual sheet basis and can result in image artifacts when correcting for large skew.

Innovation Solution

A direct marking printing system with a deskewing system, reflexive system, and controller that deskews substrate media using rollers and sensors to detect lateral positions, allowing for precise ink ejection from print nozzles without warping the image, enabling registration in multiple degrees of freedom without shifting the paper.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the paper is shifted with respect to three degrees of freedom to align with the image, then registration accuracy is improved, but the system becomes complex and speed limited

Engineering Contradiction:

Improveregistration accuracyVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Instead of physically shifting the paper to align with the image (conventional approach), the system inverts the approach by keeping the paper stationary and shifting the image position to match the paper's actual location. This is achieved by detecting the paper's lateral position and adjusting the print head or image data accordingly, eliminating the need for complex paper shifting mechanisms while maintaining registration accuracy.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent replaces mechanical paper shifting mechanisms with a detection and compensation system. Sensors detect the paper's lateral position, and the system compensates by adjusting the image position or print head position, substituting mechanical movement with sensor-based detection and electronic compensation, thereby reducing mechanical complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If the paper is shifted to correct lateral errors, then registration accuracy is improved, but the operation becomes more complex and time-consuming

Engineering Contradiction:

Improvelateral registration accuracyVSAvoidoperation simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

Instead of physically shifting the paper to correct lateral errors (complex operation), the system detects the paper's lateral position and inverts the correction by adjusting the image position or print head position. This eliminates the need for complex paper shifting operations while maintaining accurate lateral registration.

Inventive Principle:

Principle #13The other way round (Inversion)

3Manufacturing precision

If the image is warped to match media position, then registration accuracy is improved, but image quality deteriorates due to artifacts

Engineering Contradiction:

Improvemedia position alignmentVSAvoidimage quality

Core Design Contradiction:

Manufacturing precisionVSShape

Solution Approach 1:

Instead of warping the image to match the media position (which causes artifacts), the system inverts the approach by detecting the media's lateral position and adjusting the print head or image data to match the media's actual position. This maintains the image in its original, unwarped state while achieving accurate registration.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent replaces image warping (which degrades image quality) with sensor-based detection of media position and electronic compensation through print head or image data adjustment. This substitution maintains image quality while achieving accurate media position alignment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If average paper position is measured in manufacturing, then lateral image to paper registration error is reduced, but individual sheet errors are not corrected

Engineering Contradiction:

Improvelateral registration errorVSAvoidindividual sheet measurement accuracy

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

The system implements feedback by continuously detecting the actual lateral position of each individual sheet using sensors during the printing process. This real-time feedback allows the system to adjust the print head or image data to match each sheet's specific position, correcting individual sheet errors rather than relying solely on average position measurements from manufacturing.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS8469476B2Substrate media registration system and method in a printing system

Publication Date: 2013.06.25 XEROX CORP

AI summary

Embodiments described herein include a substrate media registration system in a printing system. The registration system can include a deskewing system, a reflexive system, and a controller. The deskewing system is configured to deskew substrate media. The reflexive system is configured to detect the lateral position of the substrate media and at least one of a lead edge and a trail edge of the substrate media being transported in the process direction. The controller is operatively coupled to the reflexive system and is configured to control ejection of ink from a print head system in response to detecting the lateral position of the substrate media and at least one of the lead edge and the trail edge of the substrate media.