Media Tracking Sensor Self-Calibration via Virtual Array Comparison
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Solution Overview
Problem
Current media tracking sensor calibration methods are cumbersome and require repeated procedures due to variable parameters such as sensor height, lens magnification, and print media types, leading to inaccuracies and the need for recalibration with every setup change.
Innovation Solution
A self-calibrating method using two virtual arrays within a media tracking sensor array, where one array captures a calibration reference image and the other captures multiple images, allowing for real-time comparison and determination of a resolution conversion factor based on motion data, eliminating the need for repeated distance movements and precise recalibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a standard array setup with multiple variable parameters (sensor height, lens magnification, media type) is used for calibration, then the calibration can be performed with different configurations, but the procedure must be repeated multiple times and produces inaccuracies
Solution Approach 1:
The calibration system performs self-calibration by automatically capturing images at multiple virtual arrays, comparing them to reference images, and calculating the resolution conversion factor without requiring manual intervention or repeated procedures for different configurations
Solution Approach 2:
The system pre-captures calibration reference images at the first virtual array before actual media tracking, and pre-establishes the relationship between motion data and resolution factors, so that when media type or configuration changes, the calibration is already prepared and no repetition is needed
2Measurement precision
If repeated calibration procedures are performed to account for variable parameters, then measurement accuracy can be maintained, but the complexity and duration of the calibration process increases
Solution Approach 1:
The sensor array is divided into multiple virtual arrays (first virtual array for reference images, second virtual array for comparison images) that are spatially separated, allowing simultaneous capture of reference and measurement data in a single calibration procedure rather than requiring multiple separate procedures
Solution Approach 2:
The system captures images at the second virtual array, compares them with reference images from the first virtual array, and uses the comparison results to automatically calculate and adjust the resolution conversion factor, providing immediate feedback that ensures measurement precision without manual intervention
3Measurement precision
If the calibration procedure is repeated every time print media is changed or array height is adjusted, then accuracy is maintained, but productivity and efficiency are reduced
Solution Approach 1:
The calibration system is designed to be universal and configuration-agnostic, using virtual arrays with programmable parameters that can accommodate different sensor heights, lens magnifications, and media types without requiring procedural changes, allowing a single calibration approach to serve multiple configurations
Data Source
AI summary
A media tracking sensor (MTS) apparatus for performing a calibration procedure to determine a resolution calibration factor includes: a full sensor array including: a first virtual array, having a first width, for capturing a calibration reference image; and a second virtual array having a third width equal to the first width, for capturing a plurality of images and comparing the captured images with the calibration reference image. The MTS apparatus further includes a print media positioned below the full sensor array; and a host system for moving the print media below the full sensor array. When the first virtual array captures the calibration reference image, motion data of the full sensor array will be set to zero, and when an image captured by the second virtual array matches the calibration reference image, total motion data will be recorded and used to determine the resolution conversion factor.