Multi-module printer calibration via cluster-based patch analysis
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Solution Overview
Problem
Current calibration processes for printing apparatuses with multiple print modules require significant time and resources, including large amounts of print media and ink, as each module needs to be recalibrated separately, leading to inefficiencies and waste.
Innovation Solution
A two-stage calibration process that clusters similarly performing print modules based on initial test patches, allowing extended test patches to be printed and measured per cluster rather than per module, reducing the overall number of patches needed and optimizing resource usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If calibration is performed separately for each print module, then measurement precision is improved, but loss of time and loss of substance increase
Solution Approach 1:
The patent combines calibration measurements from multiple print modules by printing test patches across all modules simultaneously on a single print medium. The measurement device then measures patches from all modules in one calibration cycle, merging what would otherwise be separate calibration processes. This reduces calibration time while maintaining precision through the use of a reference patch for normalization across modules.
Solution Approach 2:
A single print medium serves multiple functions: it contains test patches for multiple different print modules, acts as a reference standard through the included reference patch, and enables simultaneous calibration of all modules. This universal approach allows one calibration process to serve all print modules rather than requiring separate dedicated calibration media for each module.
2Measurement precision
If calibration is performed separately for each print module, then measurement precision is improved, but loss of substance increases
Solution Approach 1:
The patent merges calibration operations for multiple print modules into a single calibration cycle using one print medium. Test patches for all modules are printed on the same medium, and all patches are measured together. This consolidates what would otherwise require multiple separate calibration processes, each consuming additional media and ink, into one efficient operation.
Solution Approach 2:
A single print medium is designed to serve all print modules universally. It includes test patches for multiple modules plus a reference patch, enabling one medium to replace what would otherwise require multiple dedicated calibration media. This reduces substance consumption while maintaining the precision needed for accurate calibration of each module.
3Loss of substance
If fewer test patches are printed per module, then loss of substance decreases, but measurement precision deteriorates
Solution Approach 1:
The patent introduces a reference patch as an intermediary element that mediates between the limited test patches and the calibration accuracy requirement. The reference patch serves as a common reference standard that allows measurements from multiple modules to be normalized and compared accurately. This intermediary enables precise calibration even when each module has fewer test patches, because the reference patch provides the necessary calibration baseline.
Solution Approach 2:
The reference patch performs multiple functions: it serves as a calibration standard for all modules, enables normalization across different modules, and allows accurate measurement with fewer patches per module. This universal reference element compensates for the reduced number of patches, maintaining precision while reducing media consumption.
Data Source
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AI summary
An apparatus and method for use in generating calibration parameters for a printing apparatus comprising a plurality of print modules are disclosed. The method comprises printing a first plurality of test patches for each print module of the plurality of print modules, analysing the first plurality of test patches to identify at least two clusters of print modules, wherein each cluster comprises a sub-group of print modules having substantially similar performance, printing a second plurality of test patches comprising an extended calibration test patch set for each cluster of print modules, the second plurality of test patches being distributed across the print modules of the cluster, and analysing extended calibration test patch set for each cluster to determine a calibration parameter for the printing apparatus.