Multi-Resolution Sensor Array for Print Stitching Calibration
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Solution Overview
Problem
Current large print systems require multiple sensor systems for calibration and registration, leading to bandwidth limitations and high costs due to the need for both high-resolution and low-resolution imaging for accurate alignment and defect detection across multiple print stations.
Innovation Solution
A multi-resolution segmented image sensor (MRIS) system combining high-resolution and low-resolution sensor arrays with a single LED-illumination source and lens array, allowing for real-time monitoring of stitch and registration quality and full-page viewing, while reducing data bandwidth requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple separate sensor systems are used for high-resolution stitching calibration and low-resolution defect detection, then measurement precision and reliability are improved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple separate sensor systems into a single integrated sensor system that performs both high-resolution stitching calibration and low-resolution defect detection functions. The sensor system includes multiple sensor arrays (first sensor array, second sensor array, third sensor array) that work together to provide both high-resolution measurements for stitching and low-resolution coverage for full-page defect detection, eliminating the need for separate sensor systems and reducing overall system complexity
Solution Approach 2:
The integrated sensor system is designed to perform multiple functions simultaneously: it conducts high-resolution stitching calibration between adjacent print elements, performs low-resolution defect detection across the entire printed page, and enables registration verification. This multi-functional approach allows a single sensor system to replace what would traditionally require multiple specialized systems, reducing device complexity while maintaining measurement precision
2Manufacturing precision
If multiple high-resolution sensor systems are deployed across all print stations, then stitching accuracy is improved, but data bandwidth requirements and processing complexity increase
Solution Approach 1:
The patent applies different resolution levels to different functional requirements: high-resolution sensing is applied locally at print element boundaries where stitching calibration is needed, while low-resolution sensing is applied across the full page for defect detection. This local differentiation of quality levels ensures manufacturing precision for alignment while minimizing data bandwidth consumption by not using high-resolution sensing everywhere
Solution Approach 2:
The sensor system is segmented into multiple specialized arrays: first sensor arrays for high-resolution stitching calibration at specific locations, second sensor arrays for low-resolution full-page defect detection, and third sensor arrays for registration verification. This segmentation allows each array to be optimized for its specific function, with high-resolution arrays positioned only where needed for stitching, thereby reducing overall data bandwidth requirements while maintaining alignment accuracy
3Measurement precision
If separate sensor systems are used for stitching calibration and defect detection, then measurement precision is improved, but ease of operation and system integration become more difficult
Solution Approach 1:
The patent merges separate sensor systems into a unified integrated sensor system that performs both stitching calibration and defect detection through coordinated sensor arrays. The controller receives data from all sensor arrays and processes them together, enabling precise registration measurement while simplifying system operation through unified control and processing, thereby improving ease of operation without sacrificing measurement precision
Data Source
AI summary
A method for high-speed multi-color printing includes at least one high-resolution sensor array (23), wherein an output of the high-resolution sensor array is transmitted to a controller (19); at least one low-resolution sensor array (24); wherein the controller calculates a correction for stitch; wherein the controller, based on the calculated correction, adjusts a timing of image data provided to individual print elements comprising print stations (12) to aligned an output of the print elements; and wherein the low-resolution sensor array provides full page viewing.