Liquid Ejection Nozzle Failure Detection and Conditional Maintenance

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Solution Overview

Problem

Existing liquid ejecting apparatuses face increased liquid consumption due to frequent ejection failures in nozzles, which occur when thickened liquid or air bubbles cause clogging, leading to inefficient printing and increased maintenance needs.

Innovation Solution

A method and apparatus that detect ejection failures in nozzles, where the controller covers nozzles with a cap when the failure count is below a predetermined threshold to prevent liquid discharge and discharges liquid when failures exceed this threshold, reducing unnecessary liquid usage and addressing clogging issues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If liquid is discharged from nozzles each time ejection failure occurs, then ejection failure is resolved, but liquid consumption increases

Engineering Contradiction:

Improvenozzle ejection functionVSAvoidliquid consumption

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The system changes the maintenance parameter from always discharging liquid to conditionally discharging liquid based on the number of ejection failures detected. When failure count exceeds threshold, liquid discharge is performed; otherwise, cap replacement is performed, optimizing liquid consumption while maintaining nozzle reliability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The maintenance strategy dynamically adjusts based on the detected ejection failure rate. The system transitions from static always-discharge approach to dynamic conditional discharge approach, adapting maintenance intensity to actual nozzle performance conditions

Inventive Principle:

Principle #15Dynamics

2Reliability

If liquid is discharged frequently to maintain nozzle function, then ejection reliability is improved, but productivity decreases

Engineering Contradiction:

Improvenozzle ejection functionVSAvoidprinting efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system changes the maintenance frequency parameter from high-frequency liquid discharge to low-frequency targeted discharge based on failure detection thresholds, improving productivity while maintaining sufficient ejection reliability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system enables self-diagnosis of nozzle ejection failures and self-decision making regarding maintenance timing, performing liquid discharge only when actually needed rather than on fixed schedule, optimizing both reliability and productivity

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11230095B2Method of controlling liquid ejection apparatus and liquid ejection apparatus

Publication Date: 2022.01.25 SEIKO EPSON CORP

AI summary

A method of controlling a liquid ejecting apparatus includes detecting an ejection failure of nozzles by inspecting an ejection state of the nozzles from which liquid is ejected, covering the nozzles with a cap when the number of the nozzles whose ejection failure is detected is equal to or less than a predetermined number, and discharging the liquid from the nozzles when the number of the nozzles whose ejection failure is detected is greater than the predetermined number.