Non-Contact Optical Media Level Sensing for Printers

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Solution Overview

Problem

Conventional methods for tracking media supply levels in printers, especially in print-on-demand kiosks, are inadequate and often inaccurate, leading to potential interruptions in printing operations due to lack of reliable low media detection, particularly for high-performance imaging systems using photothermographic film.

Innovation Solution

A non-contact media level sensing system using a frame with a light source and detector, coupled with control logic to compare analog signals and report low media conditions, adaptable to various printer types and media substrates, employing reflective infrared sensors to accurately determine media stack height without mechanical interaction or modification of printer components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional contact-based media level sensing methods are used, then mechanical interaction with printer components occurs, but this leads to inaccurate detection and potential interruptions in printing operations

Engineering Contradiction:

Improvemedia level detection accuracyVSAvoidprinting operation continuity

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent replaces mechanical contact-based media level sensing with an optical sensing system using light sources and detectors positioned outside the printer. This optical system measures media level through non-contact means, eliminating mechanical wear and interference while providing accurate detection to ensure reliable printing operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If continuous staff monitoring is implemented to detect low media conditions, then printing operation interruptions are reduced, but this increases operational complexity and costs

Engineering Contradiction:

Improveprinting operation continuityVSAvoidmonitoring system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements a self-monitoring optical sensing system that automatically detects media levels and provides advance warnings without requiring continuous staff monitoring. The system independently tracks media consumption and alerts operators when media levels are low, maintaining printing operation continuity while eliminating the need for manual monitoring.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If existing printer components are modified to add media detection capability, then detection functionality is integrated, but this increases device complexity and potential interference with printer mechanisms

Engineering Contradiction:

Improveprinter adaptabilityVSAvoidprinter mechanism complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent introduces an external optical sensing system that acts as an intermediary between the printer and the media. The light sources and detectors are positioned outside the printer and measure media level through the media stack itself, which serves as the intermediary medium. This approach provides detection functionality without modifying or complicating the printer's internal mechanisms.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of operation

If non-contact optical sensing is implemented, then interference with printer mechanisms is minimized, but this requires additional external components and system setup

Engineering Contradiction:

Improveprinter operation simplicityVSAvoidsensing system complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent designs a universal optical sensing system that can detect media levels across different printer types and media formats. The external light sources and detectors are positioned to work with various media stacks without requiring printer-specific modifications, providing ease of operation across multiple applications while managing system complexity through standardized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system provides an advance warning of low media conditions, ensuring uninterrupted printing operations by accurately monitoring media supply levels, reducing the need for continuous staff monitoring and minimizing interference with printer mechanisms, thus enhancing reliability and usability in unattended printing environments.

Implementation Method 1

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS10329108B2System and method for detecting a media supply

Publication Date: 2019.06.25 CARESTREAM HEALTH INC

AI summary

A system for detecting the level of a media supply in a printer has a frame having a support for seating the printer thereon. A first light source is positioned on the support and is energizable to direct a first beam of light into the printer. A first detector is positioned on the support and provides an analog signal in response to reflection of the first beam of light from within the printer. A control logic processor is in signal communication with the first detector and compares the analog signal to a stored/predetermined value and reports a low media condition according to the comparison.