Perfector Arm Positioning Error Correction
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Solution Overview
Problem
High precision positioning systems in printers, such as duplex printing systems, face registration errors due to inaccuracies in the perfector arm's positioning, which can result in misalignment of images on the front and back sides of printed sheets, affecting the quality of duplex prints.
Innovation Solution
The implementation of a system that uses a homing sensor and encoder to detect and correct positional errors in the perfector arm, specifically addressing belt-dependent variations by ensuring one complete rotation of the belt corresponds to an integer number of rotations of the sprocket, and incorporating calibration routines to account for belt imperfections and pickup errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a belt-driven perfector positioning system is used to transport print media, then the system achieves acceptable positioning capability, but belt imperfections cause registration errors between front and back images
Solution Approach 1:
The system performs preliminary calibration by detecting the actual position of the perfector arm at multiple positions during one rotation of the belt, compares these positions to expected positions, and stores correction values in advance. This preliminary action compensates for belt imperfections before actual printing operations, ensuring consistent registration precision without requiring perfect belt manufacturing.
Solution Approach 2:
The system implements feedback by using a homing sensor and encoder to detect the actual position of the perfector arm, comparing it to the expected position, and applying corrections based on detected errors. This closed-loop feedback mechanism continuously compensates for positioning deviations caused by belt imperfections, maintaining reliable registration precision throughout operation.
2Ease of manufacture
If the belt length is not an integer multiple of the sprocket circumference, then the system is easier to manufacture, but positioning accuracy deteriorates due to non-repeatable errors
Solution Approach 1:
The system changes the parameter of belt length specification, allowing belts of any length rather than requiring integer multiples of sprocket circumference. The correction mechanism adapts to the actual belt length by detecting positions during one complete rotation and calculating corrections based on the specific configuration, maintaining positioning repeatability while simplifying manufacturing and belt replacement.
3Manufacturing precision
If correction values are stored for each belt to compensate for imperfections, then registration precision is improved, but device complexity increases due to additional calibration and storage requirements
Solution Approach 1:
The system implements self-service calibration by automatically detecting belt imperfections and generating correction values without requiring external intervention or complex manual calibration procedures. The homing sensor and encoder work together to autonomously measure positions and calculate corrections, reducing operational complexity while maintaining high registration precision.
Data Source
AI summary
A method of error correction in a printing system includes engaging a sheet of print media with a perfector arm and detecting a relative position of the perfecter arm with respect to the sheet of print media when the perfecter arm has engaged the sheet of print media, the detecting being performed using a homing sensor that is configured to sense the perfecter arm while the perfecter arm is engaged with the sheet of print media. The relative position of the perfecter arm with respect to the sheet of print media is compared with an expected relative position and any difference between the relative position and expected relative position is compensated for when feeding the sheet of print media with the perfector arm to a print engine.