Predictive Ink Delivery System for Complex Shape Printing
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Solution Overview
Problem
Existing fluid supply systems for droplet ejection heads struggle to maintain consistent back pressure during rapid acceleration, deceleration, and changes in orientation, leading to potential weeping, air ingestion, and defects in printed images on complex or large shapes.
Innovation Solution
A processor-controlled sub-controller and controller system that predicts induced fluid pressure changes based on droplet ejection head movement profiles and generates pressure correction data to maintain a predetermined pressure window, thereby dynamically adjusting fluid pressure in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the droplet ejection head is moved rapidly for printing on large/complex shapes, then productivity and printing capability are improved, but back pressure variations increase causing weeping, air ingestion, and print defects
Solution Approach 1:
The system calculates and applies pressure compensation values before and during movement operations. The controller pre-calculates the required pressure compensation based on the movement profile (acceleration, deceleration, orientation changes) and applies these corrections in advance to maintain stable back pressure during dynamic printing operations on large or complex three-dimensional shapes.
2Reliability
If active feedback control is used to maintain back pressure, then pressure stability is improved, but system complexity and response time increase
Solution Approach 1:
Instead of relying solely on real-time feedback from pressure sensors, the system pre-calculates the pressure compensation requirements based on the known movement profile. This predictive approach reduces the complexity of the feedback control system while maintaining effective back pressure stabilization during dynamic operations.
3Device complexity
If passive pressure attenuation is used, then system complexity is reduced, but the ability to compensate for rapid pressure changes during acceleration/deceleration is insufficient
Solution Approach 1:
The controller pre-calculates pressure compensation values based on the movement profile and applies these corrections proactively. This approach provides precise pressure control during acceleration and deceleration phases without requiring complex passive attenuation mechanisms, thereby maintaining both simplicity and precision.
4Manufacturing precision
If back pressure is kept within a narrow window for quality printing, then print quality is improved, but the system becomes more sensitive to movement-induced pressure variations
Solution Approach 1:
By pre-calculating and applying pressure compensation based on the movement profile, the system maintains the back pressure within the narrow required window even during dynamic movements. This allows the system to achieve high print quality while remaining adaptable to various movement conditions through proactive pressure management.
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
This solution effectively compensates for rapid pressure changes, preventing weeping, air ingestion, and defects in printed images, while ensuring reliable and high-quality droplet ejection on complex and large shapes.
Implementation Method 1
the acceleration and deceleration of the droplet ejection head may also lead to variations in the back pressure
Implementation Method 2
changes of position, and orientation, possibly in multiple directions and degrees of freedom... changes in the height of the fluid column Δh that is acting on the fluid at the nozzle plate
Data Source
AI summary
A sub-controller (20), controller (30), fluid supply system and apparatus for printing and a method for printing. Provided is a processor controlled sub-controller (20) for controlling the fluid pressure in one or more droplet ejection heads (60); wherein said controller (30) is configured to receive a droplet ejection head movement profile for each of said one or more droplet ejection heads (60), determine a respective induced fluid pressure profile at one or more predetermined locations for each of said one or more droplet ejection heads (60) using the respective droplet ejection head movement profile; and generate respective pressure correction data for each of said one or more droplet ejection heads based on the respective induced fluid pressure profile and a predetermined pressure window to be maintained at said one or more droplet ejection heads (60). Also provided is a method of printing using one or more droplet ejection heads (60) fluidically connected to a fluid supply system wherein said method comprises the steps of receiving droplet ejection head movement profile(s); determining a respective induced fluid pressure profile at one or more predetermined locations for each of said one or more droplet ejection heads using the respective droplet ejection head movement profile(s); generating respective pressure correction file(s) at said one or more predetermined locations based on said induced fluid pressure profile(s) and said predetermined pressure window.