Print Engine Synchronization Using Delta Time Control
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Solution Overview
Problem
Coupled electrophotographic print engines face challenges in synchronizing their speeds to prevent receiver sheet buckling and maintain image quality, especially when handling varying receiver sizes and inverting sheets, which can lead to registration errors and reduced productivity.
Innovation Solution
The method involves starting the secondary print engine at a slower speed and using pulse counters to adjust its speed to match the primary engine's speed, with a PI control algorithm to calculate and apply the necessary delay time, ensuring optimal timing offset and synchronization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the secondary print engine is started at normal speed, then the printing throughput is maintained, but the receiver sheet buckles due to speed mismatch with the primary engine
Solution Approach 1:
The secondary print engine is started at a slower speed before the primary engine reaches its normal operating speed. This preliminary speed adjustment ensures that both engines are synchronized before printing begins, preventing sheet buckling while allowing the system to maintain high throughput once synchronized.
Solution Approach 2:
The system dynamically adjusts the speed of the secondary print engine based on the operating conditions. During startup, the secondary engine runs at a reduced speed to match the primary engine's acceleration profile. Once synchronized, the secondary engine transitions to normal operating speed, optimizing both reliability and productivity.
2Manufacturing precision
If the print engines are synchronized with a small delta time, then the registration accuracy is improved, but the system complexity increases due to precise timing control requirements
Solution Approach 1:
The system employs feedback mechanisms where the actual speeds and positions of both print engines are continuously monitored. This feedback information is used to dynamically adjust the secondary engine's speed, ensuring small delta time synchronization and high registration accuracy without requiring overly complex predetermined timing sequences.
Solution Approach 2:
The system changes the speed parameter of the secondary print engine dynamically during operation. By adjusting the speed parameter in real-time based on the primary engine's performance and the required timing offset, the system achieves precise synchronization with minimal complexity.
3Measurement precision
If the secondary engine speed is continuously adjusted, then the synchronization precision is improved, but the motor control system complexity and energy consumption increase
Solution Approach 1:
Instead of continuous speed adjustment, the system uses periodic speed adjustments at critical moments such as startup and when timing offsets drift beyond acceptable thresholds. This periodic control approach maintains synchronization precision while significantly reducing energy consumption compared to continuous adjustment.
Solution Approach 2:
The system allows the secondary engine to quickly accelerate to the required speed during startup and then maintains that speed with minimal adjustments. This 'rushing through' the synchronization phase reduces the duration of high-energy consumption periods while achieving the required precision.
Data Source
AI summary
A method of synchronizing the timing of a plurality of physically coupled print engines using a small delta time increment. According to the first mode of practice, the second electrophotographic module, designated as E2, is started at a slower operating speed than its normal run speed. The PI control algorithm that controls the motor speed will then allow the speed of E2 to reach its nominal speed.