Print Saturation Calibration via Printhead Segmentation
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Solution Overview
Problem
Ink-based printing devices face issues with non-uniform saturation of printing material due to variations in printhead nozzles, leading to visual inconsistencies in printed content.
Innovation Solution
The printing device analyzes digital images of calibration output to determine location saturation values for each nozzle location, segments the printhead into areas with uniform saturation, and applies uniformity correction values to adjust saturation levels, ensuring consistent ink application across the print width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If printhead nozzles are used to apply printing material across the printing width, then printing coverage is achieved, but non-uniform saturation occurs due to manufacturing variations in nozzles
Solution Approach 1:
The printhead is segmented into multiple segments along the printing width, with each segment containing multiple nozzles. Uniformity correction values are calculated and applied independently for each segment, allowing localized compensation for saturation variations without requiring complete uniformity across all nozzles. This segmentation approach transforms a global uniformity problem into multiple local correction problems that are easier to solve.
Solution Approach 2:
Different uniformity correction values are applied to different segments of the printhead based on their specific saturation characteristics. Instead of using a single correction value for the entire printhead, the system tailors the correction to local conditions, recognizing that each segment may have different saturation behavior due to manufacturing variations. This local quality approach ensures that each segment achieves optimal uniformity independently.
2Manufacturing precision
If uniformity correction values are calculated for each segment, then saturation uniformity is improved, but processing complexity increases due to segmentation and analysis requirements
Solution Approach 1:
The system performs preliminary calibration by printing test patterns and capturing images before actual printing operations. Uniformity correction values are pre-calculated for each segment based on these preliminary measurements, storing the corrections in lookup tables. During actual printing, the pre-calculated correction values are simply retrieved and applied, avoiding the need for real-time complex calculations and reducing processing complexity during operation.
Solution Approach 2:
The system uses test patterns that replicate the saturation variations expected in actual printing. By printing and analyzing these test patterns, the system creates a model of the printhead's saturation behavior. This copying approach allows the system to learn correction values from simplified test cases that represent the full printing scenario, reducing the complexity of direct measurement and correction.
Data Source
AI summary
Examples include computing devices, processes, and/or machine-readable storage mediums comprising instructions to analyze at least one digital image corresponding to calibration output of a printing device to determine location saturation values for nozzle locations of the printing device. At least one printhead is segmented into segments corresponding to one or more nozzle locations. A reference segment is determined from among the segments of the printhead, and a uniformity correction value is determined for at least one segment based at least in part on the reference segment.