Printer Printhead Camera Imaging Test Pattern Segmentation
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Solution Overview
Problem
Conventional methods for detecting and adjusting printing defects in inkjet printers are complex, time-consuming, and labor-intensive, often resulting in imprecise defect detection due to inadequate imaging of test patterns.
Innovation Solution
A printer configuration that includes a printhead, camera, and processor to print and image a test pattern larger than the camera's field of view, with a light source to optimize lighting, allowing for precise defect detection and automatic adjustment of ink ejection from specific nozzles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a test pattern is printed and imaged for defect detection, then printing defects can be detected, but the imaging precision deteriorates when the test pattern area is large relative to the camera imaging area
Solution Approach 1:
The test pattern is divided into multiple sub-patterns arranged in a matrix configuration. Each sub-pattern is independently imaged by the camera, and the images are subsequently synthesized to form the complete test pattern image. This segmentation allows the camera to capture each sub-pattern with high precision while the overall large test pattern area provides comprehensive coverage for defect detection across the entire printing surface.
2Ease of operation
If manual methods are used for detecting and adjusting printing defects, then flexibility is maintained, but the process becomes complicated, time-consuming, and labor-intensive
Solution Approach 1:
The printer system performs self-diagnosis and self-adjustment by automatically imaging the test pattern, analyzing the images for defects, and adjusting the printhead nozzle characteristics without requiring manual intervention. The system uses its own integrated camera and processing units to detect printing defects and automatically modify ink ejection parameters, eliminating the need for external manual inspection and adjustment procedures.
3Area of stationary object
If the test pattern area is made large to cover the entire printing surface, then defect detection coverage is improved, but the imaging area of the camera becomes insufficient
Solution Approach 1:
The large test pattern is divided into multiple smaller sub-patterns that can be individually captured by the camera's limited imaging area. The matrix arrangement of sub-patterns ensures complete coverage of the entire printing surface while each sub-pattern remains within the camera's field of view, allowing high-precision imaging of each section through systematic scanning and synthesis.
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
Enables high-precision imaging and accurate detection of printing defects, facilitating precise device calibration and minimizing maintenance losses.
Implementation Method 1
a light source disposed to the carriage and configured to emit a specific amount of light to an imaging area of the camera; the specific amount of light from the light source being set by the processor so that the maximum amount of light reflected from the first test pattern does not exceed the maximum amount of receivable light the camera can receive
Data Source
AI summary
A printer having a printhead configured to print to a print medium; a camera configured to photograph the print medium; a carriage configured to support and move the printhead and the camera; and a processor configured to print, by the printhead, on the print medium a first test pattern that is larger than an imaging area of the camera, photograph the first test pattern by the camera, and detect a printing defect based on a result of the photograph.