Printer Carriage Speed Mismatch and Stitching Compensation
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Solution Overview
Problem
The speed of the second carriage in a printer is limited, which restricts the overall productivity of the printer, as it needs to cure radiation curable ink effectively, and inaccuracies in movement between the first and second carriages can lead to stitching issues in image formation.
Innovation Solution
The method involves a first carriage moving at a higher speed than the second carriage, with the second carriage positioned downstream to cure the ink, and a sub-carriage that can translate and rotate to compensate for inaccuracies in movement, ensuring accurate stitching and maintaining print quality while increasing printer speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the first carriage moves at high speed to increase productivity, then the printing speed improves, but the second carriage cannot keep up due to its limited speed, causing speed mismatch and potential quality issues
Solution Approach 1:
The system dynamically adjusts the speeds of the first and second carriages independently. The first carriage can operate at higher speeds for printing while the second carriage operates at its maximum feasible speed for curing, with the control system coordinating their movements to maintain proper timing and positioning despite the speed difference.
Solution Approach 2:
The printing system is divided into two independent carriage systems - a first carriage for ink application and a second carriage for curing. This segmentation allows each carriage to be optimized for its specific function, with the first carriage capable of higher speeds and the second carriage dedicated to curing operations at its own speed regime.
2Manufacturing precision
If the first carriage and recording medium move relative to each other in the sub-scanning direction to cover the entire medium, then complete image formation is achieved, but movement inaccuracies cause stitching errors between adjacent swaths
Solution Approach 1:
The system incorporates feedback mechanisms to monitor and detect movement inaccuracies during the sub-scanning direction movement. This allows the control system to identify stitching errors and adjust subsequent printing operations to compensate for detected deviations, maintaining accuracy despite higher speeds.
Solution Approach 2:
The system performs preliminary positioning and calibration movements before actual high-speed printing begins. This preliminary action establishes accurate reference positions and allows the system to pre-calculate compensation values for anticipated movement variations during high-speed operation.
3Reliability
If the second carriage is positioned downstream to cure the ink effectively, then curing quality improves, but the distance and speed limitations reduce overall printer productivity
Solution Approach 1:
The system uses periodic curing cycles where the second carriage periodically passes over printed areas to apply curing radiation. This periodic action allows effective curing to occur at the downstream position while the high-speed first carriage continues printing without waiting for the slower second carriage, maintaining productivity through overlapping operations.
Solution Approach 2:
The printing and curing operations are made continuous through coordinated independent movement of the two carriages. While the second carriage moves at its limited speed for effective curing, the first carriage continuously prints at high speed, and the system maintains continuous useful action by overlapping these operations in time and space.
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 approach allows for higher productivity without compromising print quality by allowing the first carriage to move faster while ensuring the second carriage provides sufficient curing time, and the sub-carriage adjustments improve stitching accuracy, preventing visible lines or gaps between swaths.
Implementation Method 1
curing the curable ink, deposited on the recording medium, by providing radiation, such as a UV radiation
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C~2D
AI summary
The present invention relates to a print method involving a first carriage configured to move in reciprocation in a scanning direction and a second carriage configured to move in reciprocation in a scanning direction. The first carriage carries at least one print head and the second carriage carries a source of radiation. The speed of movement of the first carriage is increased with regard to the speed of the second carriage to improve the productivity of the print process.