Printer Drop Volume Compensation via Print Mode Switching
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Solution Overview
Problem
Printers, such as inkjet and 3D printers, face challenges in maintaining consistent print quality due to variations in drop weight over the lifetime of the print head, which can lead to color loss and inaccurate application of fusing agents, as existing calibration methods can only compensate for a limited range of drop weight variations before print quality deteriorates.
Innovation Solution
Implementing a system where the printer monitors drop volume and switches to a second print mode that increases pixel print time by extending the number of passes over the pixel, rather than increasing firing frequency, to maintain print quality parameters beyond the initial compensation limit, allowing for continued color consistency and accurate ink application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the firing frequency is increased to compensate for drop weight variation, then the print quality parameter is maintained within the initial compensation range, but the compensation range is limited and print quality deteriorates beyond this range
Solution Approach 1:
The system dynamically switches between different print modes (first print mode with higher firing frequency and second print mode with extended pixel print time) based on the current drop weight variation level. This dynamic adaptation allows the system to maintain print quality across a broader compensation range by transitioning from frequency-based compensation to time-based compensation when the first print mode reaches its limitations.
Solution Approach 2:
The invention changes the compensation parameter from firing frequency to pixel print time. In the first print mode, compensation is achieved by adjusting firing frequency within a limited range. When this range is exhausted, the system transitions to the second print mode where compensation is achieved by extending the pixel print time through additional passes, thereby expanding the overall compensation range while maintaining print quality.
2Manufacturing precision
If the firing frequency is increased to maintain print quality, then color consistency is maintained, but visible artifacts occur when the compensation limit is reached
Solution Approach 1:
The system dynamically transitions from the first print mode to the second print mode when the compensation limit is approached, preventing the occurrence of visible artifacts. This dynamic switch allows continuous maintenance of color consistency by adapting the compensation strategy before artifacts can manifest in the printed output.
Solution Approach 2:
The system proactively switches to the second print mode before visible artifacts occur by monitoring the compensation range utilization. This preliminary action prevents the harmful effect of artifacts by transitioning to an alternative compensation method (extended pixel print time) while the print quality is still maintainable, thereby avoiding the artifact generation that would occur if the first print mode were pushed beyond its limits.
3Adaptability or versatility
If the pixel print time is extended by increasing the number of passes, then the compensation range is extended beyond the initial limit, but the printing process takes longer
Solution Approach 1:
The system applies partial extension of pixel print time only when necessary. Instead of always using the second print mode with extended passes, the system maintains the faster first print mode within its compensation range and only transitions to the slower second print mode when the compensation limit is approached, thereby minimizing the time loss while still achieving extended compensation range capability.
Data Source
AI summary
A printer includes a print head to print a pixel by ejecting drops of a printing fluid from the print head, and a controller. The controller monitors a drop volume of the printing fluid ejected by the print head. When the drop volume is below a threshold, the controller controls the print head in accordance with a first print mode to increase the frequency of ejecting drops of the printing fluid within the pixel print time with a decrease in the drop volume that maintains a print quality parameter. The controller changes to a second print mode to increase the pixel print time that maintains the print quality parameter.