Printer Dryer Thermal Mass Control for Print Speed
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Solution Overview
Problem
Printers with heated dryers face speed reductions during pre-heating after a cold start, which can slow down print speeds, and existing techniques do not effectively minimize this delay.
Innovation Solution
Implementing a controller that monitors the dryer's temperature and continues to apply power to the heating element after a print job to stoke the thermal mass, using pulse width modulation to efficiently reach and maintain the operational temperature, thereby reducing pre-heating time for subsequent jobs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the dryer is pre-heated to operational temperature before printing, then drying performance is improved, but print speed is reduced due to the time required to reach operational temperature
Solution Approach 1:
The system performs preliminary heating of the dryer during idle periods between print jobs, so that when a new print job arrives, the dryer is already at or near operational temperature. This eliminates the need to slow down print speed for pre-heating, as the heating action is taken in advance during non-printing time.
Solution Approach 2:
The heating element continues to operate during idle periods between print jobs, maintaining continuous useful action by keeping the dryer hot. Rather than turning off the heater completely during idle time, the system maintains thermal energy in the dryer's thermal mass, ensuring readiness for the next print job without sacrificing print speed.
2Speed
If the dryer operates continuously to maintain temperature, then print speed is improved by eliminating pre-heating delays, but energy consumption increases
Solution Approach 1:
The system dynamically adjusts the heating element operation based on real-time temperature monitoring. The controller continuously monitors dryer temperature and adjusts or terminates heating based on whether the operational temperature threshold is met, optimizing energy usage while maintaining print speed.
Solution Approach 2:
The system uses temperature feedback from the dryer to control the heating element. When the temperature reaches the operational threshold, the controller receives feedback and turns off the heating element, preventing unnecessary energy consumption while ensuring the dryer is ready for printing.
3Reliability
If the print speed is slowed during dryer pre-heating, then drying performance is ensured, but overall productivity is reduced
Solution Approach 1:
The system performs the heating action in advance during idle periods between print jobs, so that when printing resumes, the dryer is already prepared. This separates the heating timeline from the printing timeline, allowing full print speed to be maintained while still achieving proper drying performance.
Solution Approach 2:
The heating element operates continuously during idle periods, maintaining thermal energy in the dryer's thermal mass. This continuous useful action during non-printing time ensures drying performance is ready when needed, without interrupting or slowing the printing process, thereby preserving overall productivity.
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 minimizes print speed reductions by rapidly reaching operational temperature for subsequent print jobs, reducing idle time and maintaining heat retention between print jobs, thus enhancing overall print speed and efficiency.
Implementation Method 1
continues to apply power to the heating element in the dryer after executing one print job
Implementation Method 2
heat is retained in the thermal mass of the dryer to reduce the time to reach operational temperature
Data Source
AI summary
In one example, a processor readable medium having instructions thereon that when executed cause a printer controller to monitor a temperature of a dryer in the printer, continue to apply power to a heating element in the dryer after executing a first print job and before executing a second, next consecutive print job, and turn off the power applied to the heating element if the temperature of the dryer exceeds a threshold temperature while the printer is not printing.