Printer Encoder Assembly for Flexible Substrate Tracking
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Solution Overview
Problem
Large format inkjet printers face challenges in maintaining print quality due to the unpredictable stretching, shrinking, and deformation of flexible substrates, leading to improper ink drop placement.
Innovation Solution
An encoder assembly is implemented to accurately monitor the position of large format substrates by attaching either the encoder scale or sensor to the substrate, allowing for real-time corrections in ink drop placement through a process of attachment, sensing, and detachment, using vacuum boxes and carrier systems to ensure precise tracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flexible substrates are used for large format printing, then productivity and versatility are improved, but manufacturing precision deteriorates due to substrate stretching and deformation
Solution Approach 1:
The encoder scale is attached to the substrate before printing and moves with the substrate throughout the printing process. This preliminary attachment allows the system to track substrate position and deformation in real-time, enabling corrections to be made during printing rather than requiring perfect initial substrate stability.
Solution Approach 2:
The encoder sensor continuously reads the position of the encoder scale attached to the substrate, providing real-time feedback about substrate movement and deformation. This feedback is used by the control system to dynamically adjust ink drop placement coordinates, compensating for substrate stretching and deformation during the printing process.
2Manufacturing precision
If substrate position monitoring is implemented, then manufacturing precision is improved, but device complexity increases due to encoder assembly requirements
Solution Approach 1:
The encoder system is divided into two separate components: an encoder scale that attaches to the substrate and an encoder sensor that remains stationary on the printer. This segmentation allows the substrate-tracking function to be added without requiring complex moving parts in the printer itself, simplifying the overall device architecture.
Solution Approach 2:
The encoder scale acts as an intermediary element between the substrate and the measurement system. By attaching this passive scale to the substrate and using a stationary sensor to read its position, the system achieves accurate substrate tracking without requiring complex active sensing mechanisms or moving components in the printer.
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 solution enhances print quality by allowing for precise adjustments in ink drop placement, compensating for substrate deformation and improving local drop placement accuracy across the substrate.
Implementation Method 1
using vacuum boxes and carrier mechanisms to ensure accurate positioning
Data Source
AI summary
In one implementation, an encoder assembly for a printer includes: an encoder scale having indicators thereon for determining a printing parameter; an encoder sensor for sensing indicators on the scale; and a mechanism configured to alternately attach an encoder part (either the scale or the sensor) to the substrate and detach the encoder part from the substrate. In another implementation, a method includes: attaching an encoder part to a print substrate, the encoder part being either an encoder scale or an encoder sensor; the sensor sensing indicators on the scale while advancing the substrate with the encoder part attached; and detaching the encoder part from the substrate.