Digital Printer Failure Compensation Mode Selection
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Solution Overview
Problem
Digital printers face challenges in achieving high productivity while maintaining acceptable print quality due to nozzle failures, as existing methods struggle to effectively compensate for malfunctioning printing elements.
Innovation Solution
A method that simulates print operations in different modes to predict and compensate for nozzle failures by selecting a print mode with the highest productivity that can still meet quality requirements, involving the analysis of nozzle positions and image content to determine the best compensation strategy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high-productivity print mode is selected, then productivity is improved, but the number of uncompensable nozzle failures increases
Solution Approach 1:
The system performs a simulation of the print operation before actual printing to predict which nozzles will fail and whether they can be compensated. This preliminary analysis allows selection of an appropriate print mode that balances productivity with acceptable quality, avoiding the need to print test patterns and enabling proactive compensation strategy formulation.
Solution Approach 2:
The system dynamically adapts the print mode selection based on the specific pattern and position of malfunctioning nozzles detected in the print head. Rather than using a fixed print mode, the system adjusts the scan pass pattern dynamically to match the actual failure pattern, optimizing both productivity and compensation effectiveness.
2Reliability
If a low-productivity print mode is selected, then the number of uncompensable nozzle failures decreases, but productivity deteriorates
Solution Approach 1:
The system changes parameters of the print mode (such as scan pass pattern, number of passes, droplet placement strategy) based on the detected nozzle failure pattern. By adjusting these parameters dynamically, the system achieves effective compensation without necessarily sacrificing productivity, finding an optimal middle ground between high-speed and high-quality modes.
Solution Approach 2:
The system applies different compensation strategies to different regions of the print head based on local failure patterns. Rather than uniformly reducing productivity across the entire print array, the system maintains high productivity in regions with healthy nozzles while applying more conservative, quality-focused strategies only in regions affected by nozzle failures.
3Manufacturing precision
If compensation strategies are applied, then print quality is maintained, but device complexity increases
Solution Approach 1:
The system uses the existing processing unit and control logic of the digital printer to perform the simulation and compensation strategy selection, rather than requiring separate dedicated hardware. The existing failure detection system data is reused for the simulation, and the control unit that already manages print operations also selects and executes the compensation strategy, minimizing additional complexity.
Solution Approach 2:
The system creates a virtual model (copy) of the print operation through simulation, which replicates the physical printing process in software. This virtual copy allows prediction of compensation effectiveness without requiring physical test printing, reducing the need for additional hardware while maintaining print quality through software-based optimization.
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
A method of controlling a digital printer having a print head with an array of printing elements, the print head being arranged to scan a recording medium in a main scanning direction, and the print head and the recording medium being arranged to be moved relative to one another in a sub-scanning direction normal to the main scanning direction, the printer being arranged to operate in a selected one of a plurality of print modes which differ in productivity due to differences in a pattern of scan passes in which the array of printing elements moves over the recording medium, the printer further having a failure detection system arranged to detect malfunctioning printing elements, and a failure compensation system arranged to compensate a malfunction of a printing element by activating at least one other printing element in the array, characterized by the steps of: a) establishing a list (50) of print modes sorted by decreasing productivity; b) selecting (S1) an initial print mode; c) simulating (S2) a print operation in the currently selected print mode and counting (S3) a number of incidents in which a malfunction of a printing element cannot be compensated; d) if the count result is below a given threshold value: keep (S6) the selected print mode; e) if not: select (S5) the next print mode in the list (50) and repeat steps (c) to (e) for that print mode.