Printer Head Calibration via Camera-Based Coordinate Displacement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional printers often experience errors in print position, particularly when using an integral head cartridge system, leading to inaccuracies in printing applications that require precision.
Innovation Solution
A printer system that includes a head for ink ejection, a camera for capturing images of the printed calibration pattern, and a calculator to determine displacement between the print and image coordinate systems, allowing for correction of print position errors through a corrected coordinate system generated by a corrector, which adjusts ink ejection positions automatically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an integral head cartridge system is used, then device complexity is reduced and ease of manufacture is improved, but print position accuracy deteriorates
Solution Approach 1:
The patent performs preliminary calibration by printing a calibration pattern at a known position before actual printing. The camera captures this pattern and the calculator computes the displacement between the intended and actual positions. This preliminary measurement allows the system to pre-correct coordinate transformations, ensuring accurate print positions despite variations in head mounting or cartridge replacement.
2Manufacturing precision
If manual correction of print position is implemented, then print position accuracy is improved, but ease of operation deteriorates and loss of time increases
Solution Approach 1:
The system performs self-calibration automatically without requiring user intervention. The camera autonomously captures the calibration pattern, the calculator automatically computes the displacement and generates correction values, and the corrector applies these corrections to subsequent printing operations. This self-service mechanism eliminates manual adjustment while maintaining high print position accuracy.
Solution Approach 2:
The patent implements a feedback loop where the camera continuously monitors the actual print position by capturing calibration patterns. The calculator processes this visual feedback to determine displacement, and the corrector uses this information to adjust future print positions. This closed-loop feedback system automatically compensates for position errors without requiring manual intervention.
3Manufacturing precision
If physical adjustment of the head is performed, then print position accuracy is improved, but device complexity increases and loss of time increases
Solution Approach 1:
The patent replaces mechanical adjustment mechanisms with a computational correction system. Instead of physically moving or repositioning the print head through mechanical means, the system uses a camera to measure actual positions, calculates displacement, and applies software-based coordinate transformations. This substitution of mechanical adjustment with optical measurement and computational correction simplifies the overall device structure while maintaining precision.
4Manufacturing precision
If calibration is performed frequently, then print position accuracy is maintained, but productivity decreases
Solution Approach 1:
The system performs calibration as a preliminary one-time action when the cartridge is first installed or replaced. The camera captures the calibration pattern, the calculator computes the displacement, and the corrector stores these correction values for use in all subsequent printing operations. This preliminary calibration approach maintains print position accuracy throughout the cartridge's usage life without requiring frequent re-calibration, thus preserving productivity.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A printer includes head (21) that performs printing by ejecting ink at a position of ejection of the ink in a print coordinate system, camera (31) that captures an image of an area where the ink is ejected and outputs the image in an image coordinate system, camera (31) capturing an image of calibration pattern (59) printed by ejecting the ink at a calibration ejection position and outputting the image including calibration pattern (59), the calibration ejection position being a position at which calibration pattern (59) is printed by ejecting the ink, and calculator (25) that calculates the amount of displacement between the position of calibration pattern (59) in the image coordinate system and the calibration ejection position in the print coordinate system.