Printer Printhead Calibration via Integrated Camera Feedback

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Solution Overview

Problem

Conventional manual methods for calibrating large format inkjet printers are complex, time-consuming, and prone to errors, especially when adjusting for printhead installation errors, requiring significant labor and technician intervention.

Innovation Solution

A printer configuration with a first and second printhead, a camera, and a processor that automatically adjusts printhead positions and ink ejection timing by printing and photographing test marks, allowing for precise calibration without manual intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual device calibration is performed by maintenance technician, then printhead position adjustment is possible, but the process becomes complicated, time consuming, and labor intensive

Engineering Contradiction:

Improveprinthead position adjustment precisionVSAvoidcalibration time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The printer performs self-calibration using an integrated camera to photograph test marks and automatically calculate position deviations, eliminating the need for manual technician intervention while maintaining calibration precision

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The manual visual inspection and mechanical adjustment process is replaced by an optical measurement system (camera) that automatically captures test mark positions and computes correction values through image processing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If manual device calibration is performed by maintenance technician, then printhead position adjustment is possible, but the process becomes complicated and labor intensive

Engineering Contradiction:

Improveprinthead position adjustment precisionVSAvoidcalibration process complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The printer automatically executes the entire calibration sequence including test mark printing, photographing, position calculation, and correction value generation without external intervention, simplifying the process from the user perspective

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The calibration functionality is integrated into the printer system itself, combining the test mark printing capability, camera system, and processing logic into a unified automated calibration module

Inventive Principle:

Principle #5Merging (Combining)

3Measurement precision

If manual device calibration is performed by maintenance technician, then printhead position adjustment is possible, but wrong position adjustment values may be input mistakenly

Engineering Contradiction:

Improveprinthead position adjustment precisionVSAvoidadjustment accuracy

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

Manual input of adjustment values is replaced by automated optical measurement and computational calculation, eliminating human error in value entry while maintaining measurement precision through camera-based position detection

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system photographs actual test mark positions, compares them against expected positions, and automatically generates correction values based on the measured deviations, creating a closed-loop feedback system that ensures accurate adjustment

Inventive Principle:

Principle #23Feedback

4Adaptability or versatility

If conventional calibration method is used, then some adjustment is possible, but it is silent about adjusting for printhead installation errors

Engineering Contradiction:

Improveadjustment coverageVSAvoidprinting quality

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The printer autonomously detects and compensates for printhead installation errors by photographing test marks at known positions and calculating the actual position deviations, then applying correction values to compensate for these errors

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system performs preliminary calibration by printing test marks and measuring their positions before actual printing operations, identifying installation errors in advance and establishing correction values that will compensate for these errors during normal operation

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10336066B2Printer and control method of a printer

Publication Date: 2019.07.02 SEIKO EPSON CORP

AI summary

A printer including: a first printhead and a second printhead configured to eject ink to a print medium; a conveyance mechanism configured to convey the print medium; a camera configured to photograph the print medium; a carriage configured to carry and move the first printhead, the second printhead, and the camera; and a processor configured to print a third mark by the first printhead, photograph the third mark by the camera, adjust driving the conveyance mechanism and the carriage based on a result of the photograph, print a first mark and a second mark by the first printhead and the second printhead respectively, photograph the first mark and the second mark by the camera, and based on the result of the photograph, adjust the ink ejection timing of the second printhead.