Variable Resolution Printer Pulse Train Controller
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Solution Overview
Problem
Current printers are limited in their ability to print at resolutions other than their maximum capability, as altering the native resolution often results in uniform scaling of all printed elements, which is undesirable and restricts flexibility in high-volume industrial printing applications.
Innovation Solution
A variable resolution printing system that includes a controller with a sampling module to adjust the pulse train generated by a position sensor or stepper motor, allowing for flexible configuration and printing at any desired resolution by modifying the time between pulses, enabling precise control over print head activation and maintaining accurate positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If encoder translation is used to alter the native resolution of the printer, then the print resolution can be changed, but all elements of the printed indicia are compressed or expanded uniformly, which is undesirable and restricts flexibility
Solution Approach 1:
The patent segments the pulse train into individual pulses that can be selectively modified. Instead of uniformly scaling all printed elements, the system processes each pulse independently, allowing selective alteration of pulse widths while maintaining original positional information. This enables non-uniform resolution changes where specific elements can be printed at different resolutions without affecting others.
Solution Approach 2:
The patent applies local quality by allowing different portions of the printed indicia to have different resolutions. The pulse width modification can be applied selectively to specific pulses corresponding to specific elements, enabling local resolution adjustment rather than global uniform scaling. This maintains the ability to print barcodes and other indicia at appropriate resolutions for each specific element.
2Adaptability or versatility
If the pulse train generated by the encoder is sped up to change resolution, then the print resolution changes, but the parameters of the printer must be changed and configuration is affected
Solution Approach 1:
The patent extracts the resolution control function from the printer's core parameters by modifying the pulse train externally. Instead of changing printer parameters such as DPI settings or encoder resolution, the system takes the native pulse train and applies width modifications as a separate processing step. This separation allows resolution flexibility without affecting the printer's fundamental configuration parameters.
Solution Approach 2:
The patent changes only the pulse width parameter while maintaining other parameters constant. The modification process alters the duration or width of individual pulses in the pulse train, which directly controls the printed element dimensions, while leaving the printer's native resolution, speed, and other operational parameters unchanged. This selective parameter modification enables resolution flexibility without system reconfiguration.
3Adaptability or versatility
If uniform scaling is applied to change print resolution, then resolution flexibility is achieved, but print quality and accuracy deteriorate due to compression or expansion of all elements
Solution Approach 1:
Instead of scaling down the encoder's native resolution to achieve lower DPI printing, the patent inverts the approach by maintaining the high-resolution native pulse train and selectively extending pulse widths to create larger printed elements. This inversion preserves the positional accuracy of the high-resolution encoder while achieving the effect of lower resolution through controlled pulse width expansion rather than compression.
Data Source
AI summary
A variable resolution print system is provided. The system includes a variable resolution printer coupled to a positional encoder and a configuration module. The position encoder provides a pulse train to a controller in the variable resolution printer, the pulse train representing the movement of a target relative to the printer. A user of the print system enters or sets a desired resolution for printing via the configuration module. The controller calculates the difference between pulses in the pulse train. The controller then determines an adjustment to the calculate difference based on the desired resolution. The adjustment is used to generate a pulse train that actuates one or more print head of the printer.