Printer Roll Diameter Detection Using Periodic Distance Sensing
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Solution Overview
Problem
Existing barcode printers face challenges in accurately detecting the remaining number of labels in a roll and maintaining stable sheet conveyance, particularly as the roll diameter changes during printing.
Innovation Solution
A printer system equipped with a distance sensor and a processor that detects changes in distance signals to determine the roll's vibration convergence state and diameter, allowing for precise detection of the roll's diameter and remaining labels, and adjusts the printing cycle accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the distance sensor continuously monitors the roll diameter throughout printing, then the remaining number of labels can be accurately detected, but the detection accuracy deteriorates due to roll vibration during printing operations
Solution Approach 1:
The distance sensor performs periodic measurement at specific intervals during the printing cycle, specifically measuring the roll diameter at the start of printing and after a predetermined number of labels are printed. This periodic measurement approach avoids continuous monitoring that would be affected by vibration, while still maintaining accurate detection of roll diameter changes.
Solution Approach 2:
The system performs preliminary measurement of the roll diameter at the start of printing before vibration and label consumption significantly affect the roll state. This preliminary measurement establishes a baseline value that is used for calculating the remaining number of labels, ensuring accurate detection before vibration interference occurs.
2Loss of information
If the roll diameter changes during printing due to label consumption, then the remaining number of labels can be tracked, but sheet conveyance stability deteriorates as the roll size decreases
Solution Approach 1:
The system uses feedback from periodic distance sensor measurements to calculate the change in roll diameter and determine the number of consumed labels. This feedback mechanism allows the system to track remaining labels while adjusting for roll size changes, maintaining accurate counting despite the decreasing roll diameter that affects conveyance stability.
3Productivity
If printing continues without adjusting for roll diameter changes, then productivity is maintained, but print quality deteriorates due to unstable sheet conveyance
Solution Approach 1:
The system implements periodic measurement and calculation of remaining labels during the printing process, allowing continuous printing to proceed while periodically updating the roll diameter data. This ensures print quality is maintained through accurate conveyance control without interrupting productivity.
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
Enables accurate detection of the roll's diameter and remaining labels, ensuring stable and efficient sheet conveyance and printing, even as the roll size decreases, thereby preventing print failures and optimizing label usage.
Implementation Method 1
a distance sensor that detects a distance up to an outer surface of the roll
Data Source
AI summary
According to one embodiment, a printer includes an input interface and a processor. The input interface inputs a distance signal output from a distance sensor opposite to a rotating surface of a roll around which a sheet material is wound in a roll shape. The processor detects an amount of change in a distance from the distance sensor to the rotating surface of the roll based on a plurality of distance signals input at different timings, detects a vibration convergence state of the roll from the amount of change in the distance, and detects a diameter of the roll based on the distance signal input in the vibration convergence state.