Printhead Alignment Using Iterative Verification Plot
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Solution Overview
Problem
Traditional printhead alignment methods are inefficient, requiring extensive media usage and recalibration from scratch, leading to suboptimal alignment accuracy and increased printing time, especially when only one printhead needs adjustment.
Innovation Solution
An iterative alignment strategy using a verification plot that prints with the last-used alignment values, allowing for quick identification and adjustment of misaligned printheads, reducing the amount of content printed and conserving media by reusing previous alignment settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional printhead alignment methods are used, then alignment can be performed, but extensive media is consumed and recalibration must start from scratch
Solution Approach 1:
The system performs preliminary alignment of all printheads at the beginning, establishing baseline alignment values. When a printhead is replaced or realigned, the system uses these pre-established alignment values as a starting point rather than beginning from scratch, thereby reducing media consumption while maintaining alignment accuracy.
Solution Approach 2:
The system recovers and reuses previous alignment values for printheads that have been realigned. Instead of discarding the original alignment data and starting over, the system retains the alignment information and applies it to the new configuration, reducing the need for extensive media usage in recalibration.
2Productivity
If all printheads are re-aligned from scratch, then alignment is ensured, but printing time increases significantly
Solution Approach 1:
The alignment process is segmented into individual printhead alignments rather than treating all printheads as a single unit. When one printhead is replaced or needs realignment, only that specific printhead undergoes recalibration using its previous alignment values as a baseline, while other printheads maintain their alignment settings. This segmentation dramatically reduces the time required for partial realignments.
Solution Approach 2:
Instead of performing complete realignment of all printheads when only one needs adjustment, the system applies partial realignment to the affected printhead only. This partial action approach uses previous alignment values to quickly re-establish the specific printhead's alignment without the time cost of re-aligning the entire system.
3Ease of operation
If manual alignment plots are printed for each printhead, then alignment can be verified, but the process becomes complex and time-consuming
Solution Approach 1:
The alignment plot serves multiple functions simultaneously: it displays alignment information for all printheads in the system, allows verification of individual printhead alignment, and provides a reference for manual adjustment. This multi-functional design simplifies the operator's task by consolidating what would otherwise require multiple separate operations into a single plot review.
Solution Approach 2:
The alignment plot provides immediate visual feedback on the alignment status of all printheads. By displaying alignment information in a standardized format that can be quickly interpreted, the system enables operators to rapidly assess alignment quality and make adjustments only when necessary, reducing the complexity of the overall alignment process.
Data Source
AI summary
Examples relate to computer-implemented methods for a printing system comprising a printhead, and to printing systems. A method for a printing system comprises retrieving a stored first offset applied to the printhead to align the printhead, the first offset determined based on a first user input signal; and further aligning the printhead according to a further offset determined based on a further user input signal, the further offset indicating a difference from the first offset.