Print Head Timing Control Using Continuous Motion Tracking
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Solution Overview
Problem
Current printing technologies face accuracy and resolution issues due to the use of encoders that only provide discrete positional information, leading to errors from jitter and unaccounted acceleration between locations.
Innovation Solution
A system comprising a print head, a conveyance system, and an encoding sensor, where the encoding sensor continuously tracks the position and velocity of objects using sensors like laser interferometers or velocimeters, and a processor determines the optimal printing time based on this information to ensure accurate and precise printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If discrete point encoders are used to determine object position, then device complexity is reduced, but manufacturing precision and measurement precision deteriorate due to errors from jitter and unaccounted acceleration between discrete locations
Solution Approach 1:
The patent replaces mechanical encoders with optical sensors and laser-based measurement systems. The optical sensor continuously measures the distance between the print head and substrate using optical principles, while the laser velocimeter measures velocity through laser Doppler velocimetry. This substitution eliminates mechanical contact and discrete measurement points, providing continuous high-precision positional and velocity data without the jitter and acceleration errors inherent in mechanical encoder systems.
Solution Approach 2:
The patent introduces an intermediary processing system that receives continuous positional and velocity data from optical sensors and laser velocimeters, then calculates precise timing information for droplet ejection. This intermediary computation layer translates continuous physical measurements into controlled printing actions, ensuring that printing occurs at the exact moment the substrate passes through the print zone, thereby achieving high manufacturing precision.
2Device complexity
If discrete point encoders are used to determine object position, then device complexity is reduced, but measurement precision deteriorates due to insufficient resolution between discrete locations
Solution Approach 1:
The patent replaces mechanical encoders with optical sensors and laser-based measurement systems. The optical sensor continuously measures the distance between the print head and substrate using optical principles, while the laser velocimeter measures velocity through laser Doppler velocimetry. This substitution eliminates mechanical contact and discrete measurement points, providing continuous high-precision positional and velocity data without the jitter and acceleration errors inherent in mechanical encoder systems.
3Manufacturing precision
If continuous tracking with optical sensors and laser velocimeters is implemented, then manufacturing precision and measurement precision are improved, but device complexity increases
Solution Approach 1:
The patent implements a multi-functional integrated system where the optical sensor serves dual purposes: measuring both the position of the substrate and the velocity of the print head. The laser velocimeter similarly provides velocity measurements that are integrated with the positional data from the optical sensor. This multi-functionality reduces the need for separate measurement devices, thereby managing system complexity while maintaining high manufacturing precision through continuous tracking.
4Manufacturing precision
If continuous tracking is used to improve printing accuracy, then manufacturing precision is improved, but loss of time increases due to continuous data acquisition and processing
Solution Approach 1:
The patent implements preliminary action by continuously acquiring positional and velocity data before the substrate enters the print zone. The system calculates the optimal printing time in advance based on the projected position and velocity of the substrate, allowing the print head to be precisely positioned and ready for droplet ejection. This preliminary calculation and preparation eliminate delays during the actual printing process, maintaining high manufacturing precision without significant time loss.
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
This approach provides improved resolution and accuracy in printing by continuously tracking object movement, allowing for higher-speed printing with reduced errors and enhanced positional accuracy.
Implementation Method 1
sensors like laser interferometers or velocimeters
Implementation Method 2
sensors like laser interferometers or velocimeters
Data Source
AI summary
A method is provided that includes acquiring positional information regarding a pallet being translated on a conveyance system with an encoding sensor disposed proximate to the conveyance system. The method also includes receiving, with at least one processor, the positional information from the encoding sensor. Further, the method includes determining timing information using the positional information. The timing information corresponds to when a substrate disposed on the pallet will be in a print zone of a print head. The method further includes controlling the print head to print on the substrate when the substrate is in the print zone and passing beneath the print head.