Recording Device Layer Alignment via Test Pattern Feedback
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Solution Overview
Problem
Existing recording devices face challenges in accurately aligning multiple layers of images due to conveyance errors, requiring precise sensing of the conveyance roller's rotation position, which necessitates expensive sensors.
Innovation Solution
A recording device with a conveying unit, nozzle groups for forming layers, a detection unit, and a control unit that adjusts the relative positional relationship between layers by detecting conveyance errors and shifting nozzles to maintain accurate alignment using a test pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a sensor that highly senses the rotation position of the conveyance roller is used to adjust conveyance amount, then manufacturing precision of layer alignment is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses a test pattern (optical copy) printed on the medium to represent and measure conveyance errors, replacing the need for complex rotation position sensors. The test pattern serves as a visual record that can be detected by simpler sensors to determine conveyance accuracy.
Solution Approach 2:
The patent replaces the mechanical sensor system for detecting roller rotation position with an optical measurement system. Instead of sensing the roller's rotation directly, the system prints a test pattern and uses optical detection to measure the actual conveyance distance, substituting mechanical sensing with optical measurement.
2Manufacturing precision
If a test pattern is printed and detected to acquire conveyance error, then manufacturing precision is maintained, but productivity decreases due to additional processing steps
Solution Approach 1:
The test pattern is printed in advance at a predetermined position on the medium before the actual image recording. This preliminary action allows the conveyance error to be measured and corrected beforehand, ensuring that subsequent image layers are recorded with high precision without requiring rework.
Solution Approach 2:
The system uses the detected test pattern position to provide feedback about conveyance errors. This feedback is then used to adjust the conveyance amount for subsequent recording operations, creating a closed-loop control system that maintains precision while streamlining the process.
Data Source
AI summary
A recording device includes a conveying unit that conveys a medium, a first nozzle group that discharges a first liquid to form a first layer, a second nozzle group that discharges a second liquid after formation of the first layer to form a second layer, a carriage, a detection unit that acquires an error in the conveyance amount of the medium by the conveying unit, and a control unit. A test pattern is formed using the first nozzle group. The detection unit detects the test pattern and acquires an error in the conveyance amount based on a detection position. The control unit adjusts a relative positional relationship between the first layer and the second layer by shifting, in the conveying direction, a nozzle of the second nozzle group which is used and recording the second layer based on the error in the conveyance amount.