Scanner-Based Image-to-Paper Registration Setup Correction
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Solution Overview
Problem
Current image-to-paper registration methods in printers are inefficient due to manual detection and adjustment of registration errors, which can be time-consuming and prone to inaccuracies, especially when reference marks are not visible near the edges of the page, leading to increased variability and multiple iterations.
Innovation Solution
A scanner-and-processor based system that generates a test sheet image bitmap using a grayscale scanner to measure distances between reference targets and edges in units of pixels, calculates positional errors, and adjusts actuators to correct registration errors, thereby enhancing accuracy and reducing the number of iterations needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual detection and adjustment of registration errors is used, then the process is simple to implement, but the time consumption and inaccuracy increase significantly
Solution Approach 1:
The patent replaces the manual mechanical measurement process with an automated optical scanning system. A scanner captures images of registration marks, and a processor automatically calculates positional deviations, eliminating the need for manual measurement and significantly reducing setup time while maintaining simplicity through automated operation.
Solution Approach 2:
The system enables self-service registration setup where the printer automatically performs measurement and calculation without requiring user intervention. The scanner and processor work autonomously to detect registration errors and compute correction values, allowing the system to self-regulate the registration process.
2Area of stationary object
If reference marks are positioned near the edges of the page, then the measurement coverage is maximized, but the marks become invisible when printing cannot reach the edges
Solution Approach 1:
The patent introduces a border region around the printable area that serves as a dedicated measurement zone. This border contains registration marks that are always visible and measurable, separate from the main printable content area. The system measures positional deviations in this border region and uses those measurements to correct registration in the printable area, effectively decoupling the measurement location from the printing limitations.
3Manufacturing precision
If iterative adjustment is used to achieve acceptable registration, then the registration accuracy can be improved, but the number of iterations significantly increases the setup time
Solution Approach 1:
The system performs preliminary measurement and calculation of registration errors before any physical adjustment is made. By capturing an initial image of the registration marks and calculating the exact deviation values in advance, the system determines all necessary correction values upfront, eliminating the need for multiple iterative adjustments and significantly reducing setup time.
Data Source
AI summary
A method and system for carrying out an image-to-paper printer registration setup includes: using a printer undergoing registration setup, printing a test pattern on a sheet having reference targets within a printable region of the sheet; using a scanner, scanning the printed sheet to generate an image bitmap of the test pattern-bearing sheet larger than the sheet itself so that the image bitmap contains the sheet edges and measuring in numbers of pixels the distances between the reference targets and/or sheet edges using multiple swaths of the image bitmap itself as the measuring tool; and, using a processor and based on the measured distances, calculating error-associated adjustment values in millimeters to use to correct errors in the registration setup of the image-to-paper in the printer and transferring the error-associated adjustment values to the printer to perform adjustment of its setup actuators.