Sheet Thickness Estimation via Edge Detection
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Solution Overview
Problem
Current printers lack a user-friendly and accurate method to estimate the thickness of thin and flimsy print media sheets, leading to difficulties in adjusting operating parameters and potentially causing premature stoppages during printing.
Innovation Solution
A system that electronically detects individual sheet edges in a stack using a non-contacting laser optical beam reflection detector or a deflectable sheet edge contracting needle sensor, combined with a movement system to estimate sheet thickness by producing and processing electrical signals, allowing for accurate calculation and control of printer operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual entry of paper type data is required every time a different stack is loaded, then the printer can adjust operating parameters for different sheet thicknesses, but the ease of operation deteriorates and requires operator memory and manual input
Solution Approach 1:
The system automatically measures sheet thickness using a sensor that detects the position of individual sheet edges as they pass by, eliminating the need for manual operator input. The sensor system self-activates when a stack is loaded and automatically provides thickness data to the controller for parameter adjustment.
Solution Approach 2:
The manual mechanical process of operator intervention is replaced with an electronic sensing system using a laser beam or needle sensor that automatically detects sheet edges and calculates thickness through electronic signal processing.
2Reliability
If no sheet thickness measurement system is implemented, then the device complexity remains low, but the reliability deteriorates due to inability to optimize operating parameters for different sheet thicknesses
Solution Approach 1:
The system measures and detects changes in physical parameters (sheet thickness) and uses this information to dynamically adjust operating parameters such as transfer currents, fuser temperatures, and feeder forces, ensuring reliable printing across different media types.
Solution Approach 2:
The sensor system provides continuous feedback about sheet thickness to the controller, which automatically adjusts operating parameters in real-time, creating a closed-loop control system that maintains printing reliability regardless of media variations.
3Measurement precision
If simple thickness measurement methods are used, then the device complexity is low, but the measurement precision deteriorates for thin flimsy sheets
Solution Approach 1:
Traditional mechanical measurement methods are replaced with optical or electromagnetic sensing systems that can detect the position of thin sheet edges without physical contact or significant force, enabling accurate measurement of flimsy materials that would be damaged or difficult to measure mechanically.
Solution Approach 2:
A laser beam or electromagnetic field serves as an intermediary between the measurement system and the thin sheets, allowing detection of sheet edges through non-contact means that preserve sheet integrity while providing precise thickness data.
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 precise estimation of sheet thickness, optimizing printer operations and preventing premature stoppages by providing accurate control signals for sheet feeders and finishers, ensuring efficient printing.
Implementation Method 1
an electronic sensing system for electronically detecting individual sheet edges in said stack thereof and providing an electrical signal thereof
Implementation Method 2
a deflectable sheet edge contracting needle actuated sensor
Data Source
AI summary
A system and method of estimating the thickness of the individual sheets in a stack of sheets in a print media sheet input stacking tray before printing with an electronic sensing system for electronically detecting individual sheet edges in the stack thereof and a movement system providing a known traversal distance of the sheet edge sensing system relative to one side of the stack to produce multiple signals corresponding to multiple detected individual sheet edges, and dividing that multiplicity of signals into the known traversal movement to estimate the thickness of the individual print media sheets in the stack and provide a corresponding electrical output can be used for automatic control of sheet feeder, printer or finisher functions. A relatively simple contacting or non-contacting sensor may be used.