Single Motor Dynamic Ribbon Feedback System for Printers
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Solution Overview
Problem
Current thermal transfer printers require two DC motors to dynamically control ribbon tension, increasing costs and system complexity, while a solution with a single motor is needed to maintain print registration quality as the ribbon diameter changes.
Innovation Solution
A printer system with a single motor drive system that uses sensors to measure ribbon width and diameter, calculating and adjusting torque on the take-up spindle to match tension with the supply spindle, ensuring consistent ribbon tension through firmware control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two DC motors are used to control ribbon tension dynamically, then print registration capability is improved, but system complexity and cost increase
Solution Approach 1:
The patent combines the functions of two separate motors into a single motor system. The first motor controls the take-up spindle while the second motor controls the supply spindle, both working together under unified firmware control to maintain ribbon tension. This merging reduces component count and system complexity while preserving the dynamic tension control capability needed for print registration.
Solution Approach 2:
The single motor system is designed to perform multiple functions: the first motor handles both winding the ribbon during printing and rewinding the ribbon after printing, while the second motor manages the supply spindle. The firmware provides universal control logic that adapts to different operational modes, making the system multi-functional without requiring separate dedicated motors for each function.
2Manufacturing precision
If two DC motors are used to control ribbon tension dynamically, then print registration capability is improved, but product cost increases
Solution Approach 1:
The patent merges the requirement for two motors into a single motor implementation, directly reducing component costs. By using one motor to control the take-up spindle and another motor to control the supply spindle with coordinated firmware, the system achieves the same print registration capability with fewer parts, lowering manufacturing and assembly costs.
3Stability of the object's composition
If ribbon diameter changes from fresh to empty, then ribbon tension changes, but print registration deteriorates
Solution Approach 1:
The patent implements dynamic ribbon tension control by continuously monitoring ribbon diameter through encoder feedback and adjusting motor torque in real-time. As the ribbon diameter changes from fresh to empty, the firmware calculates the required torque adjustment and modifies motor output accordingly, maintaining stable ribbon tension throughout the printing process and preserving print registration quality.
Solution Approach 2:
The system uses encoder feedback to detect ribbon diameter changes on both the supply and take-up spindles. This feedback information is fed back to the firmware, which then adjusts the motor control parameters to compensate for tension variations caused by diameter changes, creating a closed-loop control system that maintains print registration.
Data Source
AI summary
A printer with a single motor system to match torques between ribbon supply and ribbon take-up is provided. The printer comprises a ribbon supply spindle, a take-up ribbon spindle, sensors to output ribbon width and diameter at ribbon supply, and a sensor which outputs ribbon diameter at ribbon take-up. The printer is provided with a drive system providing rotation to the ribbon supply via tension on the ribbon loaded on the ribbon supply spindle and taken-up on the take-up ribbon spindle. Firmware, communicatively linked to the sensors and the drive system, is configured to calculate ribbon tension at the ribbon supply spindle, to calculate the torque required on the ribbon on the ribbon take-up spindle to match the ribbon tension at the take-up spindle to the ribbon tension at the ribbon supply spindle, and to adjust the drive system to match these torques.