Single Pass Printing Image Distortion Correction on Spherical Balls
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Solution Overview
Problem
Single pass printing methods face challenges in reliably and consistently printing images on spherical balls without distortion, due to the rotation and curvature of the ball's surface.
Innovation Solution
The method involves rotating the spherical ball and using a plurality of printing nozzles to print images defined by an image area profile, with ink droplets correlating to pixels arranged in consecutive image lines. This is achieved by applying pixels to a distorted pixel map, selectively removing pixel areas, and printing based on the distorted pixel map to account for the ball's curvature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If single pass printing is used to print images on rotating spherical balls, then productivity is improved, but image distortion occurs due to ball rotation and surface curvature
Solution Approach 1:
The patent applies preliminary action by pre-distorting the image data before printing. The system calculates distortion based on the ball's rotation speed, printer head speed, and radius, then pre-adjusts the image geometry so that when printed on the rotating ball, the image appears undistorted. This anticipates the distortion that will occur during printing and compensates for it in advance.
Solution Approach 2:
The patent changes parameters by dynamically adjusting image distortion based on varying printing parameters such as ball rotation speed, printer head speed, and ball radius. The system recalculates distortion parameters when any of these variables change, allowing consistent image quality across different printing conditions while maintaining high-speed single-pass printing.
2Productivity
If the ball rotates at high speed for single pass printing, then productivity is improved, but image consistency deteriorates
Solution Approach 1:
The patent implements feedback by continuously monitoring the actual ball rotation speed and printer head speed during operation, then using this feedback to recalculate and adjust the image distortion parameters. This closed-loop control ensures that even if rotation speeds vary, the printed images remain consistent and undistorted, maintaining reliability at high throughput speeds.
3Manufacturing precision
If image distortion is corrected by multiple printing passes, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent eliminates the need for multiple correction passes by applying preliminary distortion correction to the image data before the single printing pass. The system calculates all necessary geometric adjustments in advance based on printing parameters, allowing the image to be printed correctly in one pass without requiring subsequent correction passes, thus maintaining both high precision and high productivity.
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 reduces image distortion and defects, enabling reliable, consistent, and clear single pass printing of images on spherical balls, ensuring that the images appear undistorted on the ball's surface.
Implementation Method 1
printing an image on the ball with a plurality of printing nozzles while the ball is rotating; wherein the image is printed by printing ink droplets correlating to pixels arranged in consecutive image lines
Data Source
AI summary
Single pass printing methods designed to reduce or prevent unwanted image distortion and/or image defects when printing on a ball. In some embodiments, the methods can comprise printing ink droplets based on a distorted pixel map comprising a plurality of pixel areas distorted in at least one of a width direction and a height direction, wherein select pixel areas are removed from the distorted pixel map. In some embodiments, a distorted pixel map can comprise a plurality of undistorted pixel areas and a plurality of pixel areas distorted in at least one of a width direction and a height direction.