Splice Interrupt Mechanism for Web Print Printhead Protection
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Solution Overview
Problem
Conventional printing systems face inefficiencies and errors when handling web splices during high-speed printing, leading to issues like cancelled sheets, incomplete printing, and the need for manual intervention or re-processing of print jobs.
Innovation Solution
The implementation of a system with print controllers that generate specific print interrupt instructions in response to detected web splices, allowing for controlled pause and resume of printing operations across multiple print engines, while managing printhead gaps to prevent damage from splices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional printing systems continue printing without interruption when a web splice is detected, then printing productivity is maintained, but the printhead may be damaged by the splice
Solution Approach 1:
The system performs preliminary detection of web splices using sensors before the splice reaches the printhead. Upon detection, the controller preemptively opens the printhead gap and pauses printing operations, preventing potential damage while maintaining productivity by resuming printing automatically after the splice passes through the print engine
Solution Approach 2:
The system implements a feedback mechanism where sensors continuously monitor the web for splices and provide real-time signals to the controller. The controller responds by adjusting the printhead gap and printing state, then monitors again to detect when the splice has passed, creating a closed-loop control system that balances protection and productivity
2Reliability
If the printhead gap is opened immediately upon splice detection, then printhead damage is prevented, but printing interruptions and re-processing are required
Solution Approach 1:
The system dynamically adjusts the printhead gap based on the detected splice position and web speed. Rather than opening the gap immediately at a fixed point, the controller calculates the optimal timing to open and close the gap, allowing printing to continue as long as possible while ensuring the printhead is protected when the splice arrives, thereby minimizing interruption time
3Productivity
If multiple print engines process different sides of the web simultaneously, then printing productivity is increased, but coordination complexity during splice handling increases
Solution Approach 1:
The system merges the control logic for multiple print engines into a single centralized controller that receives splice detection signals and coordinates both engines simultaneously. When a splice is detected, the controller generates gap instructions for both print engines based on their respective positions and the detected splice location, ensuring synchronized protection and resume operations across all engines
Data Source
AI summary
A system is disclosed. The system comprises one or more print controllers to generate print interrupt instructions in response to receiving a web splice signal indicating that a web splice on a web print medium has been detected, wherein the print interrupt instructions indicate a first side sheet image and a second side sheet image within a print job to pause prior to stopping printing, wherein the print interrupt instructions comprise gap instructions to open a first printhead gap at the first print engine and to open a second printhead gap at the second print engine, control printing of the first side sheet image on a first side of a web at a first print engine based on the print interrupt instructions, control printing of the second side sheet image to a second side of the web at a second print engine based on the print interrupt instructions, wherein the print interrupt instructions are generated based on a determination of an interrupted first side sheet image to be paused prior to opening the first printhead gap and a determination of an interrupted second side sheet image to be paused prior to opening the second printhead gap.