Split Inkjet Detection and Remediation in Printers
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Solution Overview
Problem
Inkjet printers face issues with split inkjets, which produce fragmented ink drops instead of single drops, leading to splotchy pixels and reduced image quality, and current methods for addressing this, such as purging, are inefficient and can only be performed infrequently, causing productivity losses.
Innovation Solution
A method that analyzes image data from a test pattern to identify split inkjets and generates remedial firing signals to adjust the inkjet operation, allowing for real-time identification and partial remediation of split inkjets without halting the printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If purging is performed to restore inkjet performance, then inkjet reliability is improved, but productivity is reduced due to complete halt of printing operations
Solution Approach 1:
The system performs preliminary detection of split inkjets by analyzing test pattern image data before they significantly degrade print quality. By identifying problematic inkjets early, the system can apply remedial firing signals to correct the split droplet issue before a complete purge is necessary, thereby maintaining continuous printing operations.
Solution Approach 2:
The system continuously monitors inkjet performance by analyzing image data from test patterns and provides feedback through adjusted firing signals. When split inkjets are detected, the controller modifies the firing signals for those specific inkjets to remediate the split droplet problem, creating a closed-loop control system that maintains inkjet performance without halting production.
2Manufacturing precision
If purging is performed frequently to maintain inkjet quality, then image quality is improved, but ink waste increases due to expelled ink
Solution Approach 1:
The system detects split inkjets early through continuous analysis of test pattern image data, allowing remediation before significant image quality degradation occurs. This early intervention reduces the frequency and extent of purging operations needed, thereby conserving ink while maintaining print quality.
Solution Approach 2:
The system changes the firing signal parameters for identified split inkjets to remediate the split droplet issue. By adjusting voltage, pulse width, or other firing parameters, the system corrects inkjet performance without requiring complete purging, thus reducing ink waste while maintaining image quality.
3Manufacturing precision
If remedial firing signals are applied to split inkjets, then image quality is improved, but device complexity increases due to real-time detection and control
Solution Approach 1:
The system uses the existing printhead controller to generate both test patterns and analyze their image data, as well as to generate remedial firing signals. By making the controller multi-functional, the system avoids adding separate detection and control devices, thereby reducing overall system complexity while maintaining image quality improvement capabilities.
Solution Approach 2:
The system uses its own printhead to generate test patterns and analyzes the resulting image data to detect split inkjets. The controller then applies remedial firing signals to the same printhead, creating a self-service detection and correction system that minimizes external complexity while improving image quality.
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 enables continuous printing by identifying and partially remediating split inkjets, improving image quality and reducing the need for frequent purging operations, thereby enhancing productivity and reducing ink waste.
Implementation Method 1
individual piezoelectric, thermal, or acoustic actuators generate mechanical forces that expel ink through an orifice from an ink filled chamber in response to an electrical voltage signal
Implementation Method 2
individual piezoelectric, thermal, or acoustic actuators generate mechanical forces that expel ink through an orifice from an ink filled chamber in response to an electrical voltage signal
Implementation Method 3
individual piezoelectric, thermal, or acoustic actuators generate mechanical forces that expel ink through an orifice from an ink filled chamber in response to an electrical voltage signal
Implementation Method 4
The optical sensor is configured to generate image data of ink drops on the image receiving member
Data Source
AI summary
A method analyzes image data of a test pattern printed on an image receiving member by a printer to identify split inkjets in the printheads of the printer. The test pattern is formed by operating each inkjet of a printhead to form a dash and the areas of the dashes are compared to an average dash area to identify split inkjets. Firing signal parameters for the split inkjets are adjusted and subsequent firing signals are generated using the adjusted parameters. Image data of the pixels formed by the split inkjets are analyzed after the split inkjets have been operated using the adjusted firing signal parameters. If the pixel size for a split inkjets indicates that the split inkjet has been remediated, then the firing signal parameters are returned to their nominal values.