Scanning printers are based on a system with two perpendicular axes: the media advance axis and the print head scan axis. The media advance axis defines the movement and position of a print medium below a print head when the print head prints a swath of printing fluid. The print head scan axis defines the movement of a print head carriage carrying the print head. A firing pulse is generated in response to the position of the print head in the print head scan axis. The firing pulse is a signal used by the print head to fire a drop of printing fluid while the media is static below the carriage.
A Page Wide Array (PWA) printer has an axis architecture in which the print head carriage is replaced by an array of nozzles that extends in a width direction across a print zone and does not move. The print medium moves through the print zone, with the media advance axis perpendicular to the width direction of the array of pens. A firing pulse is generated in a respective nozzle in response to the media movement.
The media advance axis also is referred to as Y direction, and the print head scan axis or nozzle array width also is referred to as X direction. Media position errors in the X direction might cause print image quality issues.
The media advance system 10 comprises a first set of feed rollers/pinch wheel pairs 16 and a second set of pinch wheels 18, and a number of movable baffles 20 between the first set and the second set. A print medium 100 (see
A media bubble sensor 28 is provided between the first set of feed rollers/pinch wheel pairs 16 and the second set of pinch wheels 18 wherein the bubble sensor 28 can be extended from a guiding plate 30 or retracted behind the plate 30.
In this example, a print bar or print nozzle array 32 is schematically shown in
In the example, the media advance system 10 comprises six parallel vacuum belts 22 which are driven by common idle/drive rollers 24 and 26. The media advance system 10 further comprises a vacuum chamber 40 that is formed underneath a platen 42 and is in fluid communication with the surface of the platen 42 through a plurality of suction ports 44. The vacuum chamber 40 can be partially evacuated by means of a vacuum generator, including a fan or pump 48 to reduce the pressure in the vacuum chamber 40 with respect to the atmospheric pressure in the surrounding environment. The vacuum generator may be provided within the vacuum chamber 40 or externally thereto, with a fluid connection to the vacuum chamber 40. It generates a suction force or vacuum force at the surface of the platen 42 which may be characterized in terms of a pressure that is locally decreased with respect to a pressure in a surrounding environment, in particular, locally decreased with respect to an atmospheric pressure. The vacuum force is transferred to the print medium 100 transported on the surface of the vacuum belt 22 and is translated into a normal force and a traction force which causes the print medium to follow the movement of vacuum belts 22.
The media advance system 10 further may include a position sensor (not shown) to detect a leading edge and/or a trailing edge of the print medium 100 when it is transported across the platen 42. A plurality of position sensors can be provided, e.g. at an upstream end and at a downstream end of the platen 42, and/or at an upstream end and at a downstream end of a print zone, in the media advance direction.
The media advance system 10 further may be coupled with a controller (not shown) for controlling movement and speed of the first set of feed rollers/pinch wheel pairs 16, and of the idle/drive rollers 24, 26, and further for controlling movement of the baffle 20. The controller further can control the vacuum level generated in the vacuum chamber 40. The controller can comprise one or a number of dedicated microcontrollers or other processing means.
The upper surface of the platen 42 is provided with a plurality of suction ports 122 in the form of small holes distributed across the entire platen 42. The suction ports 122 are in fluid communication with the vacuum chamber (not shown in
The vacuum belts 112a to 112f on the surface of the platen 42 may likewise be provided with little holes or openings that allow air to pass through and hence facilitate the application of the suction force to the underside of the print medium 114.
Due to the suction force, the print medium 114 is tightly held and can be positioned on the vacuum belts 112a to 112f while being advanced along the media advance direction Y. The suction force also avoids curling of the print medium 114, which could lead to media jams or degrade the printing quality.
A number of vacuum belts 112a to 112f share common rollers, such as a drive roller 26 and an idle roller 24. The vacuum holds down the print medium, provided flatness for accurate ink dot placement and providing a normal force to the print medium for generating traction to avoid slippage of media-to-belt when the print medium is transported by the vacuum belts 112a-112f.
Different causes can generate a media registration error in the X direction, i.e. perpendicular to the print media advance direction Y. A media registration error in the X direction may increase with an increase of media length wherein the print medium may make a kind of rotational movement defining a curve. The X axis registration error may reach a maximum when there is equilibrium between a tension force applied to the print medium in the media advance direction and a traction force applied to the print medium for holding the print medium on the media advance system. This is explained with reference to
If using vacuum belts, a non-symmetric belt speed profile can be caused by a misalignment between drive rollers or the use of vacuum belts generating non-homogeneous friction forces distributed across the print medium, for example. Another cause for a position error can be the use of a grit roller for transporting the print medium having a conical shape in the roller.
In
In the scenario
The X axis registration error can be reduced if the stable position is obtained at a lower tension force. On the other hand, the traction force should not be lowered arbitrarily. A certain minimum traction should be maintained when the leading edge and the trailing edge of the print medium enter and leave the print zone. A minimum vacuum level at the beginning and at the end of the plot also is useful to create a normal force to iron the leading and the trailing edges of the print media.
The vacuum level generated in the vacuum chamber and hence the normal force (suction force) applied to the print medium 65 can be varied to according to the position of the print medium 65 in the media advance system 52 and relative to the print zone (118 in
By varying the vacuum level in response to the position of the print medium in the media advance system, a higher vacuum level can be used in those instances where the print medium is to be flattened and “ironed” to the platen. This is particularly the case in the leading edge and the trailing edge areas of the print medium where a print medium coming from a roll is curled due to the roll shape. Accordingly, in one example, the first higher vacuum level can be applied from the time when the print medium enters the platen of the print media advance system until it fully covers the print zone or reaches the end of the print zone in the media advance direction. In another example, the first higher vacuum level can be applied until the leading edge of the print medium has passed the print zone by a predetermined distance. In a further example, the first higher vacuum level can be applied until the leading edge of the print medium has reached the end of the platen and the print medium fully covers the length of the platen. The second lower vacuum level than can be applied as soon as the leading edge of the print medium fully covers the print zone or has passed print zone by the predetermined distance or fully covers the length of the platen, depending on the condition defined for the first vacuum level. Further, it is possible to again apply the first higher vacuum level or a third higher vacuum level before the trailing edge of the print medium reaches the print zone. In one example, the first higher vacuum level can be applied again from the time when the trailing edge of the print medium reaches the start of the print zone in the media advance direction. In another example, the first higher vacuum level can be applied again when the trailing edge of the print medium is upstream of the print zone by a predetermined distance. In a further example, the first higher vacuum level can be applied again when the trailing edge of the print medium reaches the start of the platen.
The first higher vacuum level ensures that the leading edge area and the trailing edge area of the print medium are flattened, with good traction force, on the platen of the media advance system. Once the print medium fully covers the print zone, the traction force can be reduced and the middle part of the print medium, between the leading edge area and the trailing edge area, can still be sufficiently flattened by the combined traction and tension forces applied to the print medium.
A certain minimum vacuum level normal force should be maintained to keep the print medium “ironed” all along the plot. The normal force is directly proportional to the pressure drop at the print medium:
F
Normal
=ΔP A
hole
c
a
With
FNormal, normal force;
ΔP, pressure drop at print medium;
Ahole, hole area covered by print medium;
ca, influence area coefficient, depends on media air flow permeability.
In the same way, the traction force avoids media slippage and it is directly proportional to the pressure drop at the print medium.
F
traction
=μΔP A
hole
c
a
=μF
Normal
With
Ftraction, traction force;
μ, coefficient of friction between vacuum belts and print medium;
ΔP, pressure drop at print medium;
Ahole, hole area covered by print medium;
ca, influence area coefficient, depends on media air flow permeability.
In general, the pressure drop is lower when the platen is partially covered by the print medium and the impedance of the system is is lower than the nominal impedance value of the media advance system when the platen is fully covered.
In this example, Znot covered is the impedance for the system itself, taking into account the geometrical features of the vacuum system (pipes, elbows, pre-chambers, holes, belts hole, etc.). Zcovered includes the same impedance due to all the geometrical features plus the impedance of the print medium. This impedance is different for each print medium depending on its permeability but usually is much higher than the impedance of the media advance system (not covered). These two impedances are changing over time while the print medium moves across the platen. The equivalent impedance of the system when it is not totally covered is:
In order to have a minimum normal force and traction force when the leading edge area and the trailing edge area of the print medium cross the print zone, the first higher vacuum level may be in the range of 80 mmH2O to 120 mmH2O (about 800 Pa to 1200 Pa), such as at about 80 mmH2O (about 800 Pa), 100 mmH2O (about 1000 Pa) or 120 mmH2O (about 1200 Pa), for example, depending on media type. When the print zone is totally covered, the vacuum level can be lowered to a range of 10 mmH2O to 50 mmH2O (about 100 Pa to 500 Pa) or about 20 mmH2O (about 200 Pa) or about 30 mmH2O (about 300 Pa), for example. The first vacuum level may be about twice to about ten times the second vacuum level, or about five times the second vacuum level. When the print zone is fully covered and/or when the platen is fully covered by the print medium, the impedance of the system is relatively high due to the media impedance, so the pressure drop at the print medium is high. Additionally the hole area covered by the print medium, Ahole, reaches its maximum value during this state. Accordingly, the vacuum level can be reduced.
In one example, at any one point in time, the same vacuum level, either the first vacuum level or the second vacuum level or the third vacuum level, is applied throughout the platen. In another example, the vacuum level may be different in different areas of the platen, e.g. to accommodate different print media widths. The third vacuum level may be provided when the trailing edge of the print medium leaves the print zone wherein the third vacuum level is higher than the second vacuum level and may be the same as the first vacuum level or may be higher or lower than the first vacuum level.
Lowering the vacuum level reduces the normal and traction forces, allowing a small media slippage in X direction. Accordingly, the equilibrium between the tension force applied to the print medium in the media advance direction and the traction force applied to the print medium for holding the print medium on the media advance system is reached at a smaller rotation angle and the X axis registration error is reduced accordingly. As a result, the print medium can be fed with a small media bubble in a low position of the bubble sensor to generate an X-direction slippage opposite to the media X movement once the bubble has been consumed in one side of the buffer (see
The described concept achieves robustness when feeding a long print medium in a printer, having regard to media position errors in X direction. Even for long print media, having a length of 1 m or more, for example, a stable position in the X direction and a quite small rotation angle of the print medium can be achieved. The absolute X position error can be kept low, minimizing the image position errors, even for very long plots where it is difficult to keep the initial margin of the paper all along the plot. Additionally, the occurrence of wrinkles in the media input area due to the misalignment between the media actual position in the print zone and the feeding position can be mitigated.
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/US2017/024601 | 3/28/2017 | WO | 00 |