Patent Application
20210031528
The present application claims priority from Japanese Patent Application No. 2019-142023, filed on Aug. 1, 2019, the disclosure of which is incorporated herein by reference in its entirety.
The present disclosure relates to a liquid discharge apparatus, a liquid discharge method and a medium storing a program executable by the liquid discharge apparatus.
Japanese Patent Application Laid-open No. 2006-175849 describes a nozzle cleaning apparatus as a conventional liquid discharge apparatus. In the nozzle cleaning apparatus, in a case that a discharging test is performed and thus a nozzle which does not discharge an ink is found thereby, the nozzle cleaning apparatus executes a suction processing with respect to a nozzle array or nozzle row including the nozzle.
In the nozzle cleaning apparatus described in Japanese Patent Application Laid-open No. 2006-175849, the suction processing is executed with respect to the nozzle array including the nozzle which does not discharge the ink, and thus the ink is discharged also from another nozzle which is included in the nozzle array and which discharges the ink normally. Accordingly, the ink is consumed wastefully or unnecessarily.
The present disclosure has been made to solve the above-described problem; and an object of the present disclosure is to provide a liquid discharge apparatus, a liquid discharge method and a medium storing a program executable by the liquid discharge apparatus which are capable of lowering any wasteful consumption of the liquid.
According to an aspect of the present disclosure, there is provided a liquid discharge apparatus including:
a discharge head including a plurality of nozzles and a plurality of actuators, each of the plurality of actuators being provided corresponding to each of the plurality of nozzles, and being configured to change a volume of a pressure chamber communicating with one of the plurality of nozzles;
a liquid detecting sensor; and
a controller configured to:
calculate a discharge amount of the liquid discharged from each of the plurality of nozzles and detected by the liquid detecting sensor;
determine the discharge amount of the liquid is less than a first predetermined amount, not less than the first predetermined amount and less than a second predetermined amount, or not less than the second predetermined amount, the second predetermined amount being larger than the first predetermined amount; and
cause a first actuator of the plurality of actuators corresponding to a first nozzle, whose discharge amount is less than the first predetermined amount, and a second actuator of the plurality of actuators corresponding to a second nozzle, whose discharge amount is not less than the first predetermined amount and less than the second predetermined amount, to perform a flushing in which the volume of the pressure chamber is changed, without causing a third actuator of the plurality of actuators corresponding to a third nozzle, whose discharge amount is not less than the second predetermined amount, to perform the flushing.
According to the above-described configuration, the flushing is performed with respect to the first nozzle, whose discharge amount is less than the first predetermined amount and the second nozzle, whose discharge amount is not less than the first predetermined amount and less than the second predetermined amount, whereas the flushing is not performed with respect to the third nozzle, whose discharge amount is not less than the second predetermined amount. With this, since the liquid is not wastefully discharged from the third nozzle, it is possible to reduce any wasteful consumption of the liquid.
According to the present disclosure, it is possible to provide the liquid discharge apparatus, the liquid discharge method and the medium storing the program executable by the liquid discharge apparatus each of which is capable of reducing any wasteful consumption of the liquid.
A liquid discharge apparatus (liquid discharging apparatus) 10 according to a first embodiment of the present disclosure is an apparatus configured to discharge a liquid, as depicted in
The liquid discharge apparatus 10 adopts the serial head system, and is provided with: a platen 11, a conveying mechanism 12, a scanning mechanism 13, a head unit 14, a storing tank 15, a controller 60 and a maintenance unit 70. Note that the liquid discharge apparatus 10 may adopt the line head system. Further, the maintenance unit 70 will be described in detail later on.
The head unit 14 has a carriage 14a, a discharge head 20 and one piece or a plurality of pieces (for example, 4 pieces) of sub tank 14b. The discharge head 20 and the four sub tanks 14b are arranged on or installed in the carriage 14a, and reciprocate in a scanning direction together with the carriage 14a.
The discharge head 20 has a channel forming body and a volume changing section. The channel forming body has a liquid channel which is formed in the inside of the channel forming body, and a plurality of nozzle holes 21h (
The platen 11 is a member having a plate-like shape, and a recording medium M is placed or arranged on the upper surface of the platen 11. The platen 11 defines the distance between the recording medium M and the lower surface of the discharge head 20 which is arranged to face or to be opposite to the recording medium M. Note that although a side on the discharge head 20 with respect to the platen 11 is referred to as “upper side”, and a side opposite to this side is referred to as “lower side”, the arrangement of the liquid discharge apparatus 10 is not limited to this configuration.
The conveying mechanism 12 has, for example, two conveyance rollers 12a and a conveying motor (conveyance motor) 12b. The two conveyance rollers 12a sandwich the platen 11 therebetween in a conveyance direction, and are arranged to be parallel to each other. The conveying motor 12b is connected or linked to the conveyance rollers 12a. In a case that the conveying motor 12b is driven, the conveyance rollers 12a are rotated, thereby conveying the recording medium M on the platen 11 in the conveyance direction. Note that the conveyance direction is a direction crossing (for example, orthogonal to) the scanning direction.
The scanning mechanism 13 has two guide rails 13a, a scanning motor 13b, an endless belt, etc. The carriage 14a of the head unit 14 is supported by the two guide rails 13a, and is fixed to the endless belt. In a case that the scanning motor 13b is driven, the endless belt connected to the scanning motor 13b is thereby run. In this situation, the carriage 14a reciprocates (moves in a reciprocating manner) in the scanning direction, along the guide rails 13a.
The storing tank 15 is, for example, a detachable cartridge, and is provided on each kind of the liquid. For example, there are provided four storing tanks 15, and store black, yellow, cyan and magenta inks therein, respectively. Each of the storing tanks 15 is connected to one of the four sub tanks 14b corresponding thereto, via a tube, and supplies the liquid to the nozzle holes 12h via one of the four sub tanks 14b.
The controller 60 is connected to each of driving circuits driving the respective parts or components, etc., of the liquid discharge apparatus 10, and controls the driving of each of the respective parts, etc., by outputting control data to each of the driving circuits. For example, in a case that the controller 60 performs a printing processing, the controller 60 controls a driving circuit 17a to thereby drive the conveying motor 12b, controls a driving circuit 17b to thereby drive the scanning motor 13b, and controls an actuator driving circuit 18 to thereby drive an actuator 30 of the volume changing section.
By doing so, the controller 60 executes a pass processing including: a recording processing of causing liquid droplets, of which amount of the liquid are various, from the nozzle holes 21h, respectively, while moving the discharge head 20 in the scanning direction, to thereby form dots on the recording medium M; and a conveying processing of conveying the recording medium M in the conveyance direction. The printing processing progresses by alternately repeating the recording processing and the conveying processing, with the recording processing and the conveying processing made to be 1 (one) pass. Note that the details of the controller 60 will be described later on.
<Configuration of Discharge Head>
As depicted in
Holes and grooves which are various in size are formed in each of the plates. In the stacked body in which the respective plates are staked, the holes and grooves are combined to thereby form a plurality of liquid channels. The liquid channels include a plurality of nozzles 21, a plurality of individual channels 22 (channels), a supply manifold 23 and a return manifold 24.
Each of the plurality of nozzles 21 is formed by penetrating the nozzle plate 40 in a thickness direction thereof, and is open in a lower surface (discharge surface 40a) of the nozzle plate 40. Openings (nozzle holes 21h) of the plurality of nozzles 21 are aligned in the conveyance direction to thereby form a nozzle array or nozzle row, and a plurality of (for example, four) nozzle arrays are arranged side by side in the scanning direction.
The respective nozzle arrays correspond to liquids of mutually different colors (for example, black, yellow, cyan and magenta), respectively. Note that the plurality of nozzles 21 may be aligned in a direction crossing the conveyance direction. Further, the nozzle arrays may be arranged side by side in a direction crossing the scanning direction.
The supply manifold 23 extends in the conveyance direction, and has a supply port 23a provided on one end thereof. Further, the return manifold 24 extends in the conveyance direction, and has a return port 24a provided on one end thereof. The supply manifold 23 and the return manifold 24 are stacked on each other in a stacking direction, and are connected to each other at the other ends thereof, respectively, in the conveyance direction, by a communicating channel 25.
Each of the sub tanks 14b is connected to the supply port 23a by a supply channel 14c (supply path 14c) and is connected to the return port 24a by a return channel 14d (return path 14d). Further, the plurality of individual channels 22 are connected to the supply and return manifolds 23 and 24; each of the plurality of individual channels 22 reaches one of the plurality of nozzles 21 from the supply manifold 23, and reaches the return manifold 24 from one of the plurality of nozzles 21.
With this, the sub tank 14b, the supply channel 14c, the supply manifold 23, the communicating channel 25, the return manifold 24, the return channel 14d and the sub tank 14b construct a manifold circulation route in which the liquid is circulated in this order. Further, the sub tank 14b, the supply channel 14c, the supply manifold 23, the individual channels 22, the return manifold 24, the return channel 14d and the sub tank 14b construct a nozzle circulation route in which the liquid is circulated in this order.
The supply channel 14c is provided with a positive pressure pump 14e configured to supply the liquid from the sub tank 14b to the supply manifold 23. The return channel 14d is provided with a negative pressure pump 14f configured to supply the liquid from the return manifold 24 to the sub tank 14b. Note that either one, or both of, the positive pressure pump 14e and the negative pressure pump 14f may be provided on the manifold circulation route. Further, either one of the positive pressure pump 14e and the negative pressure pump 14f may be provided on the sub tank 14b.
The plurality of individual channels 22 connected to the supply manifold 23 and the return manifold 24 are communicated with the plurality of nozzles 21, respectively, constructing the nozzle array. In the present embodiment, each of the plurality of nozzles 21 constructing one nozzle array is connected to one piece of the supply manifold 23 and one piece of the return manifold 24 via one of the plurality of individual channels 22.
Each of the individual channels 22 has a supply-side throttle channel 22a, a pressure chamber 22b, a descender 22c and a return-side throttle channel 22d which are connected to one another in this order. Since the nozzle 21 is connected to the descender 22c, the pressure chamber 22b is communicated with the nozzle 21 via the descender 22c.
In such a liquid channel, the controller 60 (
In this situation, the liquid which has not flowed into the nozzle 21 inflows into the return manifold 24 from the descender 22c via the return-side throttle channel 22d. Further, this liquid flows thorough the return manifold 24, flows from the return port 24a through the return channel 14d and returns to the sub tank 14b. In such a manner, the liquid flows in the nozzle circulation route.
Further, the liquid which has not flowed into the individual channel 22 from the supply manifold 23 inflows into the return manifold 24 from the supply manifold 23 via the communicating channel 25. Further, this liquid flows thorough the return manifold 24, flows from the return port 24a through the return channel 14d and returns to the sub tank 14b. In such a manner, the liquid flows in the manifold circulation route.
The volume changing section is arranged on the fourteenth channel plate 54, and includes an actuator 30 and a vibration plate 31. The pressure chamber 22b of the individual channel 22 is formed to penetrate through the fourteenth channel plate 54 in a thickness direction thereof. The vibration plate 31 is fixed on the fourteenth channel plate 54, and covers an opening of the pressure chamber 22b.
The actuator 30 is a piezoelectric element including a common electrode 30a, a piezoelectric layer (partial piezoelectric layer) 30b and an individual electrode 30c, and is arranged on the vibration plate 31. The common electrode 30a covers the entire surface of the vibration plate 31; the piezoelectric layer 30b is stacked on the common electrode 30a, and the individual electrode 30c is provided on the piezoelectric layer 30b, while corresponding to each of the pressure chambers 22b. By one piece of the individual electrode 30c, the common electrode 30a and the partial piezoelectric layer 30b, which is sandwiched by the common electrode 30a and one piece of the individual electrode 30c, construct one piece of the actuator 30.
The individual electrode 30c is connected to an actuator driving circuit 18, and a driving signal from the actuator driving circuit 18 is applied to the individual electrode 30c. In contrast, the common electrode 30a is always maintained at the ground potential.
In a state that the driving signal is not applied to individual electrode 30c, individual electrode 30c and the common electrode 30a have a same potential. In a case that the driving signal is applied to the individual electrode 30c, an active portion or active part (the partial piezoelectric layer 30b which is sandwiched between individual electrode 30c and the common electrode 30a) of the piezoelectric layer 30b contracts or shrinks in a planar direction together with the two electrodes which are individual electrode 30a and the common electrode 30c. The vibration plate 31 deforms in cooperation with the actuator 30, and changes the volume of the pressure chamber 22b. With this, the pressure is applied to the liquid of (in) the pressure chamber 22b. With this, the meniscus of the nozzle hole 21h is vibrated, and/or the liquid droplet is discharged from the nozzle hole 21h. Accordingly, the actuator 30 is provided corresponding to each of the plurality of nozzles 21, and changes the volume of one of the plurality of pressure chambers 22b communicating with each of the plurality of nozzles 21.
<Controller>
As depicted in
The I/F 61 receives a variety of kinds of data such as image data, etc., from an external device D including a computer, a camera, a network, a storage medium, etc. The image data indicates an image to be printed on the recording medium M, and has color information and gradation information.
The storing section is a memory accessible from the controlling section 62, and has a RAM 63 and a ROM 64. The RAM 63 stores a variety of kinds of information temporarily. An example of the variety of kinds of information is image data and data converted by the controlling section 62.
The RAM 64 stores a computer program and a control program for performing a variety kinds of data processings. Note that the computer program may be obtained from the external device D via the I/F 61; alternatively, the computer program may be stored in another storage medium.
The controlling section 62 has an arithmetic processing unit such as a processor (for example, a CPU), and controls the respective parts or elements by executing a computer program stored by the ROM 64. For example, the controlling section 62 causes the RAM 63 to store the variety of kinds of data, etc., received by the I/F 61.
Further, the controlling section 62 executes a computer program so as to exhibit the functions of an image processing section 62a, a discharge amount calculating section 62b and a maintenance section 62c (maintenance means). The controlling section 62 causes the RAM 63 to store a plurality of pieces of data obtained or processed by the image processing section 62a, the discharge amount calculating section 62b and the maintenance section 62c, respectively. Note that the discharge amount calculating section 62b and the maintenance section 62c will be described later on.
The image processing section 62a obtains the image data from the external device D via the I/F 61. In a case that this image data is data expressed by the RGB color space, the image processing section 62a converts this data to data expressed in the CMYK color space. The image data has image gradation values for the colors, respectively.
The image processing section 62a prepares, for example, dot data for each pixel from the gradation values of the image data. The dot data has dot position information and dot size information, and the dot data is, for example, a half tone. The dot size has: a dot of which size is small (small dot), a dot of which size is greater than the small dot (intermediate dot), a dot of which size is greater than the intermediate dot (large dot), and no dot (non-dot) in which any dot is not formed.
The image processing section 62a generates controlling data for controlling the respective driving circuits, based on the image data and the dot data, and outputs the generated controlling data to the respective driving circuits. For example, the driving circuit 17a drives the conveying motor 12b based on conveying motor controlling data from the image processing section 62a. Further, the driving circuit 17b controls the scanning motor 13b based on scanning motor controlling data from the image processing section 62a.
The actuator driving circuit 18 has a waveform generating circuit 18a, and drives the actuator 30 based on actuator controlling data from the image processing section 62a. The waveform generating circuit 18a generates a driving signal having a voltage waveform indicating the driving pattern of the actuator 30, and supplies the generated driving signal to the actuator 30. The actuator 30 executes an operation in accordance with the driving signal.
Here, the actuator controlling data defines driving of the actuator 30 for generating a dot, and defines, for example, an actuator 30 to be driven, a driving timing and a driving pattern. The actuator 30 to be driven is defined by the color of the dot, the position of the dot in the conveyance direction, the order of the control data supplied from the controlling section 62 to the actuator driving circuit 18, etc.
The driving timing is defined by the position of the dot in the scanning direction, the velocity of the discharge head 20 moving in the scanning direction, etc. The velocity of the discharge head 20 in the scanning direction is previously determined.
The driving pattern is defined by the size of the dot. For example, with respect to the intermediate dot, an intermediate droplet driving pattern is defined so that an intermediate droplet which is a liquid droplet having a predetermined volume (liquid amount) is discharged from the nozzle 21. Further, with respect to the small dot, a small droplet driving pattern is defined so that a small droplet, which has a smaller liquid amount than that of the intermediate droplet, is discharged from the nozzle 21. Furthermore, with respect to the large dot, a large droplet driving pattern is defined so that a large droplet, which has a greater liquid amount than that of the intermediate droplet, is discharged from the nozzle 21. Moreover, with respect to the no dot (non-dot), a non-driving pattern is defined so that the liquid is not discharged from the nozzle 21.
<Maintenance Unit>
As depicted in
The purge mechanism 71 is arranged at a maintenance area which is adjacent, in the scanning direction, to one side of the platen 11. Accordingly, the discharge head 20 is movable, by the scanning mechanism 13, from the other side of the platen 11, passing the platen 11, and up to the maintenance area on the one side of the platen 11. The purge mechanism 71 has a cap 71a, a suction pump 71b, an atmosphere releasing valve 71c and an ascending/descending mechanism 71d.
The ascending/descending mechanism 71d causes the cap 71a to ascend to a contact position at which the cap 71a makes contact with the discharge surface 40a of the discharge head 20, and causes the cap 71a which makes contact with the discharge surface 40a to descend to a separate position at which the cap 71a is separated and away from the discharge surface 40a. In such a manner, the ascending/descending mechanism 71d ascends and descends the cap 71d between the contact position and the separate position.
The cap 71a is formed, for example, of a rubber having elasticity, and has a box-like shape of which upper part is opened (which has an opening at the upper part thereof). The opening at the upper part faces the discharge surface 40a at the separate position. The cap 71a makes tight contact with the discharge surface 40a at the contact position so as to cover the nozzle holes 21h which are opened in the discharge surface 40a, thereby forming a tightly closed space between the cap 71a and the discharge surface 40a. A suction port is opened in the cap 71a, and a suction pipe is connected to the suction port.
The suction pump 17b is connected to the suction pipe, and the atmosphere releasing valve 71c is provided on the suction pipe. In a state that the atmosphere releasing valve 71c is closed, the tightly closed space between the cap 71a and the discharge surface 40a and the suction pump 71b are connected to each other in an airtight state. With this, in a case that suction is performed in the tightly closed space by the suction pump 71b, the inside of the cap 71a which is covered by the discharge surface 40a is depressurized. In a case that the liquid is discharged, by this purge, from the nozzle hole 21h into the inside of the cap 71a, the discharge characteristic is recovered. Further, in a state that the atmosphere releasing valve 71c is opened, the space between the cap 71a and the discharge surface 40a is released to the atmosphere, and the cap 71a is removed or detached from the discharge surface 40a.
The wipe mechanism 72 has a wiper 72a and a wipe motor 72b. The wipe motor 72a moves the wiper 72a, along the nozzle arrays, with respect to the discharge surface 40a in a state that the wiper 72a makes contact with the discharge surface 40a. With this, the wiper 72a is capable of wiping any liquid and a softened trace of liquid adhered to the discharge surface 40a.
The flushing mechanism is the volume changing section, and has the actuator 30 and the vibration plate 31. The actuator 30 is driven to thereby displace the vibration plate 31, which in turn changes the volume of the pressure chamber 22b. With this, the pressure is applied to the liquid in the pressure chamber 22b, thereby causing the liquid to be discharged from the nozzle 21. The discharged liquid may be recovered to the inside of the cap 71a of the purge mechanism 71, or may be recovered by a recovery container which is provided separately from the cap 71a.
The flushing includes flushing of the pull-strike system and flushing of the push-strike system. In the flushing of the push-strike system, the volume of the pressure chamber 22b is reduced from a predetermined volume; in the flushing of the pull-strike system, the volume of the pressure chamber 22b is increased from the predetermined volume and then is reduced to be not more than the predetermined volume. The change of the volume of the pressure chamber 22b depends on a driving signal which has a pulse waveform (pulse signal of voltage) and which is applied to the actuator 30. Accordingly, driving signals of waveforms which correspond to the pull-strike system and the push-strike system, respectively, are applied to the actuator 30.
As depicted in
In a case that the voltage is applied to the detecting member 73a from an external power source, etc., an electric field E is generated between the detecting member 73a and the discharge surface 40a. Here, in a case that a liquid droplet is discharged from a nozzle hole 21h in the discharge surface 40a, the liquid droplet is electrically charged, and passes in the vicinity of the detecting member 73a. With this, an induced current is generated in the detecting member 73a, the detecting section 73b detects the induced current, and outputs a detecting single (of the induced current) to the controlling section 62. Since the induced current depends on the size of the liquid droplet, the liquid detecting sensor 73 is capable of detecting, based on the induced current, the amount of the liquid (liquid amount), which is discharged from each of the nozzle holes 21h, in one time of the discharge.
<Discharge Amount Calculating Section and Maintenance Section>
The maintenance section (maintenance unit) 62c executes a maintenance processing at a predetermined timing such as every predetermined time period, or at any timing indicated by a user through an operation of an input device such as key button, etc. The maintenance processing has an inspection processing of inspecting the discharge state of the nozzle(s) 21 and a recovery processing depending on a result of the inspection.
In the inspection processing, the discharge amount calculating section (discharge amount calculating unit) 62b calculates an amount of the liquid discharged from the nozzle 21 and detected by the liquid detecting sensor 73. Further, the maintenance section 62c determines the discharge state of the nozzle 21 based on the calculated amount (discharge amount) calculated by the discharge amount calculating section 62b.
Specifically, the maintenance section 62c causes the actuator 30 to perform a discharging operation, in which each of the plurality of nozzles 21 discharge liquid, for inspection (discharging operation for inspection processing). In the discharging operation for inspection, the maintenance section 62b outputs, to the actuator driving circuit 18, actuator controlling data for performing a discharging operation of discharging a liquid droplet form the nozzle 21 continuously for a predetermined number of times (for example, 10 times to 200 times). By doing so, the actuator driving circuit 18 supplies a discharge driving signal corresponding thereto, to the actuator 30.
With this, in a case that the liquid is discharged from the nozzle 21 corresponding to the actuator 30, the liquid detecting sensor 73 detects the liquid, and outputs a detection signal to the discharge amount calculating section 62b. The discharge amount calculating section 62b obtains the liquid amount of the liquid discharged by one time of the discharge from one nozzle 21, based on the detection signal from the liquid detecting sensor 73. The relationship between the induced current of the detection signal and the liquid amount are correlated to each other by an experiment, etc., in advance, and is stored in the ROM, etc.
The discharge amount calculating section 62b obtains a liquid amount (detected amount) detected by the liquid detecting sensor 73 per each of discharging operations which are continuously performed, and totals the detection amounts for a predetermined number of times of the discharging operations, and calculates the total amount as a discharge amount (calculated amount) of the nozzle 21.
The maintenance section 62c determines the discharge state of the nozzle 21 from the discharge amount calculated by the discharge amount calculating section 62b. For example, a nozzle 21a depicted in
In this normal discharge nozzle 21a, a liquid droplet of which liquid amount is in accordance with the driving pattern of the actuator 30 is discharged every time the discharging operation is performed. For example, in the discharging operation of the intermediate droplet driving pattern, the intermediate droplet of the predetermined liquid amount is discharged from the normal discharge nozzle 21a. Accordingly, the second predetermined amount is determined or defined by the liquid amount in accordance with the driving pattern and the number of times of the discharging operation.
Further, for example, in a nozzle 21b depicted in
In this unsatisfactory discharge nozzle 21b, a liquid droplet of which liquid amount is smaller than the liquid amount in accordance with the driving pattern of the actuator 30 is discharged. For example, even in a case that the actuator 30 is caused to perform the discharging operation of the intermediate droplet driving pattern, the liquid amount of the liquid discharged from the unsatisfactory discharge nozzle 21b is smaller than the predetermined amount of the intermediate droplet. Accordingly, the first predetermined amount is determined to be smaller than the second predetermined amount and to be greater than 0 (zero).
Furthermore, in a nozzle 21c depicted in
With respect to such non-discharge nozzle 21c and unsatisfactory discharge nozzle 21b, the maintenance section 62c performs a recovery processing (maintenance step). The recovery processing includes flushing, and purge which is performed in a case that the nozzle(s) is/are not recovered by the flushing.
In the recovery processing by the flushing, the maintenance section 62c causes the actuators 30 to perform a flushing in which the volume of the pressure chamber 22b is changed so that the liquid is discharged from the non-discharge nozzle 21c and the unsatisfactory discharge nozzle 21b, whereas the maintenance section 62c does not cause the actuator 30, which corresponds to the normal discharge nozzle 21a, to perform the flushing.
The liquid amount (flushing amount) of the liquid to be discharged by the flushing may be predetermined. Namely, in one time of the flushing, one time or a plurality of times (for example, several hundreds of times) of the discharging operation is/are performed by the actuator 30. Here, the actuator 30 is driven by any one of the predetermined patterns which are: the small droplet driving pattern, the intermediate droplet driving pattern and the large droplet driving pattern.
Further, the discharging system of the flushing is at least one of the push-strike system (push-strike method) and the pull-strike system (pull-strike method). In the flushing of the push-strike system, the actuator 30 is driven so that the volume of the pressure chamber 22b is reduced from the predetermined volume. In the flushing of pull-strike system, the actuator 30 is driven so that the volume of the pressure chamber 22b is increased from the predetermined volume and then reduced to be not more than the predetermined volume. In such a manner, accompanying with the reduction of the volume of the pressure chamber 22b, the pressure is applied to the liquid in the pressure chamber 22b and the liquid in the nozzle 21 communicating with the pressure chamber 22b.
According to the pull-strike system, even in a case that the liquid in the nozzle 21 is thicken (increased in the viscosity) due to the drying of the liquid, it is possible to pull the thicken liquid into the nozzle circulation route, by once increasing the volume of the pressure chamber 22b, so that the thicken liquid is dispersed and the viscosity is lowered. With this, it is possible to improve any non-discharge or unsatisfactory discharge due to the increase in the viscosity.
Further, according to the push-strike system, the volume of the pressure chamber 22b is not increased. Accordingly, it is possible to lower any breakage of the meniscus which would be otherwise caused due to any air bubbles entering into the nozzle 21, and to reduce any pulling of air bubble into the nozzle 21. Accordingly, it is possible to improve any non-discharge or unsatisfactory discharge of the liquid due to the air bubble.
Here, it is allowable that the discharging system in a case that the flushing is performed is one of the push-strike system and the pull-strike system, and that the discharging system before the flushing is the other of the push-strike system and the pull-strike system. Namely, the discharging system at the time of the flushing may be changed from that in the recording processing and that in the inspection processing before the flushing.
With this, for example, there is such a case that any thicken liquid or any foreign matter such as an air bubble, etc., which could not be removed by the discharging operation of the pull-strike system, can be removed by using the push-strike system which is different from the pull-strike system, in some cases. Further, similarly, there is such a case that any foreign matter which could not be removed by the discharging operation of the push strike system, can be removed by using the pull-strike system, in some cases.
In a case that the discharge state of the non-discharge nozzle 21c is not improved even with the flushing, the maintenance section 62b performs a purge for the discharge head 20 including the non-discharge nozzle 21c. When performing the purge, the maintenance section 62c controls a driving circuit 17e to drive the suction pump 17b, controls a driving circuit 17f to drive the atmosphere releasing valve 71c, and controls a driving circuit 17g to drive the ascending/descending mechanism 71d.
The maintenance section 62c drives the scanning motor 13b so as to move the discharge head 20 in the scanning direction so that the discharge surface 40a faces the cap 71a. In this state, the maintenance section 62c controls the ascending/descending mechanism 71d so as to move the cap 71a from the separate position to the contact position. With this, the cap 71a makes tight contact with the lower surface of the discharge head 20 to cover the nozzle holes 21h of the discharge surface 40a.
Further, the maintenance section 62c drives the suction pump 71b so as to lower the pressure in the inside of the cap 71a, thereby forcibly discharge (exhaust) the liquid from the nozzle holes 21h. By this purge, it is possible to discharge (exhaust) any foreign matter entered into the nozzles 21, the individual channels 22, etc., in the discharge head 20, and to recover the discharge state of the nozzles 21.
Due to such flushing and purge, any liquid remains in the discharge surface 40a, in some cases. In view of such a situation, the maintenance section 62c performs wipe, following the flushing and the purge. Here, the maintenance section 62c drives the scanning motor 13b so as to move the discharge head 20 in the scanning direction so that the discharge surface 40a faces the wiper 72a. Then, the maintenance section 62c controls the driving circuit 17h to drive the wipe motor 72b, thereby moving the wiper 72a along the nozzle arrays in a state that the wiper 72a makes contact with the discharge surface 40a. With this, the liquid on the discharge surface 40a is removed.
Further, in a case that the discharge state of the non-discharge nozzle 21c is not improved even with the purge, the maintenance section 62c sets a complementary nozzle 21 with respect to the non-discharge nozzle 21c. This complementary nozzle 21 is a nozzle 21 which is included in the plurality of nozzles 21, which is different from the non-discharge nozzle 21c, and which discharge the liquid of the same color as that discharged from the non-discharge nozzle 21c. The maintenance section 62c may sets the complementary nozzle 21 in accordance with the non-discharge nozzle 21c based on a predetermined corresponding relationship between the nozzles 21, or may set the complementary nozzle 21 based on the image data.
For example, in a case that the image processing section 62a generates the actuator controlling data based on the dot data, the image processing section 62a make a setting so as not to drive the non-discharge nozzle 21c. Then, the maintenance section 62c specifies, as the complementary nozzle 21, a nozzle 21 which is included in other nozzles 21 discharging the liquid of the same color as that discharged from the non-discharge nozzle 21c and which is capable of forming a dot of the liquid discharged from the non-discharge nozzle 21c, based on a color and a position of the dot data. Then, the image processing section 62a allocates the actuator controlling data for the non-discharge nozzle 21c to the complementary nozzle 21. With this, the dot is complemented by the liquid from the complementary nozzle 21, it is possible to suppress any lowering in the image quality which would be otherwise occurred due to any lack of the dot due to the non-discharge.
<Liquid Discharging Method>
The liquid discharging method according to the present embodiment is performed by the controlling section 62 executing a computer program for operating the liquid discharge apparatus 10, in accordance with a flow chart depicted in
The maintenance section 62c of the controlling section 62 causes the actuator 30 to perform a discharging operation for inspection (step S10). In this situation, the actuator 30 is driven continuously for a predetermined number of times, in the discharging system of the pull-strike system. In a case that the liquid is thereby discharged from a nozzle 21 corresponding to the actuator 30, the liquid detecting sensor 73 detects that the liquid has been discharged (liquid discharge), and outputs a detection signal to the discharge amount calculating section 62b.
The discharge amount calculating section 62b obtains the liquid amount, in accordance with the detection signal outputted from the liquid detecting sensor 73 within a predetermined period of time since the start of the driving of the actuator 30 for the inspection processing. The predetermined period of time is a time required for the discharging operation for inspection, and is a time required for the liquid to be discharged from the nozzle 21 in the case that the actuator 30 is driven continuously for the predetermined number of times.
The discharge amount calculating section 62b adds, for each of the nozzles 21, the discharged liquid amounts, and regards a total amount of the liquid amounts discharged within the predetermined period of time as a discharge amount (calculated amount) of each of the nozzles 21 (step S11). Then, the maintenance section 62c determines as to whether or not the discharge amount is not less than the first predetermined amount (step S12).
In step S12, in a case that the discharge amount is not less than the first predetermined amount (step S12: YES), then, the maintenance section 62c determines as to whether or not the discharge amount is not less than the second predetermined amount (step S13). The second predetermined amount is a value greater than the first predetermined amount.
In step S13, in a case that the discharge amount is not less than the second predetermined amount (step S13: YES), then the maintenance section 62c determines that the nozzle 21 is the normal discharge nozzle 21a. Accordingly, the maintenance section 62c ends the maintenance processing without performing the flushing for the normal discharge nozzle 21a.
On the other hand, in step S13, in a case that the discharge amount is in a range of not less than the first predetermined amount and less than the second predetermined amount (step S13: NO), the maintenance section 62c determines the nozzle 21 to be the unsatisfactory discharge nozzle 21b. In this case, there is a high possibility that the unsatisfactory discharge might be due to the increase in the viscosity, etc., the maintenance section 62c causes the actuator 30 to perform the flushing of the pull-strike system (step S14), and ends the maintenance processing.
In such a manner, the flushing is not performed with respect to the normal discharge nozzle 21a, but performed with respect to the unsatisfactory discharge nozzle 21b. Accordingly, since the liquid is not discharged wastefully from the normal discharge nozzle 21, it is possible to reduce any wasteful consumption of the liquid.
In step S12, in a case that the discharge amount is less than the first predetermined amount (step S12: NO), the maintenance section 62c determines the nozzle 21 to be the non-discharge nozzle 21c. In this case, there is a high possibility that the non-discharge might be due to the air bubble, etc., the maintenance section 62c causes the actuator 30 corresponding to the non-discharge nozzle 21c to perform the flushing of the push-strike system (step S15).
In such a manner, since the flushing is not performed with respect to the normal discharge nozzle 21a, but performed with respect to the non-discharge nozzle 21c, it is possible to reduce any wasteful consumption of the liquid. Further, with respect to the non-discharge nozzle 21c of which discharge state is quite unsatisfactory, the discharging system is changed from the discharging system for the inspection processing, thereby making it possible to easily improve the discharge state. Further, by the discharging system of the push-strike system, it is possible to lower the occurrence of the breakage of meniscus which would be otherwise caused by the air bubble.
Next, in order to confirm the change in the discharge state brought about by the flushing as described above, the maintenance section 62c causes the actuator 30 corresponding to the non-discharge nozzle 21c to perform the discharging operation for the inspection (step S16). With this, in a case that the liquid is discharged from the non-discharge nozzle 21c, the liquid detecting sensor 73 detects the discharged liquid, and the discharge amount calculating section 62b calculates a discharge amount (calculated amount) of each of the nozzles 21c in accordance with the detection signal from the liquid detecting sensor 73 (step S17). Then, the maintenance section 62c determines as to whether or not the discharge amount is not less than the first predetermined amount (step S18).
In step S18, in a case that the discharge amount is not less than the first predetermined amount (step S18: YES), the non-discharge nozzle 21c is improved by the flushing. Accordingly, the maintenance section 62c subsequently determines as to whether or not the discharge amount is not less than the second predetermined amount (step S13). The processings of step S13 and step S14, respectively, are similar to those described above.
On the other hand, in step S18, in a case that the discharge amount of the non-discharge nozzle 21c is less than the first predetermined amount (step S18: NO), the non-discharge nozzle 21c is not improved by the flushing. Accordingly, the maintenance section 62c further causes the purge mechanism 71 to perform the purge for the discharge head 20 (step S19).
Next, in order to confirm the change in the discharge state brought about by the purge as described above, the maintenance section 62c causes the actuator 30 corresponding to the non-discharge nozzle 21c to perform the discharging operation for the inspection (step S20). With this, in a case that the liquid is discharged from the non-discharge nozzle 21c, the discharge amount calculating section 62b calculates a discharge amount (calculated amount) of each of the nozzles 21c in accordance with the detection signals from the liquid detecting sensor 73 (step S21).
Then, the maintenance section 62c determines as to whether or not the discharge amount of the non-discharge nozzle 21c is not less than the first predetermined amount (step S22). In this situation, in a case that the discharge amount of the non-discharge nozzle 21c is not less than the first predetermined amount (step S22: YES), then the maintenance section 62c determines that the non-discharge nozzle 21c is improved by the purge, and ends the maintenance.
On the other hand, in a case that the discharge amount of the non-discharge nozzle 21c is less than the first predetermined amount (step S22: NO), then the maintenance section 62c determines that the discharge state of the non-discharge nozzle 21c is hard to be improved, and sets a complementary nozzle 21 which complements the non-discharge nozzle 21c (step S23). With this, it is possible to prevent any lacking of the dot due to the non-discharge, and to suppress any lowering in the image quality.
Note that in the flow chart of
Further, in the flow chart of
<First Modification>
In a liquid discharge apparatus 10 according to a first modification, it is allowable that the maintenance section 62c drives the actuator 30, in a case that the flushing is performed, so that the liquid is discharged from the unsatisfactory discharge nozzle 21b, in an amount (liquid amount) according to the discharge amount (calculated amount) of the nozzle 21 calculated in step S11.
A liquid discharging method according to the first modification is, for example, performed by the controlling section 62 executing a computer program for operating the liquid discharge apparatus 10, in accordance with a flow chart depicted in
In step S13, in a case that the discharge amount (calculated amount) of the nozzle 21 is in a range of not less than the first predetermined amount and less than the second predetermined amount (step S13: NO), the maintenance section 62c calculates a flushing amount according to the discharge amount of the unsatisfactory discharge nozzle 21 (step S30). Note that the discharge amount and the flushing amount are correlated to or are made to correspond to each other in advance as the relationship therebetween, and the relationship is stored in the ROM, etc.
Namely, the liquid amount (flushing amount) to be discharged from a certain nozzle 21 by the flushing corresponds to the volume change amount, of a certain pressure chamber 22b, to be changed in the flushing by a certain actuator 30 corresponding to the certain nozzle 21. The volume change amount is adjusted by at least one of a number of times of driving of the actuator 30 and a driving pattern of the actuator 30 in the flushing. Accordingly, as the discharge amount is smaller, the discharge state is more unsatisfactory, and thus the maintenance section 62c increases the number of times of driving of the actuator 30 to thereby increase the flushing amount.
Further, the driving pattern of the actuator 30 depends on the volume change amount of the pressure chamber 22b by the actuator 30. The volume change amount becomes greater in an ascending order of the small droplet driving pattern, the intermediate droplet driving pattern and the large droplet driving pattern. Accordingly, as the discharge amount of the unsatisfactory discharge nozzle 21b is smaller, the driving pattern is selected so that the volume change amount becomes greater, and thus making the flushing amount to be greater.
With this, the flushing amount and the liquid amount to be discharged by the flushing are adjusted based on a degree of unsatisfactory discharge. Accordingly, it is possible to improve the unsatisfactory discharge while lowering any wasteful consumption of the liquid.
In a liquid discharge apparatus 10 according to a second embodiment of the present disclosure, the discharge amount calculating section 62b calculates amounts of the liquid discharged, by the flushing, from the non-discharge nozzle 21c and the unsatisfactory discharge nozzle 21b, respectively. Other than this, the configuration, action and effects, etc., of the liquid discharge apparatus 10 according to the second embodiment are same as or similar to those of the first embodiment, and thus, any explanation therefor will be omitted.
A liquid discharge method according to the second embodiment is performed, for example, by the controlling section 62 executing a computer program for operating the liquid discharge apparatus 10, in accordance with a flow chart depicted in
With respect to the non-discharge nozzle 21c of which discharge amount is less than the first predetermined amount, the maintenance section 62c causes the actuator 30 to perform the flushing of the push-strike system (step S15). In this flushing, the discharging operation is performed by the actuator 30 for a several hundreds of times. With this, in a case that the liquid is discharged from the non-discharge nozzle 21c, the liquid is detected by the liquid detecting sensor 73, and the discharge amount calculating section 62b calculates a discharge amount (calculated amount) of each of the nozzles 21c in accordance with the detection signal from the liquid detecting sensor 73 (step S17). Note that it is allowable that the liquid amount in all the discharging operations in the flushing in step S15 is made to be the discharge amount, or that the liquid amount in a part of the discharging operations is made to be the discharge amount.
According to this manner, the liquid discharged from the non-discharge nozzle 21c in the flushing can be used for the detection performed by the discharge detecting section 73b. Accordingly, it is not necessary to discharge the liquid separately for the purpose of the detection, and to lower any wasteful consumption of the liquid.
In a similar manner, the maintenance section 62c causes the actuator 30 to perform the flushing of the pull-strike system with respect to the unsatisfactory discharge nozzle 21b of which discharge amount is less than the second predetermined amount (step S14). In this flushing, several hundreds of times of the flushing are performed by the actuator 30. With this, in a case that the liquid is discharged from the unsatisfactory discharge nozzle 21b, the liquid is detected by the liquid detecting sensor 73, and the discharge amount calculating section 62b calculates a discharge amount (calculated amount) of each of the nozzles 21b in accordance with the detection signal from the liquid detecting sensor 73. In a case that the calculated amount is less than the second predetermined amount, the maintenance section 62c executes step S14 again.
In all the embodiments described above, although the pull-strike system is used for the discharging system of the discharging operation for inspection, it is allowable to use the push-strike system. With this, since the discharging system of the flushing with respect to the unsatisfactory discharge nozzle 21b is made to be different from that in the discharging operation for inspection, it is possible to easily improve the discharge state of the unsatisfactory discharge nozzle 21b. Further, in this situation, it is also allowable to change the discharging system of the flushing with respect to the non-discharge nozzle 21c to the pull-strike system.
In all the embodiments described above, the suction purge is used, as the purge, in which the liquid is sucked and is forcibly discharged from the nozzle holes 21h. Note that, however, the purge is not limited to this, and may be a pressurized purge in which the liquid is pressurized and is forcibly discharged from the nozzle holes 21h. In such a case, for example, the pumps 14e, 14f, which are provided on the sub tank 14b, the supply channel 14c or the return channel 14d apply the pressure to the plurality of nozzles 21 communicating with the manifolds 23 and 24, thereby causing the liquid to be discharged from the plurality of nozzles 21.
In all the embodiments described above, although the return manifold 24 is included in the liquid channel, it is allowable that the return manifold 24 is not included in the liquid channel. In such a case, the supply manifold 23 is provided with the supply port 23a and the return port 24a on both ends, respectively, in the conveyance direction of the supply manifold 23, and each of the individual channels 11 does not have the return-side throttle channel 22d.
Accordingly, the liquid flows from the sub tank 14b via the supply channel 14c and inflows into the supply manifold 23 via the supply port 23a, and branches into the plurality of individual channels 22 while flowing through the supply manifold 23. In each of the individual channels 22, the liquid flows in the supply-side throttle channel 22a, the pressure chamber 22b and the descender 22c in this order, and inflows into the nozzle 21. Further, the liquid which has not flowed into the plurality of individual channels 22 from the supply manifold 23 is discharged (exhausted) from the supply manifold 23 via the return port 24a, flows through the return channel 14d and returns to the sub tank 14b.
In all the embodiments described above, the total amount obtained by totaling the predetermined number of times of the liquid amount (detected amount) detected by the liquid detecting sensor 73 is made to be the discharge amount (calculated amount) of the nozzle 21. In contrast, it is also allowable to plot the detection amounts of the liquid detecting sensor 73 with respect to the time, and to determine the discharge state of the nozzle 21 based on the inclination of the plotted detection amounts. With this, in a case that the discharge state of the nozzle 21 is improved by the discharging operation by the actuator 30, the detection amount (inclination) with respect to the time becomes great (greater). Also based on such a change in the inclination, it is possible to determine the discharge state of the nozzle 21.
Note that all the embodiments as described above may be combined with each other, unless the embodiments are mutually exclusive. For example, it is allowable to further perform the liquid droplet converting processing (flushing amount changing processing) of the first modification in the liquid discharge apparatus 10 of the second embodiment.
Further, a large number of improvements and/or other embodiments of the present disclosure would be apparent, from the above-described explanation, to a person skilled in the art. Accordingly, the above-described explanation should be interpreted as merely exemplary, and as being provided for the purpose of providing, to the person skilled in the art, the best mode for carrying out the present invention. It is possible to substantially change the details of the configurations and/or the functions described above, without departing from the gist and scope of the present invention.
The present disclosure is applicable to the liquid discharge apparatus, the liquid discharge method and the medium storing the program executable by the liquid discharging apparatus which are capable of lowering any wasteful consumption of the liquid.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2019-142023 | Aug 2019 | JP | national |
