Patent Application
20060033768
1. Field of the Invention
The present invention generally relates to a liquid jetting device and a drive voltage correction method for individual drop, and more particularly to a liquid jetting device and a drive voltage correction method used for an ink jet printer to set uniform droplet from all nozzles, a manufacturing apparatus coating a liquid material, and the like.
2. Description of the Related Art
An ink jet printer is generally known as an image recording apparatus recording an image on a recording medium such as paper. A liquid jetting device for jetting ink is installed in an ink jet printer, and the liquid jetting device is equipped with a recording head to jet the ink from a plurality of nozzles, and a drive circuit to drive the recording head.
The recording head is equipped with a jetting energy generating element to each nozzle for jetting ink from each of the plurality of nozzles. As the jetting energy generating element, a heater element generating air bubbles by heat to jet the ink by the pressure of the generated air bubbles, an actuator jetting the ink by deforming to apply a pressure to the ink, and the like are known. Hereinafter, the actuator is exemplified to be described as the jetting energy generating element.
The actuator as the jetting energy generating element is connected to the drive circuit, and is configured to expand and shrink based on a drive signal inputted from the drive circuit for jetting the ink droplet from a nozzle. By the way, even if a drive signal of the same voltage value is applied to each nozzle, the deformation speeds and the deformation rates of the actuators are fluctuated owing to the individual differences of the nozzles, and the fluctuation has been an adverse effect of high-definition image recording as a result. There has been the same adverse effect also in the recording head adopting the heater element as the jetting energy generating element.
For settling the problem, in recent years, a liquid jetting device configured to measure a jetting speed and a jetting quantity to correct the fluctuation among them through drive voltage control based on the measured values has been developed (see, for example, JP-Tokukaihei-7-256884A and JP-Tokukai-2004-90621A). For example, the liquid jetting device (an ink jet printer) described in JP-Tokukaihei-7-256884A is provided with a jetting speed measuring device measuring the jetting speed of the ink droplet from the nozzle, and is configured to correct the voltage value of the drive signal by getting the feedback of a measured value of the jetting speed measuring device. On the other hand, the liquid jetting device described in JP-Tokukai-2004-90621A is provided with a jetting quantity measuring device measuring a jetted ink quantity, and is configured to correct the voltage value of a drive signal by multiplying a measured value of the jetting quantity measuring device by a correction coefficient to converge the measured value.
Here,
Moreover, because there is the fluctuation between nozzles mentioned above also in the jetting quantity similarly in the jetting speed, there is the possibility that a value of a small frequency is used for a correction even in the case where a measured value is multiplied by a correction coefficient as in the liquid jetting device of JP-Tokukai-2004-90621A, and there has been a problem of the accuracy of a correction. In particular, in the case where a singular value of a small frequency is used for a correction, the convergence of values takes a long time and further there is a possibility of diverging without converging even if the multiplication of the correction coefficient is performed.
It is an object of the present invention to achieve the improvement of image quality by heightening the accuracy of a drive voltage correction.
It is a further object of the present invention to correct drop property variation with an improved correction method.
To solve the above problem, in accordance of the first aspect of the present invention, the liquid jetting device, comprises:
In accordance of the second aspect of the present invention, the drive voltage correction method, comprises:
In accordance of the third aspect of the present invention, the liquid jetting device, comprises:
In accordance of the fourth aspect of the present invention, the drive voltage correction method, comprises:
The present invention will become more fully understood from the detailed description given hereinafter and the accompanying drawings which are given by way of illustration only, and thus are not intended as a definition of the limits of the present invention, and wherein;
In
The conveyance mechanism comprises, for example, a conveyance motor, conveyance rollers and the like, which are not shown, and is configured to convey the recording medium by rotating the conveyance rollers by the drive of the conveyance motor. The conveyance mechanism is configured to convey the recording medium intermittently by repeating the conveyance and the stop of the recording medium with the operation of a carriage 5, which will be described later, at the time of image recording.
Above the platen 4, a guide member 6 extending in the lateral direction in the inside of the printer main body 2 is provide in a prescribed location as shown in
Moreover, a maintenance unit 7 for maintaining a plurality of recording heads 20 mounted on the carriage 5 is provided on the right side of the platen 4 in the scanning direction A. The maintenance unit 7 is provided on the lower side of the carriage 5 in the moving range of the carriage 5.
Moreover, on the left side of the platen 4 in the scanning direction A, a plurality of ink tanks 8 storing ink are provided in a prescribed location.
A liquid jetting device 30 for jetting ink (liquid) to a recording medium is provided in the ink jet printer 1 as shown in
As shown in
In the actuators 22, a plurality of parallel liquid flow path grooves 221 guiding ink to each of the plurality of nozzles 21 is formed. Furthermore, a no-liquid groove 222, which is parallel to the liquid flow path grooves 221, and in which any ink does not flow, is formed between each liquid flow path groove 221 in the actuators 22. Then, electrodes 223 connected to the drive circuit 25 are provided on the inner side surfaces of the liquid flow path grooves 221 and the no-liquid grooves 222. When a drive signal generated by the drive circuit 25 is supplied to the electrodes 223, the electrodes 223 apply a voltage based on the drive signal to an actuator 22. Therefore, the actuator 22 is configured to deform according to the voltage. The actuator 22 deforms so as to perform shearing deformation with a change of the voltage, and a liquid flow path groove 221 is made to be expanded and shrunk by the deformation. Because the inside of the liquid flow path groove 221 becomes a negative pressure at the time of an expand, ink is led into the liquid flow path groove 221. Because the inside of the liquid flow path groove 221 becomes a positive pressure at the time of a shrinkage, the ink in the liquid flow path groove 221 is jetted from the nozzle 21. In
As shown in
The control unit 50 is configured to create and output control signals to the drive circuit 25, the drive signal adjustment circuit 26 and the voltage control unit 53 based on a detection result of the liquid detection sensor 40. Moreover, the conveyance mechanism conveying a recording medium, the drive mechanism scanning the carriage 5, and the like are connected to the control unit 50.
The drive signal adjustment circuit 26 is configured to acquire the waveform of the drive signal for driving the actuator 22 based on a control signal from the control unit 50, and to create an adjustment signal based on the waveform to output the adjustment signal.
On the other hand, the voltage control unit 53 is connected with the control unit 50, and determines a voltage value based on the control signal from the control unit 50. The voltage control unit 53 is provided with a D/A converter 531 converting the control signal from the control unit 50 into an analog signal, and a plurality of amplifiers 532 for amplifying the analog signal from the D/A converter 531 to a predetermined voltage value so as to correspond to each nozzle 21. An offsetting power source 27 supplying offsetting electric power and the D/A converter 531 are connected to the input terminals of the amplifiers 532.
Then, the drive circuit 25 is provided with a drive signal output unit 54 for synthesizing the drive signals from the waveform creating unit 52 and the voltage values from the voltage control unit 53 to generate a drive signal of an independent waveform to each nozzle 21. The drive signal output unit 54 is provided with a plurality of FET elements 541. To the input terminal of each of the FET elements 541, an output terminal of an AND element 521 of the waveform creating unit 52 and an output terminal of an amplifier 532 of the voltage control unit 53 are severally connected. To the output terminal of each of the FET elements 541, the electrode 223 of the actuator 22 is connected. Thereby, the FET element 541 is configured to synthesize the drive signal from the waveform creating unit 52 and the voltage value from the voltage control unit 53 to every nozzle 21, and to output the synthesized signal to the electrode 223 of the actuator 22.
The control unit 50 controls the drive circuit 25 and the voltage control unit 53 to output at least two or more drive signals of different voltage values to the actuator 22, and makes the nozzle 21 to be corrected jet a plurality of ink droplets at the time of a correction of the drive voltage. At this time, the liquid detection sensor 40 detects the jetting speeds of the plurality of ink droplets jetted from the nozzle 21, and outputs the detection result to the control unit 50. The control unit 50 calculates a voltage correction coefficient α used for the correction calculation of the drive voltage based on the detection result from the liquid detection sensor 40. For example, in the case where the actuator 22 is driven by two drive signals of different voltage values and two ink droplets are jetted, and when it is supposed that the jetting speed of a first ink droplet is denoted by Ve1 and a first voltage value is dented by VO1, and that the jetting speed of a second ink droplet is denoted by Ve2 and a second voltage value is denoted by VO2, the voltage correction coefficient α is expressed as “α=(VO1−VO2)/(Ve1−Ve2).
The correction operation of the control unit 50 is next described concretely using a drive voltage-jetting speed diagram of
Then, the control unit 50 controls the drive circuit 25 and the voltage control unit 53 to make them output a drive signal of a predetermined voltage value to the actuator 22, and then makes the nozzle 21 jet one ink droplet. At this time, the control unit 50 calculates a difference voltage value (correction data) ΔV to a target value from a jetting speed Ver of the ink droplet detected by the liquid detection sensor 40, a voltage value V0p at the time of the jetting, a target value Veg of the jetting speed, and the voltage correction coefficient α. The difference voltage value ΔV is expressed by “ΔV=(Veg−Ver)×α.” Then, in order to make it easy to converge the jetting speed to the target speed Veg of the jetting speed, the control unit 50 multiplies the difference voltage value ΔV by a convergence coefficient β, which is set within a range of from 0.50 or more to less than 1.00. Then, the control unit 50 adds the multiplied value to a voltage value V0p at the jetting to calculate a correction voltage value V0r. That is, the control unit 50 calculates the correction voltage value V0r as follows: “V0r=V0p+ΔV×V0p+(Veg−Ver)×α×β.”
After that, the control unit 50 controls the drive circuit 25 and the voltage control unit 53 to make them output the drive signal of a correction voltage value V0r to the actuator 22, and makes the nozzle 21 jet one ink droplet. At this time, when the jetting speed of the ink droplet detected by the liquid detection sensor 40 is within a predetermined allowable error range from the target value, the control unit 50 completes the correction of the drive voltage. When the jetting speed of the ink droplet is out of the allowable error range from the target value, the control unit 50 calculates the difference voltage value ΔV and the correction voltage value V0r by setting the voltage value and the jetting speed at the nearest preceding time of ink jetting as the voltage value V0p and the jetting speed Ver, respectively, and the control unit 50 again makes the nozzle 21 jet one ink droplet by means of the obtained correction voltage value V0r. If these processes are repeated, because the correction voltage value V0r before attaining the target value is reflected in subsequent processes, the jetting speed gradually approaches the target value, and finally enters within the allowable error range. Thus, the corrected drive voltage value is determined.
Next, the image recording and the drive voltage correction method which are performed in the ink jet printer 1 are described.
When the image recording is started, the control unit 50 controls the conveyance mechanism to convey a recording media intermittently. At the intermittent conveyance time, the control unit 50 controls the drive mechanism and the drive circuit 25 to scan the carriage 5 while making the recording heads 20 jet ink to the recording medium with the timing of the stops of the recording medium. By repeating the operation, an image is recorded on the recording medium.
Next, at the time of the correction of the drive voltages, the control unit 50 controls the drive mechanism to make the drive mechanism move the carriage 5 onto the maintenance unit 7, and then the control unit 50 starts the correction processing of the drive voltages.
At Step S2, the control unit 50 calculates a voltage correction coefficient α based on the detection results of the plurality of jetted ink droplets from the liquid detection sensor 40.
At Step S3, the control unit 50 makes the nozzle 21 jet one ink droplet, and the control unit 50 calculates a difference voltage (correction data) ΔV to a target value and a correction voltage value V0r based on the jetting speed Ver of the ink droplet detected by the liquid detection sensor 40, the voltage value V0p at the time of the jetting, the target value Veg of the jetting speed, and the voltage correction coefficient α.
At Step S4, the control unit 50 makes the drive signal of the correction voltage value V0r be outputted to the actuator 22, and makes the nozzle 21 jet one ink droplet. At this time, when the jetting speed of the ink droplet detected by the liquid detection sensor 40 is out of the predetermined allowable error range from the target value, the processing of the control unit 50 shifts to Step S3. When the jetting speed of the ink droplet is within the predetermined allowable error range, the processing of the control unit 50 shifts to Step S5.
When the processing of the control unit 50 has shifted from Step S4 to Step S3, the control unit 50 calculates the difference voltage value (correction data) ΔV and the correction voltage value V0r by setting the voltage value and the jetting speed at the time of ink jetting at Step S4 as the voltage value V0p and the jetting speed Ver. That is, the correction voltage value V0r before attaining the target value is reflected in the subsequent processes. Consequently, if the Steps S3-S4 are repeated, the jetting speed gradually approaches the target value, and finally is within the allowable error range. Thus, the corrected drive voltage value is determined.
At Step S5, the control unit 50 judges whether the correction of the drive voltage has been performed to all the nozzles 21 of the recording heads 20 or not. When the correction of the drive voltage has not been performed to all the nozzles 21, the processing of the control unit 50 shifts to Step S6.
At Step S6, a nozzle 21 other than the nozzles 21 which have become the correction objects until now is selected, and the processing of the control unit 50 shifts to Step S1.
When the control unit 50 judges that the correction of the drive voltage has been performed to all the nozzles 21 at Step S5, the control unit 50 ends the correction processing of the drive voltages.
In the drive voltage correction method described above, the detection of the jetting speed by the liquid detection sensor 40 may be performed to the nozzle 21 to be corrected by jetting ink from all the nozzles 21 including the nozzles 21 which are not the correction objects in addition to the nozzle 21 to be corrected. Moreover, the nozzle 21 to be corrected may be plural.
Thus, droplet speed from individual nozzle can be controlled through independently corrected pulse. Then, a droplet placement error becomes minimum.
As described above, according to the liquid jetting device 30 of the present embodiment, the voltage value of the drive signal is corrected based on the correction value obtained by multiplying the difference voltage value as the correction data of the present invention by the convergence coefficient within a range of from 0.5 or more to less than 1.00, and adding the multiplied difference voltage value to the drive voltage value at the time of measuring the jetting speed of the ink droplet. Consequently, even when the correction voltage value becomes likely to diverge to the target value, the correction voltage value converges on the target value. Thereby, even if the correction voltage value has been created based on a singular value, the accuracy of the drive voltage correction can be improved, and as a result the image quality can be improved.
Here, as mentioned above, the convergence coefficient is set within a range of from 0.50 or more to less than 1.00. However, the number of trial repetitions at the time of the drive voltage correction processing is preferably smaller because the processing time can be shortened. Accordingly, the inventors of the present invention performed experiments to acquire the optimum convergence coefficient. In the experiments hereupon, the ink jet printer 1 described above was used. The target value of the jetting speed was set to 4 m/s, and the allowable error range was set to ±0.5%. The drive voltage correction processing was performed by changing the convergence coefficient at nine steps of 1.00, 0.99, 0.98, 0.95, 0.90, 0.80, 0.70, 0.50 and 0.40.
Based on these facts, the inventors of the present invention performed various experiments, and found that it is possible to decrease the number of times of corrections until the jetting speed becomes the target value when the convergence coefficient is 0.99 or less. That is, as long as the convergence coefficient is 0.99 or less, the number of times of correction can be reduced, and it becomes possible to shorten the time necessary for the correction.
Moreover, the inventors of the present invention found that the number of times of correction until the jetting speed becomes the target value can be reduced furthermore when the convergence coefficient is 0.70 or more. That is, when the convergence coefficient is 0.70 or more, the number of times of correction can be reduced, and it becomes possible to shorten the time necessary for the correction.
Furthermore, the inventors of the present invention found that the number of times of correction until the jetting speed becomes the target value can be reduced furthermore when the convergence coefficient is 0.98 or less. That is, when the convergence coefficient is 0.98 or less, the number of times of correction can be reduced, and it becomes possible to shorten the time necessary for the correction furthermore.
Moreover, because the correction data is created from the jetting characteristic values of the liquid jetted a plurality of times, values displaced to the + side from a reference value and values displaced to the − side from the reference value are included in the plurality of times of the jettings, and the displaced values are canceled at the time of the creation of correction data. Thereby, the reliability of the correction data is heightened and the divergence from a target value at the time of correction can be prevented.
Then, it is desirable to create the correction data based on the mean value of the jetting characteristic values of the liquid jetted a plurality of times detected by the liquid detection sensor 40. Thus, if correction data is created based on the mean value of a plurality of jetting characteristic values acquired by a plurality of times of liquid jetting, the correction data can be prevented from being created based on a singular value, and the accuracy of the correction data can be improved.
Although one ink droplet is made to be jetted from the nozzle 21 at the time of measuring the jetting speed of the ink droplet by the liquid detection sensor 40 in the present embodiment, a plurality of ink droplets may be made to be jetted and one of the ink droplets may be measured.
As shown in
At Step S12, the control unit 50 calculates the voltage correction coefficient α used for the correction calculation of the drive voltages based on the detection result from the liquid detection sensor 40.
At Step S13, the control unit 50 controls the drive circuit 25 and the voltage control unit 53 to make them output the drive signal of a predetermined voltage value to the actuator 22, and to make the nozzle 21 jet an ink droplet a plurality of times (n1 times). At this time, the control unit 50 calculates the difference voltage value (correction data) ΔV to the target value and the correction voltage value V0r based on a mean jetting speed VeA of the ink droplets for n1 times detected by the liquid detection sensor 40, the voltage value V0p at the time of the jetting, the target value Veg of the jetting speed, and the voltage correction coefficient α. The difference voltage value ΔV can be expressed by “ΔV=(Veg−Ver)×α”, and the correction voltage value V0r can be expressed by “V0r=V0p+ΔV=V0p+(Veg−Ver)×α.”
At Step S14, the control unit 50 controls the drive circuit 25 and the voltage control unit 53 to make them output the drive signal of the correction voltage value V0r to the actuator 22, and to make the nozzle 21 jet one ink droplet n2 times. At this time, when the mean jetting speed of the ink droplets for n2 times detected by the liquid detection sensor 40 is out of the predetermined allowable error range from the target value, the processing of the control unit 50 shifts to Step S13. When the mean jetting speed of the ink droplets is within the predetermined allowable error range, the processing of the control unit 50 shifts to Step S15.
When the processing of the control unit 50 has shifted from Step S14 to Step S13, the control unit 50 calculates the difference voltage value (correction data) ΔV and the correction voltage value V0r by setting the voltage value and the jetting speed at the time of ink jetting at Step S14 as the voltage value V0p and the jetting speed Ver. That is, the correction voltage value V0r before attaining the target value is reflected in the subsequent processes. Consequently, if the Steps S3-S4 are repeated, the jetting speed gradually approaches the target value, and finally is within the allowable error range. Thus, the corrected drive voltage value is determined.
At Step S15, the control unit 50 judges whether the correction of the drive voltage has been performed to all the nozzles 21 of the recording heads 20 or not. When the correction of the drive voltage has not been performed to all the nozzles 21, the processing of the control unit 50 shifts to Step S16.
At Step S16, a nozzle 21 other than the nozzles 21 which have become the correction objects until now is selected, and the processing of the control unit 50 shifts to Step S11.
When the control unit 50 judges that the correction of the drive voltage has been performed to all the nozzles 21 at Step S15, the control unit 50 ends the correction processing of the drive voltages.
As described above, according to the liquid jetting device of the second embodiment, because the correction voltage value as the correction data of the present invention is created based on the jetting speeds of the ink jetted at a plurality of times, values displaced to the + side from a reference value and values displaced to the − side from the reference value are included in the plurality of times of the jettings, and the displaced values are canceled at the time of the creation of the correction voltage values. Thereby, because the reliability of the correction voltage value is heightened, it becomes possible to improve the accuracy of the drive voltage correction in comparison with the case where the jetting speed of the once jetted liquid is fed back to correct the voltage value, and consequently it becomes possible to improve the image quality.
Although the ink droplet is jetted a plurality of times only at the time of the ink jetting at Steps S13 and S14, and the correction voltage value is calculated based on the mean jetting speed of the ink droplets or it is judged whether the mean jetting speed is within the allowable error range or not in the second embodiment, if an ink droplet is made to be jetted a plurality of times (n3 times) and the voltage correction coefficient is calculated from the mean jetting speed of the ink droplets also at Step S12, the accuracy of the voltage correction coefficient itself also can be improved.
Moreover, when the voltage correction coefficient is calculated, the jetting speeds of the ink droplets by three or more different drive voltages may be detected with the liquid detection sensor 40, and an approximate straight line of the relation of the detected jetting speeds and the drive voltages may be acquired by the least-square method or the like. Then, by adopting the inverse number of the inclination of the straight line as the voltage correction coefficient, the accuracy of the voltage correction coefficient can be improved.
Moreover, although a plurality of ink droplets (n ink droplets) are made to be jetted from the nozzle 21 and the jetting speeds of the n ink droplets are measured when the jetting speeds of the ink droplets are measured by the liquid detection sensor 40 in the second embodiment, m (m>n) ink droplets may be jetted and n ink droplets among the m ink droplets may be measured.
Here, when the inventors of the present invention applied a drive signal of a predetermined voltage value to the actuator 22 to make a single nozzle 21 jet liquid many times and examined the fluctuation in the jetting speeds of the liquid, the histogram of the dispersion was a normal distribution in any nozzles 21 as the results. Thus, if the dispersion of the jetting speeds is the normal distribution, a value with high statistical reliability can be acquired even if the numbers of samples is 5 to 10 times. That is, when ink is jetted by a plurality of times (n1 times, n2 times or n3 times), it is preferable that the number of jetting times be set within a range of from five times to ten times both inclusive in any case. Even if the jetting speed is not the mean jetting speed of the ink droplets jetted by a plurality of times, a jetting speed of a median may be adopted.
Furthermore, although the correction voltage value acquired at Step S13 is made to be reflected in the subsequent processes in the second embodiment, the correction voltage value may be acquired by adding the difference voltage value, which is the correction data, multiplied by the convergence coefficient to the drive voltage value at the time of the measurement of the jetting speeds of the ink liquid droplets, and the acquired correction voltage value may be reflected to the subsequent processes similarly to the first embodiment also in the second embodiment. Thereby, even when the correction voltage value calculated based on the mean jetting speed is likely to diverge to the target value, it becomes possible to converge the correction voltage values to the target value.
It is needless to say that the present invention is not limited to the first and the second embodiments described above, but can be suitably modified.
For example, although the case where the jetting speed of ink is detected with the CCD camera 42 is exemplified to be described in the present embodiments, any aspects capable of detecting the jetting speed of ink may be adopted. In addition to the CCD camera 42, for example, a method of detecting the jetting speed by jetting ink to pass an emitted light ray from an LED light source and acquiring the time during which the emitted light ray is intermitted can be cited.
Furthermore, the case where the liquid detection sensor 40 detects the jetting speed of ink is exemplified to be described in the present embodiments. But, even if the liquid detection sensor detects the jetting quantity of ink, the size (cross-section area) of an ink droplet, the diameter of the ink droplet, or the like, it is possible to acquire the same operation, and the same effects as those of the drive voltage correction described above. Here, in a case of detecting the jetting quantity of ink, for example, a method of performing the image processing of extracting the areas of the ink droplet parts from an image photographed with the CCD camera 42 to calculate the capacity of the ink droplets from the obtained areas can be used. Moreover, the areas of the ink droplet parts acquired by the CCD camera 42 may be treated as the sizes of the droplets. Moreover, as for the sizes of the droplets, a method of performing the image processing of extracting the edges of the ink droplet parts of the image photographed with the CCD camera 42 to calculate the diameters of the edges can be used.
As mentioned above, although the case where the liquid jetting device and the drive voltage correction method according to the present invention are applied to the ink jet printer 1 is exemplified to be described, the liquid jetting device and the drive voltage correction method of the present invention can be also adopted in a manufacturing apparatus or the like which is used for coating an EL material of an organic EL display, coating a color filter material of a liquid crystal display panel, and the like.
The entire disclosure of Japanese Patent Application No. Tokugan 2004-235451 which was filed on Aug. 12, 2004 including specification, claims, drawings and summary is incorporated herein by reference in its entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2004-235451 | Aug 2004 | JP | national |
