Media advance accuracy is an important parameter for any type of printer. Media advance concerns the media moving over a predetermined distance and/or at a predetermined speed, with respect to a print head, to allow the print head to print subsequent strokes on the media, in a controlled manner. A lack of accuracy in media advance may result in non-aligned print drops or strokes, and defects such as banding or grain. Media advance accuracy is important for every print technology. Print technologies include, but are not limited to, inkjet and laser driven print systems.
To improve media advance accuracy, the media drives of printers are oftentimes calibrated. This reduces the amount of error in the media drive, and as a consequence the banding and grain may be reduced. Such media drive calibration can be carried out at different moments, for example at the factory site, at the end of the manufacturing process, during installation at the customer site, or during a service operation, for example when replacing a component such as a main roller or an encoder disc.
A common calibration method involves printing specially arranged lines and/or fiducial marks on the media. After printing, the media is taken out of the printer and scanned by an external scanning tool to allow automatic processing of the printed lines and/or marks. From these lines and/or marks, information about the media advances can be derived. Subsequently the media drive can be calibrated, based on this information, to compensate for the errors that were detected.
A similar calibration method involves printing lines and/or marks, then taking the media from the printer, and placing it onto a print platen in transverse direction.
Then the printed plot is scanned by a line sensor that is present in the print head carriage.
For the purpose of illustration, certain embodiments of the present invention will now be described with reference to the accompanying diagrammatic drawings, in which:
In the following detailed description, reference is made to the accompanying drawings. The embodiments in the description and drawings should be considered illustrative and are not to be considered as limiting to the specific embodiment of element described. Multiple embodiments may be derived from the following description and/or drawings through modification, combination or variation of certain elements. Furthermore, it may be understood that also embodiments or elements that are not literally disclosed may be derived from the description and drawings by a person skilled in the art.
In
The printer 1 may comprise rollers and/or axes 2, 3 for advancing media 4 through the printer 1. The printer 1 may comprise a media roll 2 and a drive roller 3. The printer 1 may comprise further rolls that may aid in advancing the media 4 but that are not shown in the drawing. The media roll 2 may be a consumable roll, adapted to unwind and be replaced within the printer 1. The drive roller 3 may be arranged to advance the media 4 from the media roll 2. The drive roller 3 may form part of, and be driven by, a media drive 5, in
The printer 1 may comprise a printhead 6. The printhead 6 may comprise any type of printhead, for example an inkjet printhead for printing a plurality of colors, amongst which Cyan, Magenta, Yellow and Black, or the like, and others. The printhead 6 may comprise a scanning printhead 6 arranged to scan across the width of the media 4. The media drive 5 may be arranged to advance the media 4 between each one or more scanning actions of the printhead 6. In another embodiment, the printhead 6 may comprise a page wide printhead. In again another embodiment, the printhead may comprise a transfer mechanism for liquid or dry toner, for example for a laser driven printer.
The printer 1 may comprise a media support 7. The media support 7 may support the media 4 near the printhead 6. The printer 1 may comprise a media surface detector 8, configured to detect media advances within the printer 1. The media surface detector 8 may be configured to detect a non-printed media material texture. The media surface detector 8 may comprise an optical detector embedded in the printer 1. The media surface detector 8 may comprise an optical media advance sensor. An embodiment of an optical media advance sensor 8 is explained below with reference to
The media surface detector 8 may be adapted to measure media advances. In this disclosure, a media advance may refer to a distance of a media movement. In an embodiment, the media advance may comprise a distance that is moved in one step to allow the media to be printed in swaths. In one embodiment, the media may move relatively continuously, wherein the media advance may comprise intermediate distances that the media is moved, or one full distance corresponding to a full print that the media is moved.
For scanning print heads 6, The media 4 may be printed when it is held relatively stationary between media advances. A media advance may require the media 4 to move a relatively precise and repeatable distance, for example by first accelerating, then moving at constant velocity, and then decelerating. In this disclosure, the media surface detector 8 may be used to calibrate the media drive 5 so that the media advance may be more accurate than before calibration.
The printer 1 may comprise a memory device 10, which may comprise a digital, non-volatile storage unit. The memory device 10 may store parameters that correspond to a certain media drive movement. The parameters may determine the motion of the media drive 5. The parameters may be configured to correspond to a certain effective diameter of the respective rollers 3. The parameters may be set at manufacturing. The parameters may be arranged in a table. The parameters may be configured to adjust the drive roller 3 frequency to compensate for irregularities in the radius of the roller 3. Typical parameters may correct a deviation in the radius of the roller 3, as well as an eccentricity of the roller 3.
In an embodiment of this disclosure, calibration of the media drive 5 may be achieved by calibrating the parameters stored in the memory device 10. The parameters may be configured to compensate for a single frequency cycle very turn, which may relate to a roller 3 having a certain eccentricity. The parameters may compensate for a couble frequency cycle at every turn of the roller 3, which may relate to a certain elliptical shape in the roller 3. The parameters may compensate for slip of the media 4 with respect to the roller 3. An embodiment of this disclosure relates to adapting the parameters by advancing and detecting media 4 within the printer 1.
The printer 1 may comprise a processor 11. The processor 11 may comprise a controller for controlling the media drive 5 in accordance with the parameters and/or a media drive algorithm. The processor 11 may comprise a digital signal processor (DSP) for processing the signals received from the media surface detector 8.
The processor 11 may further be configured to determine an error in a detected media advance, in accordance with the signals outputted by the media surface detector 8. The error in the media advance may comprise a difference between a measured media advance and a desired media advance. For example, a desired media advance may comprise approximately 44 millimeters, or for example a distance between 1 and 1000 millimeters. If an error in the media advances is determined by the processor 11, it may adapt at least one of the parameters stored in the memory device 10 so as to decrease the level of error, so that the measured media advance is closer to the desired media advance. The parameters may be adapted manually, automatically or semi-automatically. Since having a media advance error of zero is practically impossible, a certain media advance error may be allowed as long as it does not exceed certain predetermined threshold values. The memory device 10 may store such threshold values.
The printer 1 may comprise a media drive calibration system that is integrated with the printer 1. The media drive calibration system may comprise the media surface detector 8 and the memory device 10 storing said parameters and/or at least one comparison threshold value corresponding to respective parameters. The media drive calibration system may further comprise the processor 11 configured to, on the one hand, derive the media advance distance from the incoming detector signals, and, on the other hand, adapt a parameters when a detected media advance error corresponding to that parameter exceeds said at least one threshold value.
The media drive 5 may comprise an encoder 14, 15, for example such encoder 14, 15 may be connected to one or both of a motor output axis 16 and a drive roller axis 17. The encoder 14, 15 may allow determination of a certain angular position of a motor axis so as to allow a relatively precise control of that axis. The encoder 14, 15 may be provided with encoder units arranged along a full circle. In an embodiment, the encoder units may comprise markings, for example lines or points, that may be detectable by optical recognition. The encoder 14, 15 may comprise an optical sensor for recognizing the encoder units. The encoder may comprise a transparent disc. The encoder units may comprise markings arranged over 360 degrees of the transparent disc, wherein each encoder unit may correspond to a respective angle the respective axis, for example the drive axis 17. For example, the encoder may comprise more than 2000 encoder units evenly distributed over 360 degrees along the circumference of the disc. This may allow a relatively exact determination of the angular position of a roller or axis connected to the drive 5, for example the drive roller 3.
In an embodiment, a certain number of encoder units may correspond to a certain media advance. In an embodiment, the parameters may associate certain numbers of encoder units to a corresponding media advance. For example, a predetermined number of encoder units may correspond to a 180 degrees turn of a drive axis 17 and/or of the drive roller 3. Correspondingly, the 180 degrees movement of the drive roller 3 may result in a media advance of a certain number of centimeters, millimeters or micrometers, depending on the print swath settings. The drive roller 3 may be rotated over a predetermined angle, for example corresponding to 1000 encoder units, in accordance with the desired media advance.
In
The media surface detector 8 may comprise an optical assembly 18 and a printed circuit board 19. The optical assembly 18 may comprise a hardened glass window that may be in contact with the back side of the media 4 to establish focus. A light source such as light emitting diodes 20 may be provided to provide adjustable and/or uniform illumination. The optical assembly 18 may comprise a lens system 21 and/or an aperture plate 22, to project an image of the media surface texture onto an image sensor 23. A circuit may be provided to drive the LEDs in a flashing mode so as to be able to freeze the motion on the image sensor 23.
The media surface detector 8 may be connected to the processor 11 and the memory device 10. The media surface detector 8 may be connected to the digital signal processor (DSP). Further interface circuitry may be provided to aid in signal processing, and to connect the detector 8 in the printer 1.
An embodiment of a method of detecting media advances is shown in
In an embodiment, matching of regions A and B′ may be performed by optical correlation techniques. The matching may be performed with known pattern recognition techniques. In certain embodiments FFT correlation and/or least squares correlation may be applied.
For an embodiment having a distance AB of approximately 3.5 millimeters, about 13 captures may be processed for a media advance of approximately 44 millimeters. A total media advance error dXi may be calculated for a full media advance step. Also smaller or larger media advances may be detected for errors, for example in ranges of between 1 and 1000 millimeters, or between 10 and 100 millimeters. Also intermediary media advance errors may be calculated for a longer continuous movement, for example having a media advance of several centimeters, decimeters, or meters.
An embodiment of a method of calibrating a media drive 5 is shown in
The media surface detector 8 may detect the media advances that result from the movement of the drive roller 3, as indicated by block 610. The media surface detector 8 may detect the distance the media has advanced at each step. For example, each step may deviate between 0.001 and 0.05 millimeters from the desired media advance.
The processor 11 may apply a mathematical transformation to the incoming detected media advance signals, as indicated by block 620. The transformation may filter out irregularities such as residual errors in the incoming detected media advance signals, so that media advance errors that reoccur with certain regularity, for example at each drive roller rotation, may be distinguished. Such reoccurring errors may for example correspond to an eccentricity in a drive roller 3. The detected media advance signals may be filtered using any suitable mathematical transformation, for example a Fourier Transform or a Fast Fourier Transform.
After transforming, drive advance signals may be compared with the transformed detected media advance signals, in block 630. The drive advance signals correspond to the expected media advances. Discrepancies N between the drive advance signals and the media advance signals may be determined through said comparison. When the discrepancies N exceed a certain predetermined threshold X (block 640), the processor 11 may adapt the parameters for signaling the drive 5, as indicated by block 650, and store the altered parameters in the memory device 10. The processor 11 may adapt the parameters only for the drive advance signals that correspond to the determined discrepancy. Other parameters may remain in the memory device 10 without being adapted. Where the discrepancies do not exceed said threshold, the corresponding parameters may not be adapted, as indicated by 660. After the parameters were adapted so as to calibrate the drive 5, the calibrated drive 5 may be tested, as indicated by block 670, and as will be explained with reference to
The parameters may be configured so that each media advance may be associated with a predetermined angular rotation of the drive 5 in an optimized manner. The parameters may be configured so that each media advance is associated with a number of encoder units that correspond to said angular rotation. Accordingly, in a block 650, the parameters may be adjusted so as to also adapt the number of encoder units associated with the media advance containing the error.
In an embodiment, a menu may be presented, and an operator and/or service operator may select a calibration option from the menu wherein the media roll 2 is advanced and the calibration may be self executed, for example in accordance with the series of blocks 600-670. The calibration method may be executed without the use of external devices. No or little waste may be produced by the calibration method, because the media portion used for calibration is still clean afterwards, and can therefore be re-used for commercially printing.
After the calibration method the same media portion that was used for calibration may be printed with an image for delivering the printed product.
After the calibration method, as explained with reference to
To verify whether the calibration method has been successful using the mentioned test method, it may be sufficient to advance the media 4 over a relatively small distance, as compared to the advanced distance of the calibration method. For example, for the calibration method, the media 4 may be advanced over a distance that corresponds to at least approximately 3, or at least approximately 4, or at least approximately 5 rotations of the media drive 5. For the test method, it may be sufficient to advance the media over a distance corresponding to approximately 3 or less rotations, or approximately 2 or less rotations, or approximately 1 rotation or less of the media drive 5. In this way the test method will take significantly less time than the calibration method and may be executed relatively rapidly.
The remaining media advance error may for example be approximately 0.004 millimeter or less.
Embodiments of the printer 1 may have a drive roller 3 that is arranged before or after the printhead 6. Further rolls may be provided in the printer 1, before and after the support 7. The printer 1 may comprise a final drive roller and/or pinch wheels. In principle at least one detector 8 may be provided. The media advance calibration system and method may be configured to detect deviations in any of these rolls. Accordingly, one or more media surface detectors 8 may be arranged at one or multiple locations along the media path.
The method and system of this disclosure may prevent that media needs to be printed for calibration. The method and system of this disclosure may prevent that external devices, separate from the printer 1, need to be applied for performing the printer calibration. The media drive 5 of the printer 1 may be calibrated at any site, for example, at the printing site or manufacturing site. The printer 1 may be calibrated multiple times, for example at multiple service operations, during the full lifetime of the printer 1. The method of calibration may be performed automatically.
In certain embodiments the cost savings of the calibration method and system has been calculated to be around approximately 30 USD per calibration performed on the printer 1, as compared to traditional calibration methods. Cost savings may be made by preventing media waste, ink consumption and saving operator time.
Defects that may relate to deviations in the surface of one of the drive rollers 3 may be prevented. For example, it has been shown that by applying the calibration method and system of this disclosure, image defects such as banding and grain were prevented or decreased.
The above description is not intended to be exhaustive or to limit the invention to the embodiments disclosed. Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. The indefinite article “a” or “an” does not exclude a plurality, while a reference to a certain number of elements does not exclude the possibility of having more elements. A single unit may fulfil the functions of several items recited in the disclosure, and vice versa several items may fulfil the function of one unit.
In the following claims, the mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Multiple alternatives, equivalents, variations and combinations may be made without departing from the scope of the invention.
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