Method and apparatus for actuating a pump in a printer

Abstract

A printer apparatus and method of actuating a fluid pump in a printer to deliver fluid to an ink jet printhead without removing the printhead from a printhead carriage particularly useful for priming inkjet printheads using an air displacement pump to deliver air under positive pressure to the printheads. The pump is located proximate a service station on the printer and is automatically actuated by movement of the carriage to service station. The pump may be arcuately positionable to align the pump with a selected one of air passageways provided in a printhead holddown cover on the printhead carriage. Algorithms are provided for locating the precise position of the pump outlet along the carriage scan axis relative to its intended design location and for arcuately positioning the pump relative to the carriage to engage the pump outlet with a selected one of conduits in the carriage connected to each printhead.

Description

BACKGROUND OF THE INVENTION AND PRIOR ART

The present invention relates to the art of computer driven printers, particularly, color inkjet printers. Printers of this type have a printhead carriage which is mounted for reciprocal movement on the printer in a direction orthogonal to the direction of movement of the paper or other medium on which printing is to take place through the printer. The printer carriage of a color printer typically has four or more removable thermal ink jet printheads mounted thereon. Each of the printheads contains or is attached to a supply of ink and occasionally it is necessary to prime one or more printheads by creating a pressure differential to force ink to flow through the ink delivery orifices.

Printhead priming has previously been done by positioning a compliant seal around the nozzle plate of the printhead after the printhead carriage has been parked at a service station. In these systems, ink is drawn through the printhead nozzles by applying a negative pressure to the outside of the nozzle plates of the printheads to suck ink through the orifices. The source of the negative air pressure differential has been, among others, a collapsing air bellows or a remote pump connected by a fluid conduit. In these systems, the pressure is maintained by pressing a compliant cap against the surface surrounding the nozzles to create a chamber closed to the atmosphere but connected to the pressure source. The use of negative pressure to prime a printhead can have several disadvantages such as ink foaming, excessive waste ink and lack of precise control over the priming operation. Accordingly a system for printhead priming is required which does not rely upon negative pressure priming and by which a printhead can be primed in a controlled manner with minimal risk of system damage.

SUMMARY OF THE INVENTION

In its broadcast aspects, the present invention provides a method of actuating a fluid pump in a printer to exchange fluid with an ink jet printhead without removing the printhead from a printhead carriage comprising the steps of:

a) providing a printhead carriage having at least one fluid conduit extending from a first end which is open to atmosphere to a second end;

b) positioning a printhead on said carriage, said printhead having a fluid port in fluid communication with said second end of said conduit;

c) moving said printhead carriage to a fluid exchange position to bring said first port of said conduit into fluid transferring engagement with a fluid port of a fluid pump; and

d) further moving said printhead carriage so as to actuate said fluid pump and to exchange a predetermined amount of fluid at a predetermined pressure through said conduit with said printhead.

The present invention further provides, in a printer which includes a moveable carriage having at least one inkjet printhead thereon, the improvement comprising: a fluid pump having a fluid outlet for delivering fluid to said inkjet printhead without removing the printhead from said printhead carriage, said pump outlet being positioned on said printer proximate an end of the path of carriage travel for engagement by said carriage to actuate said pump to deliver a controlled volume of said fluid to said printhead.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a large format printer in which the present invention is useful.

FIG. 2 is a top plain view of the printer with its cover removed to show the automatic priming pump and service station at the right end of the path of travel of the printhead carriage.

FIG. 3 is a front elevation view of the service station and priming pump.

FIG. 4 is a right side elevation view of the service station and priming pump.

FIG. 5 is a cross-sectional elevation view taken at line 5 — 5 in FIG. 3 , of the mechanism for moving the pump to selected positions to prime selected printheads.

FIG. 6 is a cross-sectional elevation view through the pump.

FIG. 7 is a right side elevation view of the printhead carriage with cover in the closed position.

FIG. 8 is a front elevation view of the carriage showing the printhead cover in the raised position.

FIG. 9 is a top plan view of the carriage with printheads installed in two stalls and the cover in raised position.

FIG. 10 is a plan view of the carriage cover partly broken away showing air passageways therein.

FIG. 11 is a graph plotting air pressure profiles delivered by the pump.

FIG. 12 is a graph of a velocity servo soft bump algorithm implementation.

FIG. 13 is a graph of a velocity servo hard bump algorithm implementation.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows a large format printer 10 of the type which includes a transversely movable printhead carriage enclosed by a cover 12 which extends over a generally horizontally extending platen 14 over which printed media is discharged into a catcher basket. At the left side of the platen are four removable ink reservoirs 20 , 22 , 24 , 26 which, through a removable flexible tube arrangement to be described, supply ink to four inkjet printheads mounted on the movable carriage.

In the plan view of FIG. 2 in which the carriage cover 12 has been removed, it is seen that the printhead carriage 30 is mounted on a pair of transversely extending slider rods or guides 32 , 34 which in turn are affixed to the frame of the printer. Also affixed to the frame of the printer are a pair of tube guide support bridges 40 , 42 from which front and rear tube guides 44 , 46 are suspended. The printhead carriage 30 has a pivotal printhead hold down cover 36 fastened by a latch 38 at the front side of the printer which securely holds four inkjet printheads, two of which is shown in FIG. 9 in place in stalls C, M, Y, K on the carriage. The front tube guide 44 is angled near the left bridge support 40 to provide clearance for opening the printhead cover 36 when the carriage is slid to a position proximate the left side of the platen 14 so that the printhead hold down cover 36 can be easily opened for changing the printheads.

A flexible ink delivery tube system conveys ink from the four separate ink reservoirs 20 , 22 , 24 , 26 at the left side of the printer through four flexible in tubes 50 , 52 , 54 , 56 which extend from the ink reservoirs through the rear and front tube guides 44 , 46 to convey ink to printheads on the carriage 30 . The ink tube system may be a replaceable system as described and claimed in co-pending application Ser. No. 09/240,039 filed Jan. 29, 1999 owned by the assignee of the present invention, the disclosure of which is hereby incorporated herein by reference.

At the right side of the printer is a printhead service station 48 at which the printhead carriage 30 may be parked for cleaning and priming the printheads. The printhead service station 48 is comprised of a plastic frame mounted on the printer adjacent the right end of the transversely extending path of travel of the printhead carriage 30 . The printhead carriage 30 ( FIGS. 8 and 9 ) includes four stalls C, M, Y, K which respectively receive four separate printheads containing colored ink such as cyan, magenta, yellow and black. The service station 48 also includes four separate servicing stalls C, M, Y, K which may be provided on a drawer which is moveable forwardly and rearwardly of the printer. The servicing stalls each include a spittoon to capture ink discharged by the printheads during priming. The moveable drawer construction of the servicing station forms no part of the present invention.

A printhead servicing pump 50 is mounted on the upper end of a pump positioning arm 80 . A gear enclosure frame 60 is affixed to the right sidewall of the frame of the service station 48 and is spaced therefrom to provide a pocket containing a speed reduction gear mechanism which positions the arm 80 and thus the pump 50 with respect to the printhead carriage 30 . The positioning arm 80 is mounted for movement on a pivot axis 82 extending between the right sidewall of the service station frame and the gear enclosure frame 60 . An arm positioning electric step motor 90 rotates a drive gear 92 thereon which is engaged with the teeth of a large driven gear 94 connected on a common shaft to a small driven gear 96 having teeth which mesh with an arcuate arm positioning gear 98 formed on the pump positioning arm 80 to move the arm through an angle of slightly less than 90°. Movement of the arm 80 positions the pump at various locations along an arc centered on the pivot axis 82 of the arm to align a pump outlet 520 with the inlet end of one of four air conduits 100 , 102 , 104 , 106 arcuately positioned on the side of a pivotally mounted printhead holddown cover 36 on the printhead carriage 30 .

The four air conduits each 100 , 102 , 104 , 106 are each sized to have a substantially equal volume and extend from the inlet ends at the side of the hold down cover 36 internally of the cover and terminate in downwardly directed (when the cover is closed) fluid outlets 110 , 112 , 114 , 116 on the underside of the printhead holddown cover. The air outlets each have a compliant seal 111 , 113 , 115 , 117 therearound which mates with corresponding air inlet ports on the top surfaces of the four printheads when positioned in their respective stalls in the printhead carriage. Also shown on the underside of the printhead holddown cover 36 are spring loaded printhead positioners 120 , 122 , 124 , 126 . It will be seen that the printhead holddown cover is pivotally connected to the carriage and fastened in its closed or printhead holddown position by a finger latch 38 and retainer 39 .

The air pump 50 , which may be removably affixed to the upper end of the positioning arm 80 or permanently attached thereto as desired, comprises an open ended cylinder 510 in which an elongated piston 522 having a pair of spaced piston alignment discs 523 , 524 or collars slideably engageable with the inner wall of the cylinder is received. The piston 522 is biased outwardly of the cylinder by a compression spring 525 which is seated at one end against a spring seat 526 in the pump cylinder and which is seated at its other end against a collar 57 surrounding the inner end of a hollow piston stem 58 having an elongated axial passageway 59 therethrough. A compliant seal 61 is seated against the inner piston alignment disc 54 and slideably engages the inner wall of the cylinder to provide an air seal therebetween. The walls of the seal 61 engage the cylinder 510 at an angle so that the seal 61 unidirectionally holds a positive pressure within the air chamber 68 when the piston 522 moves to the right, but does not hold a vacuum when piston 522 moves to the left. The cylinder is closed by a cover 63 attached to the outer wall of the cylinder by one or more fasteners 65 , the construction of which is not relevant to the present invention. Alternatively, the cover may be threadedly affixed to the cylinder. The piston 522 has an enlarged collar 67 at its outer end on which a compliant gasket 69 is affixed for engaging the side wall of the printhead holddown cover 36 and providing an air seal between the outlet 520 of the pump and the side wall of the printhead holddown cover 36 during positioning of the carriage against the piston at the service station.

Servicing of the printheads on the printhead carriage is accomplished in part by positioning the pump 50 for alignment with the air passageway 102 , 104 , 106 , 108 in the printhead holddown cover which conveys air to the printhead to be serviced. Movement of the carriage 30 into the service station 48 with the pump so positioned causes the carriage to engage the compliant gasket 69 at the outlet of the pump with continued movement of the carriage moving the pump piston 522 to the right into the cylinder to discharge air from the air chamber 68 in the cylinder through the central passageway 59 in the piston to thus provide a source of positive air pressure to the printhead which causes ink to be forced through the printhead orifices at the bottom of the printhead into the appropriate spittoon in the service station 48 . The nozzles of the printheads C, M, Y, K may thus be primed with ink flow caused by a positive air pressure supplied by the pump 50 . It will be appreciated by persons skilled in the art that the air pressure supplied by the pump need not contact the ink in the printheads and in fact should not do so to avoid introducing air which must be warehoused in the pen body. Accordingly, a printhead configuration in which ink in the printhead is contained in a chamber having a volume which can be reduced by application of air pressure to another chamber in the printhead is preferred. Travel of the printhead carriage away from the pump 50 as it leaves the service station 48 extracts the air which has been previously forced into the printhead cover. If some of the air introduced under pressure to the printhead had escaped during the process, the pump may apply an undesired amount of vacuum to the printhead. The pump design allows the pressure to be clipped at a small negative pressure of approximately −5.0 inches of water to avoid creating a vacuum before damage is done to the printhead. The seal between the pump outlet and the passageway in the printhead holddown cover is broken after the pump piston has travelled under the bias of the spring 55 to the end of its stroke. Thus any backpressure within the printhead necessary for its correct functioning should remain unaffected by the priming operation.

The pump 50 is arcuately positionable as best seen in FIG. 5 anywhere between a rest position O and a reference position R which are defined by stops 84 , 86 on the gear enclosure frame 60 which are engaged by the sides of the positioning arm 80 . Positions of the arm for delivery of air by the pump to the cyan, magenta, yellow and black ink printhead conduits 100 , 102 , 104 , 106 on the printhead carriage holddown cover 36 are shown in FIG. 5 at positions preferably spaced by approximately 6° degrees from each other.

The stepper motor 90 preferably steps the gear 92 at 3.75°/half-step and the gear train preferably provides a 30:1 reduction between the stepper motor 90 and the gear 98 on the pump positioning arm 80 .

The hard stops 84 , 86 which define the limits of travel of the pump positioning arm are preferably placed at 84° from one another. For each printhead servicing cycle, the pump 50 is moved from the parking or rest position O in which the arm 80 engages the parking hard stop 84 to the reference position R in which the positioning arm engages the reference stop 86 . The reference stop 86 is positioned closer than the parking or rest stop 84 to the functional angular positions K, Y, M, C in which the pump 50 engages the cyan, magenta, yellow and black printhead conduits 100 , 102 , 104 , 106 on the carriage holddown cover. After movement of the pump positioning arm from the rest position O to the reference position R, the arm is then moved in a reverse (clockwise as seen in FIG. 3 ) direction to the preliminary position P. The stepper motor 90 then moves the pump positioning arm 80 in the original direction (counterclockwise in FIG. 3 ) to position the pump 50 in alignment with the desired functional location C, M, Y or K for connection to the related conduit 100 , 102 , 104 , 106 . This movement is performed to assure that, due to backlash, the same gear tooth face set that is used to move the pump positioning arm against the reference hard stop 86 is used to complete the accurate positioning of the pump 50 in the selected functional position.

The hard stops 84 , 86 are integrally formed with the gear enclosure frame 60 . This design sacrifices a small amount of positional accuracy in the nominal position of the pump 50 but decouples the hard stop function from the vertical adjustment of the gear enclosure frame 60 . An over-stepping algorithm is used to ensure that the pump positioning arm 80 has contacted the reference hard stop 86 . The over-stepping algorithm includes margin for both backlash and possible lost steps.

All functional angles are placed at even multiples of the nominal angular resolution. This is done to ensure that there are no pump positioning errors because an odd step total for a half-stepping algorithms is, by definition, less stable than an even step total.

The inlets on the printhead holddown cover to the conduits 100 , 102 , 104 , 106 are placed at angles of 6° from one another and are centered around a vertical line which extends through the axis 82 of rotation of the pump positioning arm 80 and are located at the same radius as the outlet of the pump 50 . The axis 82 of rotation of the positioning arm 80 is placed at a maximum reasonably feasible radius from the inlets to the conduits 100 , 102 , 104 , 106 to minimize the vertical distance ( FIG. 4 ) between the inlets to facilitate the design of the holddown cover 36 .

The radial margin around each air inlet is preferably about 2.5 mm to the inner diameter of the pump discharge gasket and 3.5 mm to the outside diameter. In the case that the vertical and horizontal alignment error of the axis of rotation 82 of the positioning arm 80 is 0, this translates to a stepping error of about 16 half-steps before the interface fails.

The stroke length or axial displacement of the pump 50 may be easily selected or adjusted to discharge a controlled volume of air to each of the printheads on the carriage. Design control of the length and cross-sectional area of each of the air passageways 100 , 102 , 104 , 106 in the printhead holddown cover 36 to insure that the total volume of each passageway is substantially the same insures that, for a given pump stroke, the pump delivers the same volume and pressure of air to each printhead regardless of which printhead is being serviced. Each printhead priming process may be tuned individually by adjusting the pump stroke appropriately.

The pressure profile delivered by the pump is shown in FIG. 11 and is dependent upon the volume of the air passageways 102 , 104 , 106 , 108 in the printhead holddown cover, the resting volume of the air chamber 68 in the pump itself and the rest position of the printhead carriage prior to priming. The curves shown in FIG. 11 are based upon an air passageway volume of 1.8 cc and a resting pump chamber volume of 3.2 cc. Three curves are shown. The 3.5 mm COMP curve shows the pressure profile at 3.5 mm axial displacement of the pump while the 7.0 mm COMP curve shows the pressure profile at 7.0 mm axial displacement of the pump. The third curve demonstrates the curve form when an air leak in the system is present. In this case, the priming pressure delivered to the printheads is slightly diminished but is still adequate to perform the priming function.

The precise location on the printer of the position of the compliant gasket at the pump outlet is determined by the use of a novel velocity servo bumping algorithm. The algorithm has general application to any two relatively moveable components but is more conveniently described in the context of an inkjet printer with reference to movement of the carriage 30 (a first component) with respect to the pump outlet 520 (a second component) to bump the components together preferably through a number of bumping cycles during which the current drawn by an electric motor used to move the carriage to cause the relative movement between the carriage and pump outlet is measured to establish a pulse width modification (PWM) threshold which is exceeding during the bumping. The deflection of one of the components (the pump outlet) has been characterized when the load power exceeds the threshold value.

Most bumping strategies require that the two contacting components have a minimum rigidity to function correctly. They typically assume that once the parts contact there will be no deformation or at least that the resulting deformation will be less than the precision required by the system. These algorithms, therefore, cannot be applied to systems having flexible components such as the compliant gasket 69 at the pump outlet 520 . FIG. 13 shows a plot of carriage drive motor load pulse width modification (PWM) against interruptions in milliseconds for printhead carriage measurements for a hard bump environment.

To recognize the contact of a flexible component, the algorithm must react to single impulses in the PWM profile. This is to say that they servo algorithm must respond if the threshold is exceeding for a single processor interruption (1/1000 sec.). Also, the servo parameters must have a very undamped response to velocity error. The algorithm depends on the PWM instability at the point of contact to recognize the flexible component. Because the impact can be somewhat unstable and because there is additional noise in the system due to other sources, several bumping samples must be taken to insure data consistency. This data must pass the following sanity checks to be considered valid:

1. The average reading must not exceed a maximum variation from the nominal value (taken as 4 σ of the distribution across many previous printers);

2. The 3 σ value of the measurement distribution must not exceed a critical value for mechanism function (reading Cp); and

3. No single reading can vary from each machine's own distribution average by more than a critical value (erroneous date point).

Because of the delay of the servo and the compressibility of the flexible components, an offset should be calculated when determining the bump position. As seen in the PWM evolution shown if FIG. 12 where the horizontal axis indicates interruptions in milliseconds, time B indicates when the PWM threshold (−28 as shown) was exceeded and time A indicates the point at which the true first contact occurred. The positional offset due to these effects has been characterized and shown to be repeatable. This occurs particularly in the case in which two flexible components are assembled in series (the gasket and the spring) with one of the two having a much higher stiffness and particularly preload.

FIG. 12 also demonstrates the transient noise which occurs due to both inertial and friction/stiction effects while accelerating the carriage and approaching the pump. To reduce the risk that the PWM threshold will be exceeding during this phase, carriage movement is started sufficiently far from the nominal position to ensure that discarding the first half of the PWM profile will both eliminate this noise and ensure the flexible component (the pump) is not touched during the initial movement.

The carriage is repeatedly positioned to deflect the pump outlet and during the bumping procedure. The currently preferred algorithm includes the following:

1. Number of bumping cycles: 12.

2. Offset due to connect gasket compression: 6 encoder units (0.25 mm).

3. Maximum variation of average reading from nominal: 24 encoder units (1.0 mm).

4. Maximum 3 σ value: 12 encoder units.

5. Maximum single point deviation from average: 6 encoder units.

It has been found that the position of the pump outlet can vary by up to 1.0 mm during construction of a printer. Use of the above positioning algorithm reduces the error between actual pump outlet position and optimum pump outlet position to a maximum of 0.25 of this amount.

It will be appreciated by those skilled in the art that, while the specific embodiment of the present invention described utilizes a carriage actuated pump to deliver air under pressure to a printhead, the invention also extends to the use of a carriage actuated pump to generate a vacuum within a printhead and to deliver a liquid, such as ink, to a printhead.

Person skilled in the art will understand that the above disclosure of the preferred embodiment of the invention may be modified and that the scope of the invention is defined in its broadcast sense only by the following claims.

Claims

1. A method of actuating a fluid pump in a printer to exchange fluid with an ink jet printhead without removing the printhead from the printhead carriage comprising the steps of:a) providing a printhead carriage having at least one fluid conduit extending from a first end which is open to atmosphere to a second end; b) positioning a printhead on said carriage, said printhead having a fluid port in fluid communication with said second end of said conduit; c) moving said printhead carriage toward a fluid pump to a fluid exchange position to bring said first end of said conduit into fluid transferring engagement with a fluid port of said fluid pump; and d) further moving said printhead carriage toward said fluid pump to move a part of said pump so as to actuate said fluid pump and to transfer a predetermined amount of fluid at a predetermined pressure from said pump through said conduit to said printhead.

2. The method of claim 1, comprising the step of delivering said predetermined amount of fluid at positive pressure from said pump through said conduit to said printhead.

3. The method of claim 2, comprising the step of actuating a pump plunger by contact of said plunger with said carriage as said carriage moves to a printhead service station.

4. The method of claim 3, further comprising the step of providing multiple printheads on said carriage and multiple conduits on said carriage and automatically delivering predetermined amounts of servicing fluid to selected ones of said conduits while said carriage is positioned at said service station.

5. The method of claim 4, further comprising the steps of:a) first moving said pump in a first direction from a rest position through an arc to a reference position; b) then moving said pump in a second direction through an arc to a preliminary position; c) then moving said pump in said first direction through an arc from said preliminary position to a desired position wherein said pump is positioned in the desired position with respect to said carriage conduits; and d) returning said pump to said rest position by moving said pump in said second direction from said desired position to said rest position.

6. The method of claim 5, comprising the further step of determining that said pump has reached said reference position before moving said pump in said second direction.

7. The method of claim 6, comprising the further step of arcuately aligning said pump positions and fluid entry ends of said carriage conduits at equal angular spacings from each other.

8. The method of claim 7, comprising the step of bringing said carriage into contact with said pump outlet when said pump outlet is in one of said desired positions.

9. The method of claim 8, comprising the steps of bringing said carriage into contact with said pump when said pump is in each of said desired positions.

10. The method of claim 9, further comprising the step of transferring fluid through fluid connections established between said pump outlet and said carriage conduits when said pump is in each of said desired positions.

11. The method of claim 2, wherein said fluid is air and further including the step of using said air to cause priming of said printhead.

12. The method of claim 1, further comprising determining the position of said carriage relative to said pump outlet by the steps of:a) moving said carriage with respect to said pump outlet to bump said carriage and said outlet together; b) measuring the current drawn by a motor used to move said carriage during said bumping; c) establishing a threshold current which is exceeded during said bumping; and d) characterizing the deflection of one of said carriage and said pump outlet when said current exceeds said threshold value.

13. The method of claim 12, wherein said carriage pump outlet has a compliant contact area.

14. The method of claim 13, wherein the velocity at which said pump outlet is bumped by said carriage is substantially constant.

15. The method of claim 14, wherein said contact area of said pump outlet is more compliant than a contact area of said carriage.

16. The method of claim 15, comprising the further step of repeatedly bumping said pump outlet with said carriage and establishing said threshold value based on data collected during each bumping cycle.

17. The method of claim 16, wherein said threshold value is established based on data collected during not less than 12 bumping cycles.

18. The method of claim 17, wherein said bumping comprises a linear bump.

19. The method of claim 18, further comprising the step of transferring fluid through a fluid connection established between said pump outlet and said carriage when said pump outlet is in contact with said carriage.

20. In a printer which includes a moveable carriage having at least one inkjet printhead thereon, the improvement comprising: a fluid pump having a fluid outlet for delivering fluid to said inkjet printhead without removing the printhead from said printhead carriage, said pump outlet being a moveable outlet positioned on said printer proximate an end of the path of carriage travel for engagement by said carriage to move said pump outlet to actuate said pump to deliver a controlled volume of said fluid to said printhead.

21. The printer of claim 20, further comprising multiple fluid delivery conduits on said carriage and a pump position actuator for moving said pump outlet to a selected position to connect said pump outlet to supply fluid under pressure to a selected conduit and printhead.

22. The printer of claim 21, wherein said actuator comprises an arm pivotally mounted on said printer for movement in an arcuate path about a pivot axis which extends parallel to the direction of carriage movement and said pump is mounted on said arm.

23. The printer of claim 22, further comprising a motor and a gear train connecting said motor to said arm for moving said arm to move said pump in said arcuate path.

24. The printer of claim 20, wherein said pump comprises: a housing defining a pump chamber therein, a pump piston in said chamber, said piston having a stem with a fluid discharge conduit extending through said stem to terminate at said pump outlet, a spring biasing said piston to maximize the volume of said pump chamber, and a seal at said pump outlet for engagement with a fluid delivery conduit on said printer carriage in fluid communication with said printhead.

25. The printer of claim 24, wherein said pump outlet is positioned to be axially moved by engagement with a side of said carriage to compress said spring to expel fluid from said stem.

26. The printer of claim 25, wherein said seal is of a unidirectional design.

27. The printer of claim 26 wherein said fluid is air.