1. Field of the Invention
The present invention relates to an imaging apparatus, and, more particularly, to a method of dot size determination by an imaging apparatus.
2. Description of the Related Art
An imaging apparatus forms an image on a print medium, such as for example, paper or a transparency, by applying ink or toner onto the print medium. The ink or toner is applied as a series of dots, which when viewed as a whole represent the image. The size of the dots formed on the print medium may be dependent on one or more of a variety of factors. For example, in an ink jet printer, the size of ink dots formed may be dependent on the nozzle opening size, temperature, fire energy, ink type, actuator type (e.g., an electrical heater), the location of the actuator relative to the nozzle opening, and print medium characteristics. In a laser printer, the size of dots formed may be dependent, for example, on the laser energy, the characteristics of the photoconductive surface, the voltage applied to the photoconductive surface, and temperature.
By knowing the amount of imaging substance, e.g., ink or toner, forming each dot, and by counting the number of dots formed, an estimate of the amount of imaging substance that has been used can be obtained. In turn, by knowing the amount of imaging substance prior to imaging, a remaining amount of imaging substance, i.e., level, in a supply item can be determined by subtracting the amount of imaging substance used from the amount of imaging substance that was present prior to imaging.
One challenge to be overcome in providing an accurate imaging substance level determination in a supply item is being able to account for imaging substance dot mass variations due to changed imaging conditions and/or imaging apparatus settings. Accordingly, the more accurate the imaging substance dot mass estimate, the more accurate the imaging substance level determination. In ink jet printing, for example, it is generally accepted that the ink dot mass is directly proportional to the ink dot size on the print medium, but ink dot size may vary due to the changes in imaging conditions and/or imaging apparatus settings described above.
What is needed in the art is a method of dot size determination that can be used under a variety of imaging conditions and/or imaging apparatus settings.
The present invention provides a method of dot size determination that can be used under a variety of imaging conditions and/or imaging apparatus settings.
The invention in one form thereof, relates to a method of dot size determination. The method includes the steps of printing a pattern on a print medium that changes in dot density along a scan path; scanning a reflectance sensor across the pattern to determine a reflectivity of the pattern at a plurality of points along the scan path; determining a change of the reflectivity along the scan path; and correlating the change in the reflectivity to a dot size.
An advantage of the present invention is that an accurate dot size determination can be achieved at various imaging conditions (e.g., temperatures) and/or imaging apparatus settings (e.g., fire energies for ink jet imaging). Such an accurate dot size determination may be used, for example, for accurate imaging substance level determinations, or may be used to adjust halftoning algorithms and/or color tables to optimize the quality of the printed output.
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
Referring now to the drawings, and particularly to
Imaging system 10 includes an imaging apparatus 14, which may be in the form of an ink jet printer, as shown. Thus, for example, imaging apparatus 14 may be a conventional ink jet printer, or may form the print engine for a multi-function apparatus, such as for example, a standalone unit that has faxing and copying capability, in addition to printing.
Host 12, which may be optional, may be communicatively coupled to imaging apparatus 14 via a communications link 16. Communications link 16 may be, for example, a direct electrical connection, a wireless connection, or a network connection.
In embodiments including host 12, host 12 may be, for example, a personal computer including a display device, an input device (e.g., keyboard), a processor, input/output (I/O) interfaces, memory, such as RAM, ROM, NVRAM, and a mass data storage device, such as a hard drive, CD-ROM and/or DVD units. During operation, host 12 includes in its memory a software program including program instructions that function as a printer driver for imaging apparatus 14. The printer driver is in communication with imaging apparatus 14 via communications link 16. The printer driver, for example, includes a halftoning unit and a data formatter that places print data and print commands in a format that can be recognized by imaging apparatus 14. In a network environment, communications between host 12 and imaging apparatus 14 may be facilitated via a standard communication protocol, such as the Network Printer Alliance Protocol (NPAP).
In the embodiment of
Media source 28 is configured to receive a plurality of print medium sheets from which a print medium, i.e., an individual print medium sheet 30, is picked by sheet picking unit 22 and transported to feed roller unit 20, which in turn further transports print medium sheet 30 during an imaging operation. Print medium sheet 30 may be, for example, plain paper, coated paper, photo paper or transparency media.
Printhead carrier system 18 includes a printhead carrier 32 for mounting and carrying a color printhead 34 and/or a monochrome printhead 36. A color ink reservoir 38 is provided in fluid communication with color printhead 34, and a monochrome ink reservoir 40 is provided in fluid communication with monochrome printhead 36. Those skilled in the art will recognize that color printhead 34 and color ink reservoir 38 may be formed as individual discrete units, or may be combined as an integral unitary printhead cartridge. Likewise, monochrome printhead 36 and monochrome ink reservoir 40 may be formed as individual discrete units, or may be combined as an integral unitary printhead cartridge.
Printhead carrier system 18 further includes a reflectance sensor 42 attached to printhead carrier 32. Reflectance sensor 42 may be, for example, a unitary optical sensor including a light source, such as a light emitting diode (LED), and a reflectance detector, such as a phototransistor. The reflectance detector is located on the same side of a media as the light source. The operation of such sensors is well known in the art, and thus, will be discussed herein to the extent necessary to relate the operation of reflectance sensor 42 to the operation of the present invention. For example, the LED of reflectance sensor 42 directs light at a predefined angle onto a reference surface, such as the surface of print medium sheet 30, and at least a portion of light reflected from the surface is received by the reflectance detector of reflectance sensor 42. The intensity of the reflected light received by the reflectance detector varies with the density of a printed image present on print medium sheet 30. The light received by the reflectance detector of reflectance sensor 42 is converted to an electrical signal by the reflectance detector of reflectance sensor 42. The signal generated by the reflectance detector corresponds to the reflectivity from print medium sheet 30, including any image scanned by reflectance sensor 42. Thus, as used herein, the term “reflectivity” refers to the intensity of the light reflected from the print medium and/or image scanned by reflectance sensor 42, which may be used in accordance with the present invention in dot size determination.
Printhead carrier 32 is guided by a pair of guide members 44, 46, which may be, for example, in the form of guide rods. Each of guide members 44, 46 includes a respective horizontal axis 44a, 46a. Printhead carrier 32 includes a pair of guide member bearings 48, 50, each of guide member bearings 48, 50 including a respective aperture for receiving guide member 44. The horizontal axis 44a of guide member 44 generally defines a bi-directional scan path 52 for printhead carrier 32. Accordingly, scan path 52 is associated with each of printheads 34, 36 and reflectance sensor 42.
Printhead carrier 32 is connected to a carrier transport belt 53 via a carrier drive attachment device 54. Carrier transport belt 53 is driven by a carrier motor 55 via a carrier pulley 56. Carrier motor 55 has a rotating carrier motor shaft 58 that is attached to carrier pulley 56. Carrier motor 55 can be, for example, a direct current (DC) motor or a stepper motor. At the directive of controller 24, printhead carrier 32 is transported in a reciprocating manner along guide members 44, 46, and in turn, along scan path 52.
The reciprocation of printhead carrier 32 transports ink jet printheads 34, 36 and reflectance sensor 42 across the print medium sheet 30, such as paper, along scan path 52 to define a print/sense zone 60 of imaging apparatus 14. The reciprocation of printhead carrier 32 occurs in a main scan direction (bi-directional) that is parallel with bi-directional scan path 52, and is also commonly referred to as the horizontal direction, including a left-to-right carrier scan direction 62 and a right-to-left carrier scan direction 63. Generally, during each scan of printhead carrier 32 while printing or sensing, the print medium sheet 30 is held stationary by feed roller unit 20.
Mid-frame 26 provides support for the print medium sheet 30 when the print medium sheet 30 is in print/sense zone 60, and in part, defines a portion of a print medium path 64 of imaging apparatus 14.
Feed roller unit 20 includes a feed roller 66 and corresponding index pinch rollers (not shown). Feed roller 66 is driven by a drive unit 68. The index pinch rollers apply a biasing force to hold the print medium sheet 30 in contact with respective driven feed roller 66. Drive unit 68 includes a drive source, such as a stepper motor, and an associated drive mechanism, such as a gear train or belt/pulley arrangement. Feed roller unit 20 feeds the print medium sheet 30 in a sheet feed direction 70, designated as an X in a circle to indicate that the sheet feed direction is out of the plane of
Controller 24 includes a microprocessor having an associated random access memory (RAM) and read only memory (ROM). Controller 24 is electrically connected and communicatively coupled to printheads 34, 36 via a communications link 72, such as for example a printhead interface cable. Controller 24 is electrically connected and communicatively coupled to carrier motor 55 via a communications link 74, such as for example an interface cable. Controller 24 is electrically connected and communicatively coupled to drive unit 68 via a communications link 76, such as for example an interface cable. Controller 24 is electrically connected and communicatively coupled to sheet picking unit 22 via a communications link 78, such as for example an interface cable. Controller 24 is electrically connected and communicatively coupled to reflectance sensor 42 via a communications link 80, such as for example an interface cable.
Controller 24 executes program instructions to effect the printing of an image on the print medium sheet 30, such as for example, by selecting the index feed distance of print medium sheet 30 along print medium path 64 as conveyed by feed roller 66, controlling the acceleration rate and velocity of printhead carrier 32, and controlling the operations of printheads 34, 36, such as for example, by controlling the fire time of individual nozzles of printhead 34 and/or printhead 36. As used herein, the term “fire time” is the time between firings of a nozzle of a printhead in forming adjacent dots on the same scan line of an image. In addition, controller 24 executes instructions to perform dot size determination in accordance with the present invention, based on reflectance data received from reflectance sensor 42.
At step S100, a pattern is printed on a print medium, such as print medium sheet 30, that changes in dot density along scan path 52.
As illustrated in
As a further alternative, the step increases in printhead carrier velocity illustrated in
As a specific example for using a single cycle in multiple passes of printhead carrier 32, with respect to
As illustrated in
Referring again to
At step S102, reflectance sensor 42 is scanned across the pattern, e.g., one of patterns 82, 86, 90 and 96, to determine a reflectivity of the pattern at a plurality of points along scan path 52.
Each of the
In the graphs of
In each of
In
At step S104, a change of the reflectivity (AR) along scan path 52 is determined. The change of the reflectivity (AR) may be calculated by controller 24, and may be stored in an associated memory. Alternatively, the change of the reflectivity (AR) may be calculated by host 12, and may be stored in an associated memory.
With each of the printed patterns 82, 86 and 90 of
With the printed pattern 96 of
At step S106, the change in reflectivity (ΔR) is correlated to a dot size. Such a correlation may be performed, for example, by comparing the change in reflectivity (ΔR) to a threshold (T), and if the change in reflectivity (ΔR) has reached threshold T, then a dot density associated with one of the adjacent points is identified. The determination of whether threshold (T) has been reached may be based, for example, on the change in reflectivity (ΔR) being equal to threshold (T), or the change in reflectivity (ΔR) being less than threshold (T). Threshold (T) may be some predetermined value, such as a change of 0 to 5 percent.
Thereafter, a dot size determination may be made through a calculation, or alternatively, through reference to a look-up table stored in memory, such as in a memory of one of imaging apparatus 14 or host 12, based on the identified dot density of the selected one of the adjacent points.
In the case of a calculation, for example, a reciprocal of the dot density that was identified with respect one of the adjacent points is taken to determine the dot size. More particularly with respect to this example, with respect to
In the case of a look-up table, for example, the dot size for a particular dot density may be predetermined and stored in the look-up table resident in one of imaging apparatus 14 and host 12. By using the dot density at the point along scan path 52 identified above, a location in the look-up table containing a dot size associated with the dot density is accessed, and the dot size information is retrieved.
While this invention has been described with respect to embodiments of the present invention, the present invention can be further modified within the spirit and scope of this disclosure. For example, while the present invention was described with respect to an imaging apparatus as an ink jet printer, those skilled in the art will recognize that the principles of the present invent may be readily applied to other imaging technologies, such as for example, electrophotographic imaging (e.g., a laser printer). This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.