Patent Grant
8262187
The presently disclosed embodiments relate to ink jet architectures for high speed production printing, and more particularly, production piezo ink jet (PIJ) architectures employing a large array of printheads in a direct to web architecture; however, the embodiments also apply to other modular jet architectures producing print by employing a large array of printheads.
A piezo ink jet printhead will expel a volume of ink upon an ink chamber contraction resulting from an applied voltage. Normally the ink has to be heated to a comparatively high temperature because the ink will be solid at room temperature. In a production printing embodiment, 20 or more printheads are configured in an array with each printhead having several hundred jets. Because all jets must be working at the same time, reliability requirements for the printheads are compounded. In other words, the need to mitigate disruptions associated with jet failures is critically important in any production printing embodiment that employs large numbers of non-redundant jets.
Printheads experience a jet failure whenever any of their jets are either not jetting enough ink or not jetting any ink at all. Some jet failures are intermittent, which means the corresponding jets either spontaneously recover, or are recovered by a maintenance procedure. Other jet failures are chronic, which means the function of the corresponding jets cannot be recovered. When a jet fails, it is not known if the failure is chronic until several attempts to recover the jet have failed.
The process of attempting to recover failed jets is fairly involved and not always successful. First, a relatively large volume of ink is forced through the head in an effort to purge whatever is blocking the failing jet. The nozzle plate is then wiped and the printhead jetting performance is inspected. The purge, wipe and inspect cycle is repeated until either jet performance is restored or until the service operator considers one or more jet failures to be unrecoverable. With such a large total number of jets, stopping a large production web for every jet shortfall is untenable. Even assuming rates of hard or chronic jet failures are manageable, soft or recoverable printhead failures still have the potential of being very disruptive.
One can imagine that for a large roll of paper comprising a production web, if a purging operation had to occur every time any one of the substantial number of jets failed, then the purge operation would be very disruptive to the extent that no reasonable commercial operation could result. Nevertheless, jet failures have to be dealt with, and in a typical production environment, operators may frequently be faced with an uncomfortable trade-off between printing with less than optimal jet performance versus dealing with the potentially time consuming disruption of performing printhead purge and maintenance cycles, and the additional trouble shooting procedures in the printer to recover one or more printheads. When a failing printhead has to be “swapped” with a replacement head, a “cold swap” is performed so that the system cannot return to a production ready state until the replacement unit and the delivery ink are heated to a print-ready production status and the function of the new head is verified.
The problem sought to be overcome by the subject embodiments is undesirable down time of system functioning due to faulty printheads. A solution would minimize the down time and repair recoverable faulty printheads. More particularly, there is a need for a print system printhead recovery unit to rejuvenate printheads and determine whether or not a head failure is chronic or recoverable so that an operator can assess proper further handling of the faulty printhead while the printing system continues to operate in production mode.
According to the aspects illustrated herein, there is provided an off-line printhead inspection and recovery unit to rejuvenate printheads and determine whether or not the head failure is chronic or recoverable. The unit comprises component instrumentation to perform printhead maintenance, deliver ink and fire the printhead, as well as sensing to detect failed jets, where the printhead ink delivery subsystem may be comprised in part or in whole of common printing system parts. The availability of such a printhead inspection and recovery unit simultaneously reduces disruption and costs associated with diagnosing and recovering from failed jets.
One disclosed feature of the embodiments comprises a printhead inspection and recovery unit for an ink jet printing system. A modular printhead assembly is disposed within the printing system for on-line printing operation, where the printhead assembly may include a complete ink delivery subsystem or portions thereof. An off-line printhead inspection and recovery unit includes a printhead assembly dock for receiving the printhead assembly wherein the inspection and recovery unit is locally disposed relative to the printing system for ready diagnostic inspection and recovery of printhead operation and includes a user interface for reporting the diagnostic results. The inspection and recovery unit includes a printhead driver/docking module, a head maintenance subsystem, an image receiver, a receiver sensor array, an ink delivery system as necessary and a user interface. A spare modular printhead assembly may be disposed within the off-line printed inspection and maintenance unit and be maintained in the on-line print-ready state.
The head maintenance subsystem includes a head rejuvenator processor for executing printhead maintenance cycles, and also includes a diagnostic processor for selectively identifying nonrecoverable and recoverable printhead failures from data detected by the receiver sensor array.
Another disclosed feature of the embodiments comprises a method for inspecting and maintaining a printhead assembly of an ink jet printing system including an off-line printhead inspection and recovery unit locally associated with the ink jet printing system. A printhead failure in an operating, on-line printhead assembly in the ink jet printing system is identified. The failing on-line printhead assembly is removed and installed in the off-line printhead inspection and recovery unit, wherein the off-line printhead inspection and recovery unit is preconditioned before the installing to an on-line print-ready state. Any jet failures of the off-line printhead assembly are characterized as chronic or recoverable and results are communicated to a system operator through a user interface. The diagnosing comprises one or more off-line maintenance and inspection cycles. Maintenance typically includes purging and wiping the printhead, and inspection is generally achieved by printing on a print receiver and sensing print output by the printing assembly on the print receiver.
With reference to the Figures wherein the illustrated embodiments are presented for purposes of illustration and not limitation to the specific embodiments shown therein, a method and apparatus are provided which employs an off-line inspection and recovery unit in an ink jet printing system to rejuvenate failing printheads and determine whether or not a particular head failure is chronic or recoverable, and, if recoverable, restore the printhead to on-line print-ready status.
With particular reference to
An off-line printhead inspection and recovery unit 50 is local to the on-line printing operation being executed by one or more of the printhead assemblies 16 for performing printhead maintenance including ink delivery and firing, as well as sensing failed jets.
With particular reference to
With particular reference to
While such spare assembly is maintained, an on-line assembly failure may be identified 72. Typically such a failure occurs as a result of a blockage being disposed within the jet. To quickly return the system to a production operation, an operator removes 74 the failing on-line head assembly and installs 76 the fully functional spare head assembly in place of the removed on-line head assembly, and because the spare head assembly is maintained in a print-ready state in the inspection and recovery unit 50, production operation can be quickly returned.
The removed failing on-line head assembly is installed 78 in the printhead inspection and recovery unit 50 where it is supplied ink by the ink delivery system 60 and fired by the docking station 52 to impart ink on the drum 56 which is sensed by the sensor array 58 in a manner to execute an inspection cycle 80. If failed jets are detected, then the first of a set of sequentially scripted maintenance cycles 86 is performed, and the printhead is inspected again 80. A simple example of a set of sequentially scripted maintenance cycles would be a set of five cycles each consisting of a purge and a wipe. Alternative or repetitive actions could be included in any maintenance cycle. The set of sequentially scripted maintenance cycle need not be static. It could be programmed to change in response to whether or not any given jet consistently fails or passes a preset number of maintenance and inspection cycles. The script could also be reprogrammed by an operator. If failed one or more failed jets is still detected after a second inspection 80, the second scripted maintenance option is executed, and the printhead is inspected yet again until either all the jets are working or until the last of the set of sequentially scripted maintenance cycles has been executed 84. If any inspection shows that all jets are working 82 the result is communicated to the operator through the user interface 62 and the head is reclassified as a spare 88. If, on the other hand, failed jets are detected after the set of all sequentially scripted options has been executed 84, then the failure is reported as chronic and the head is reclassified as failed 90. If the printhead is rejuvenated, it can be maintained in the inspection and recovery unit 50 until it is needed as a replacement for another failing printhead within the system 10. The maintenance of the spare head assembly in a print-ready state, locally disposed relative to the system 10, provides advantageous disposition of a replacement spare printhead upon removal of a failing on-line printhead.
Although a drum 56 is shown in the inspection and recovery unit, any type of known image receiver can be employed, such as a belt, that can just as easily facilitate the detection by the sensor array 58 of the imparted ink by the printhead 16.
Structurally, the inspection and recovery unit could be a local stand alone structure, or could be an integral part of the printing system 10. Another alternative is that instead of only swapping printheads between the printer and the unit docking station 52, one could include connectors to the ink delivery subsystem 60, or include the printhead's entire ink delivery subsystem in the swap.
Although the embodiments have been discussed relevant to a particular piezo ink jet architecture, they also are extensible to other ink jet technologies.
For printing technologies, where the ability to “hot swap” printheads exist, these subject embodiments could also be used as a printhead prep and standby station. Specifically, before installing a printhead, an operator could use the inspection and recovery unit 50 to perform all initialization procedures and to also verify that the printhead is working before installation. Such prep and standby steps would further minimize the downtime associated with printhead interventions.
For color printing or as an additional fail safe, the printhead inspection and recovery unit 50 could alternatively have the means to keep multiple printhead assemblies in a standby state. This is especially important for color printing because there is no way to predict which color or head will fail at any given time. Architectural options would include
multiple complete units as described for a single printhead assembly;
an integrated unit with multiple stations all having complete inspection and recovery capabilities, but with a common GUI and possibly integrated power, controllers, air handling, etc.; and,
an integrated unit with one station for inspection and recovery and multiple stations for holding recovered/spare printhead assemblies in standby.
The inspection and recovery unit 50 may employ alternative jet recovery methods beyond those compatible or desirable in the integrated printing system 10.
It will be appreciated that various aspects of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
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