The present invention relates to apparatuses and methods to improve efficiency for printers, and in particular provide feedback to a user on the status of the media/ribbon in a printer.
Generally speaking a media/ribbon hanger or a “hanger” for media or ribbon of a printer is a mechanical hanger that holds media/ribbon in place, but does not comprise any feedback capability. A user may be required to manually view the printer in order to determine the status of media/ribbon in the printer.
Therefore, a need exists for a printer to provide a feedback mechanism to a user on to the status of the media/ribbon in the printer.
Accordingly, in one aspect, the present invention embraces a method and apparatus for providing feedback to a user on the status of media/ribbon of a printer. The feedback may be provided by incorporating a feedback mechanism in a media/ribbon hanger or “hanger” of a printer. The feedback mechanism of the printer may be designed to work with one or more sensors to provide a feedback loop so that without an input from a user, the printer is able to detect the presence/absence of media/ribbon, as well as determine the width of the loaded media/ribbon. In another embodiment, the feedback mechanism is able to determine the weight of the roll of media/ribbon and hence determine the quantity of media/ribbon available on the media/ribbon hanger.
In an exemplary embodiment, a media/ribbon hanger of a printer provides feedback on a status of a roll of media/ribbon loaded in the media/ribbon hanger. The media/ribbon hanger comprises a plurality of moveable buttons located on a top layer of the media/ribbon hanger; a plurality of flaps located in a middle interior of the media/ribbon hanger, where each of the plurality of flaps is in an open state or a closed state based on the status of the roll of media/ribbon loaded in the media/ribbon hanger; and one or more sensors that determine a presence or an absence of the roll of media/ribbon on the media/ribbon hanger. If the one or more sensors determine the presence of the roll of media/ribbon loaded in the media/ribbon hanger, the one or more sensors then can determine a width of the roll of media/ribbon loaded in the media/ribbon hanger. Based on the determinations of the one or more sensors, the printer receives the status of the roll of media/ribbon loaded in the media/ribbon hanger.
Each of the plurality of moveable buttons is associated with a corresponding one of the plurality of flaps. If the roll of media/ribbon is not loaded on the media/ribbon hanger, the plurality of moveable buttons does not press down on the plurality of flaps causing an open state for the plurality of flaps. If the roll of media/ribbon is loaded on the media/ribbon hanger, a portion of the plurality of moveable buttons underneath the media ribbon presses down the plurality of flaps causing a closed state for the plurality of flaps.
In another exemplary embodiment, the one or more sensors comprise a reflective sensor. The reflective sensor transmits a first light signal through the middle interior of the media/ribbon hanger, wherein, the first light signal reflects off a first flap in an open state causing a generation of a second light signal. The reflective sensor receives the second light signal with different light intensity depending on the location of the first flap allowing determination of the status of the roll of media/ribbon loaded on the media/ribbon hanger. The reflective sensor is located at one end of the media/ribbon hanger.
In yet another exemplary embodiment, the one or more sensors may comprise a plurality of transmissive sensors. Each transmissive sensor includes a light emitter and a light receiver. Each of the plurality of transmissive sensors transmit a light signal via the light emitter. If the light signal of each of the plurality of transmissive sensors is in proximity to one of the plurality of flaps in an open condition, then the each of the light receivers do not received the light signal from the light emitter and generate a low level signal. If the light signal of each of the plurality of transmissive sensors is in proximity of the one of the plurality of flaps in a closed condition, then the each of the plurality of light receiver receive the light signal from the light emitter and generate a high level signal. The number of high or low level signals received by the plurality of transmissive sensors determines the status of the roll of media/ribbon.
In another exemplary aspect, the present invention embraces a method comprising transmitting, by a sensor, a first light signal into a media/ribbon hanger of a printer; receiving, by the sensor, a second light signal generated from a reflection of the first light signal; and sending, by the sensor, a light intensity information of the second light signal to a system. The system determines a status of the roll of media/ribbon loaded on the media/ribbon hanger. The status of the roll of media/ribbon comprises a determination whether the media/ribbon hanger is empty. If the media/ribbon hanger is not empty, the system determines a width of the roll of media/ribbon. The light intensity information of the second light signal is based on whether the roll of media/ribbon presses down on one or more of a plurality of moveable buttons causing the second light signal to reflect off a specific one of a plurality of flaps. The plurality of moveable buttons is located on top of the media/ribbon hanger, and the plurality of flaps is located in a middle interior of the media/ribbon hanger and is each coupled to the plurality of moveable buttons. Each sensor comprises an emitter for transmitting and a receiver for receiving.
In yet another exemplary embodiment, a method may comprise transmitting, by each sensor of a plurality of sensors, a corresponding light signal into a media/ribbon hanger of a printer; receiving or not receiving, by each sensor of the plurality of sensors, the corresponding light signal based on a flap status of each of a plurality of corresponding flaps in the media/ribbon hanger generating, by each sensor of the plurality of sensors, either a high level signal or a low level signal based on a reception status of each corresponding receiver of the plurality of sensors; and sending, by each sensor of the plurality of sensors, their respective signal level to a system. The system counts a number of high level signals or low level signals to determine a status of a roll of media/ribbon loaded on the media/ribbon hanger Each sensor of the plurality of sensors comprise a corresponding emitter for transmitting and a corresponding receiver for receiving.
The status of the roll of media/ribbon comprises a determination whether the media/ribbon hanger is empty, and if the media/ribbon hanger is not empty, the system determines a width of the roll of media/ribbon. The flap status of each of the plurality of corresponding flaps in the media/ribbon hanger is determined based on whether the roll of media/ribbon presses down on one or more of a plurality of moveable buttons causing the corresponding flap to obstruct the light signal transmission from the emitter to the receiver of each of the plurality of sensors. The one or more of the plurality of moveable buttons are located on top of the media/ribbon hanger, and the plurality of corresponding flaps are located in a middle interior of the media/ribbon hanger and are correspondingly coupled to the plurality of moveable buttons.
In an exemplary embodiment, a media/ribbon hanger of a printer for providing feedback on a status of a roll of media/ribbon loaded on the media/ribbon hanger may comprise: 1) a plurality of moveable buttons located on a top layer of the media/ribbon hanger. The roll of media/ribbon loaded on the media/ribbon hanger applies pressure on the plurality of moveable buttons; 2) a plurality of pressure sensors, located underneath the plurality of moveable buttons. Each of the plurality of pressure sensors is paired with a corresponding one of the plurality of moveable buttons; 3) a pivot bar located on a bottom of the media/ribbon hanger; and 4) a load force sensor located at one end of the media/ribbon hanger and positioned on an edge of the pivot bar. The plurality of pressure sensors and the load force sensor provide feedback to a processor of the printer to determine the status of the roll of media/ribbon including a presence of the roll of media/ribbon, a width of the roll of the media/ribbon, and a quantity of media/ribbon available in the roll of media/ribbon.
The plurality of pressure sensors determines the presence of the roll of media/ribbon. The plurality of pressure sensors determines the width of the roll of media/ribbon and the quantity of media/ribbon available in the roll of media/ribbon. A number of pressure sensors located on the media/ribbon hanger determines an accuracy of the width determination. If the roll of media/ribbon is not loaded on the media/ribbon hanger, the plurality of moveable buttons does not press down the plurality of pressure sensors and activate the plurality of pressure sensors. If the roll of media/ribbon is loaded on the media/ribbon hanger, a portion of the plurality of moveable buttons underneath the media/ribbon presses down the plurality of pressure sensors, causing a force to be applied to the pivot bar, which in turn is sensed by the load force sensor. An output of the load force sensor determines the quantity of media/ribbon available in the roll of media/ribbon. A diameter of the roll of media/ribbon is proportional to an amount of contract pressure applied to the load force sensor. When the roll of media/ribbon is a label, the printer monitors a pressure change over a period of time and determines a number of labels printed in the period of time. When the roll of media/ribbon is a ribbon, the printer monitors a pressure change over a period of time to determine an amount of distance of continuous ribbon remaining on the roll of media/ribbon.
In another exemplary embodiment, a method for providing feedback on a status of a roll of media/ribbon loaded on the media/ribbon hanger may comprise the steps of: 1) loading, at a media/ribbon hanger of a printer, a roll of media/ribbon on the media/ribbon hanger; 2) applying pressure, at the media/ribbon hanger, by the roll of media/ribbon on a number of a plurality of pressure sensors located underneath the roll of media/ribbon; and 3) sending, at the media/ribbon hanger, the number of the plurality of pressure sensors receiving pressure from the roll of media/ribbon to a processor of the printer. The processor of the printer determines a width of the roll of media/ribbon based on the number of the plurality of pressure sensors receiving pressure from the roll of media/ribbon, and determines a quantity of media/ribbon available in the roll of media/ribbon based on a determination of a weight of the roll of media/ribbon. If the number of the plurality of pressure sensors receiving pressure from the roll of media/ribbon is zero, the roll of media/ribbon is not present.
Located on a top layer of the media/ribbon hanger, above the plurality of pressure sensors, is a plurality of moveable buttons. Each of the plurality of moveable buttons is paired with a corresponding one of the plurality of pressure sensors. An accuracy for determining the width of the roll of media/ribbon is based on a quantity of pressure sensors located on the media/ribbon hanger.
In yet another exemplary embodiment, a method for providing feedback on a status of a roll of media/ribbon loaded on the media/ribbon hanger may comprise the steps of: 1) loading, at a media/ribbon hanger, a roll of media/ribbon on the media/ribbon hanger; 2) applying pressure, at the media/ribbon hanger, by the roll of media/ribbon on a pivot bar located on a bottom of the media/ribbon hanger; 3) pivoting, at the media/ribbon hanger, by the pivot bar, based on a force applied by the roll of media/ribbon, causing contact pressure to be applied to a load force sensor; and 4) sending, at the media/ribbon hanger, to a processor of a printer associated with the media/ribbon hanger, a signal representing the contact pressure of the load force sensor. The processor of the printer determines a presence of the roll of media/ribbon, and if present, the processor of the printer determines a diameter of the roll of media/ribbon.
The diameter of the roll of media/ribbon is proportional to an amount of contact pressure applied to the load force sensor.
When the roll of media/ribbon is a label, the printer monitors a pressure change over a period of time and determines a number of labels printed in the period of time.
When the roll of media/ribbon is a ribbon, the printer monitors a pressure change over a period of time to determine an amount of distance of continuous ribbon remaining on the roll of media/ribbon. When the contact pressure reached a predefined threshold, an alert is sent to the processor of the printer to indicate a status of the roll of media/ribbon.
In yet another exemplary embodiment, a printer may provide feedback on a status of a roll of media/ribbon loaded in the media/ribbon hanger. The printer comprises: (1) a housing; (2) a hanger having a top surface and open portion below the top surface; (3) a plurality of moveable buttons located on a top of the hanger; (4) a plurality of flaps located below the top surface of the hanger, wherein each of the plurality of flaps is associated with a corresponding one of the plurality of moveable buttons; (5) each of the plurality of flaps being in an open state or a closed state based on a position of a roll of media/ribbon loaded on the hanger; (6) one or more sensors that determine a state of at least one of the plurality of flaps and output at least one signal corresponding to the state; and (7) a processor for processing the at least one output signal to determine at least one of a presence of the roll of media/ribbon loaded on the hanger and a width of the roll of media/ribbon loaded on the hanger.
The one or more sensors comprise a reflective sensor. The reflective sensor transmits a first light signal through the open portion of the hanger, wherein, the first light signal reflects off a first flap in the open state causing a generation of a second light signal. The reflective sensor receives the second light signal with a different light intensity, depending on a location of the first flap, allowing a determination of a status of the roll of media/ribbon loaded on the hanger. the reflective sensor receives the second light signal, and based on a measured time of flight determines if the media/ribbon is loaded on the hanger and/or determines the width of the media/ribbon loaded on the hanger.
In yet another exemplary embodiment, a method may comprise: transmitting, by an emitter, a first light signal into a hanger of a printer; receiving, by the emitter, a second light signal generated from a reflection of the first light signal; and outputting, by the emitter, information corresponding to the second light signal to a processor. The processor determines a width of a roll of media/ribbon loaded on the hanger.
The emitter receives the second light signal, and based on a measured time of flight determines if the media/ribbon is loaded on the hanger and/or determines the width of the media/ribbon loaded on the hanger.
The second light signal is based on whether the roll of media/ribbon presses down on one or more of a plurality of moveable buttons causing a displacement of the one or more corresponding flaps, thereby causing the first light signal to reflect off a specific one of a plurality of flaps. The specific flap is the first flap in an open state.
In yet another exemplary embodiment, a printer comprising: (1) a housing; (2) a hanger having a top surface and an edge adjacent the housing; (3) a plurality of moveable buttons located on a top surface of the hanger; (4) a plurality of pressure sensors, located underneath the plurality of moveable buttons. Each of the plurality of pressure sensors is paired with a corresponding one of the plurality of moveable buttons, and the roll of media or ribbon loaded on the hanger applies pressure on at least one of the plurality of moveable buttons, thereby registering a pressure on the at least one corresponding pressure sensor. (5) A pivot bar located at one end of the hanger. And (6) a load force sensor supported by the housing and positioned adjacent to an edge of the hanger, wherein, when the media or ribbon is loaded onto the hanger the edge of the hanger presses against the load force sensor. The plurality of pressure sensors and the load force sensor provide feedback to a processor of the printer to determine the status of the roll of media or ribbon including at least one of a presence of the roll of media or ribbon, a width of the roll of the media or ribbon, and a quantity of media or ribbon available in the roll of media or ribbon.
The foregoing illustrative summary, as well as other exemplary objectives and/or advantages of the invention, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings.
The present invention, as described herein, is based on applications supporting a variety of types of media. The media may include, but not limited to, ribbon, paper, labels and tickets. The term “media/ribbon”, as used herein, refers to the variety of types of media. The term “media/ribbon” may also be referred to as a “roll of media/ribbon”. Also “media/ribbon” is equivalent to “media or ribbon”. A hanger of the printer supports the media or ribbon.
The present invention embraces a method and apparatus for providing feedback to a user on the status of media/ribbon of a printer. The feedback may be provided by incorporating a feedback mechanism in a media/ribbon hanger or “hanger” of a printer. The printer may be a thermal printer, but may be another type of printer. The feedback mechanism of the printer may be designed to work with one or more sensors to provide a feedback loop so that without an input from a user, the printer may detect the presence/absence of roll of media/ribbon, as well as determine the width of the loaded media/ribbon. In another embodiment, the feedback mechanism is able to determine the weight of the roll of media/ribbon and hence determine the quantity of media/ribbon available on the media/ribbon hanger.
In two exemplary embodiments, media/ribbon hanger with a feedback mechanism may comprise moveable buttons with moving flaps and one or more light sensors (or optical sensors). These two exemplary embodiments are referred to as a first solution (reflective sensor) and a second solution (transmissive sensor). Upon loading of a roll of media/ribbon, the moveable buttons may compress the flaps based on the weight of the roll of media/ribbon to allow the light sensors to determine the width of the roll of media/ribbon and provide a feedback message to the printer/user. The sensors may be a reflective sensor or a transmissive sensor. The moveable buttons may be another type of sensor that is mounted on the top of the hanger.
In another exemplary embodiment, the feedback mechanism may comprise a plurality of pressure sensors and a load force sensor. This exemplary embodiment may be referred to as a third solution.
In one aspect of the third solution, when a roll of media/ribbon is loaded into the media/ribbon hanger, the weight of the roll of media/ribbon applies pressure on the pressure sensors underneath the roll of media/ribbon. The plurality pressure sensors may then detect information relative to 1) the presence of the roll of media/ribbon, 2) the weight of the roll of media, and subsequently the diameter/quantity available on the roll of media/ribbon, and 3) the width of the roll of media/ribbon. The sensors provide a feedback message to a processor of the printer that then generates a message or alert for a user.
In another aspect of the third solution, when a roll of media/ribbon is loaded into the media/ribbon hanger, the weight of the roll of media/ribbon applies pressure on a pivot bar, which subsequently applies pressure on the load force sensor. Based on the pressure applied to the load force sensor, the load force sensor may then detect information relative to 1) the presence of the roll of media/ribbon, 2) and if present, detects the weight of the roll of media, and subsequently the diameter/quantity available on the roll of media/ribbon. The sensors provide a feedback message to a processor of the printer that then generates a message or alert for a user.
Based on the feedback messages from the plurality of pressure sensors and the load force sensor, the printer may monitor the change in pressure over time. The printer may determine the status of the media or ribbon and if the media or ribbon is depleted. The printer may provide a low media alert message to a user.
The feedback mechanism may detect the presence/absence and width of media/ribbon 304. Knowledge of the width may provide assistance to a user for print registration.
The feedback mechanism has two states: and open state and a closed state. In the open state, media or ribbon are not installed on the media/ribbon hanger 202. The media/ribbon hanger 202 is empty or depleted as illustrated in
Accordingly, media/ribbon hanger 502 is configured in an open state. In the absence of media or ribbon, the plurality of buttons 503 are not pressed down. Correspondingly, the plurality of flaps 508, which are located underneath the plurality of buttons 503, freely fall from an approximate horizontal position to a position that is largely vertical, as illustrated by the plurality of flaps 508. Also, as illustrated, there is a 1:1 association between one of the plurality of buttons 503 and a corresponding one of the plurality of flaps 508. For example, moveable button 505 corresponds with flap 509. As illustrated in
Reflective sensor 506 comprises a transmitter/receiver that may be used to transmit and receive signal of light in the middle interior portion of the media/ribbon hanger 502. Transmitted light may be reflected off flap 509, since it has an open state, and be received by the reflective sensor 506. Since the signal of light reflects of the flop closest to the reflective sensor 506, the amount of light received is higher than if the light signal reflected on one of the other flaps. This information is sent to a system in the printer that determines a roll of media or ribbon is not present on media/ribbon hanger 502.
More specifically, the reflective sensor 506 transmits a first light signal 510 through the middle interior portion of the media/ribbon hanger 502. Per
Reflective sensor 526 transmits a third light signal 530 through the middle interior portion of the media/ribbon hanger 522. The third light signal 530 is reflected off the surface of flap 528, generating a fourth light signal 532 that is subsequently received by a phototransistor 704 (see
In the second solution, transmissive sensors 606, are positioned below the plurality of flaps. The spacing between each sensor may be based on the desired resolution desired to determine the width of the roll of media or ribbon. A sample value for the resolution may be approximately 1 inch. Transmissive sensors 606 may detect the presence of one of a plurality of flaps 608 and based on this detection, transmissive sensors 606 may provide a high level signal or a low level signal. The width of media or ribbon may be estimated based on the detection of one of the plurality of flaps 608. In one embodiment, either a transmissive type of sensor or a reflective type of sensor may be used for second solution implementation. In another embodiment, a plurality of reflective filters may be used in the second solution.
Transmissive sensors 606 may comprise an emitter (generally an InfraRed (IR) LED) and a receiver (generally an IR phototransistor), as illustrated in
A high level signal may refer to a signal which has the same value as the sensor power voltage (usually written as VCC). A low level signal may refer to a signal close to the ground level (e.g., 0V) or with a value of −VCC, which is opposite the sensor power voltage. Example values may be a high level signal equals 5V (or 3.3V) and low level signal equals 0V.
Moveable button 625 is pressed down, by the weight of media/ribbon 624, causing corresponding flap 629 to be in a closed state. Similarly, moveable button 627 is not pressed down by roll of media/ribbon 624 allowing flap 628 to freely fall into an open state. When roll of media/ribbon 624 is loaded on media/ribbon hanger 522, one edge of the roll of media/ribbon 624 is positioned next to face 631 of the printer such that the media/ribbon 624 is pressing against face 631.
The transmissive sensors 626 may detect whether flap 628 and flap 629 is in an open state or a closed state. Based on that detection, the presence and width of the media or ribbon may be estimated.
Referring to
Per
To summarize for the plurality of pressure sensors 901: As illustrated in
To summarize for the load force sensor 906: The load force sensor 906 is illustrated
A determination of the number of labels remaining on the roll of media/ribbon 904 may be based on the pressure applied to the plurality of pressure sensors 901. The weight of the roll of media/ribbon 904 is proportional to the amount pressure applied to the plurality of the pressure sensors 901. A high pressure measurement indicates the roll of media/ribbon 904 is full. A low pressure measurement indicates the roll of media/ribbon 904 is low or empty. From a determination of the weight, the diameter of the roll of media/ribbon 904 may be determined.
For simple printer implementations, a processor of the printer provides a low media trigger signal when the diameter reaches a predefined threshold. Hence, a user receives an alert to indicate a low media status of the roll of media/ribbon.
For advanced implementations, the printer may determine the label length through Label Stop Sensor or media distance fed for continuous media. The printer monitors the pressure change over a period of time and determines the number labels printed in the same time period. Then, the printer may determine the amount of pressure caused by one label. The printer may determine the number of labels or the amount of distance of continuous ribbon or media that can still be printed with the remaining roll of media/ribbon 904.
In summary, referring to
A method for a first solution may comprise the following steps:
Reflective sensor 526 transmits a third light signal 530 into media/ribbon hanger 522. (step 1102)
Reflective sensor 526 receives a fourth light signal 532. The third light signal 530 reflects on flap 528 to generate the fourth light signal 532. The fourth light signal 532 may have varying light intensity depending on open/closed state of individual flaps. Based on the light intensity of the fourth light signal 532, reflective sensor 526 emits (or transmits) a sensor signal to a system in a printer. (step 1104)
Reflective sensor 526 generates a sensor signal proportional to the received light intensity of the fourth light signal 532. The reflective sensor 526 communicates the sensor signal to a system in a printer. (step 1106)
The system analyzes sensor signal received from reflective sensor 526 and determines the width of media/ribbon or if hanger is empty. (step 1108)
A method for a second solution may comprise the following steps:
Transmissive sensors 626 each transmits a light signal. (step 1202)
Transmissive sensors 626 may detect the presence of a particular flap, for example, flap 628 or flap 629. Based on this detection, transmissive sensors 626 may sense a high level signal or a low level signal. A system of the printer receives this information and counts the number transmissive sensors emitting a high level signal and/or low level signals. (step 1204)
Based on the count, determine a width of the media/ribbon 624, or determine if media/ribbon hanger 622 is empty. (step 1206)
A method for a third solution may comprise the following steps:
A roll of media/ribbon 904 weight presses down on moveable buttons 903 at the location of media force 905. (step 1302)
Pressed down moveable buttons 903 push the pivot bar 907. (step (step 1304)
Pivot bar 907 applies proportional pressure to the media weight on the load force sensor 906. Higher pressure may mean that the media/ribbon 904 is full. Lower pressure may mean that media/ribbon 904 is empty or depleted. (step 1306)
Pressure on load force sensor 906 generates a signal which is analyzed by a processor of the printer. More pressure may result in a higher level signal. (step 1308)
Printer CPU detects the media/ribbon 904, determines the quantity of media/ribbon 904 left in the roll. From the change in the amount of contact pressure on load force sensor 906 over time, the printer can determine the weight sensed and the status of the media/ribbon 904, included whether the media/ribbon 904 is depleted. The diameter of the roll of media/ribbon 904 may also be determined. (step 1310)
Another method for a third solution may comprise the following steps:
Media/ribbon weight presses down on moveable buttons 903 at the location of media force. (Step 1322)
Press down moveable buttons 903 onto the plurality of pressure sensors 901. (Step 1324)
Each pressure sensor generates a signal which is analyzed by the printer CPU. (Step 1326)
Printer CPU determines if media/ribbon is present, the quantity of media/ribbon left in the media/ribbon roll and the width of the roll of media/ribbon 904. (Step 1328)
A method utilizing a TOF sensor may comprise the following steps: (1) TOF emits pulsed light; (2) pulsed light is reflected by the first open flat back to the sensor; (3) TOF received pulsed light with a delay from the time it emitted the light; (4) the delay is translated to a distance measurement; and (5) printer defines the media width.
To supplement the present disclosure, this application incorporates entirely by reference the following commonly assigned patents, patent application publications, and patent applications:
In the specification and/or figures, typical embodiments of the invention have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation.
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Entry |
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Number | Date | Country | |
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20190118529 A1 | Apr 2019 | US |