Patent Application
20140362135
This disclosure relates generally to printers and, more specifically, to inkjet printers that eject ink drops onto image receiving members to form printed images.
Inkjet printers operate a plurality of inkjets in each printhead to eject liquid ink onto an image receiving member. The ink can be stored in reservoirs that are located within cartridges installed in the printer. Such ink can be aqueous ink or an ink emulsion. Other inkjet printers receive ink in a solid form and then melt the solid ink to generate liquid ink for ejection onto the imaging member. In these solid ink printers, the solid ink can be in the form of pellets, ink sticks, granules, pastilles, or other shapes. The solid ink pellets or ink sticks are typically placed in an ink loader and delivered through a feed chute or channel to a melting device, which melts the solid ink. The melted ink is then collected in a reservoir and supplied to one or more printheads through a conduit or the like. Other inkjet printers use gel ink. Gel ink is provided in gelatinous form, which is heated to a predetermined temperature to alter the viscosity of the ink so the ink is suitable for ejection by a printhead. The printer supplies either aqueous liquid ink or a phase change ink in a liquid phase to printheads for ejection through inkjets onto an image receiving surface of an image receiving member, such as a print medium or an indirect imaging belt or imaging drum. Liquid inks dry and phase change inks cool into a solid state after being transferred to a print medium, such as paper or any other suitable medium for printing.
A typical inkjet printer uses one or more printheads with each printhead containing an array of individual nozzles through which drops of ink are ejected by inkjets across an open gap to an image receiving member to form an ink image. The image receiving member can be a continuous web of recording media, a series of media sheets, or the image receiving member can be a rotating surface, such as a print drum or endless belt. Images printed on a rotating surface are later transferred to recording media by mechanical force in a transfix nip formed by the rotating surface and a transfix roller. In an inkjet printhead, individual piezoelectric, or electrostatic actuators generate mechanical forces that expel ink through an aperture, usually called a nozzle, in a faceplate of the printhead. The actuators expel an ink drop in response to an electrical signal, sometimes called a firing signal. The magnitude, or voltage level, of the firing signals affects the amount of ink ejected in an ink drop. The firing signal is generated by a printhead controller with reference to image data. A print engine in an inkjet printer processes the image data to identify the inkjets in the printheads of the printer that must be operated to eject a pattern of ink drops at particular locations on the image receiving member to form an ink image corresponding to the image data. The locations where the ink drops landed are sometimes called “ink drop locations,” “ink drop positions,” or “pixels.” Thus, an imaging operation can be viewed as the placement of ink drops on an image receiving member with reference to electronic image data.
In order for the printed images to correspond closely to the image data, both in terms of fidelity to the image objects and the colors represented by the image data, the printheads are registered with reference to the imaging surface and with the other printheads in the printer. Registration of printheads refers to a process in which the printheads are operated to eject ink in a known pattern and then the printed image of the ejected ink is analyzed to determine the relative positions of the printheads with reference to the imaging surface and with reference to the other printheads in the printer. Operating the printheads in a printer to eject ink in correspondence with image data presumes that the printheads are level with one another across a width of the image receiving member and that all of the inkjets in the printhead are operational. The presumptions regarding the positions of the printheads, however, cannot be assumed, but must be verified. Additionally, if the conditions for proper operation of the printheads cannot be verified, the analysis of the printed image should generate data that can be used either to adjust the printheads to better conform to the presumed conditions for printing or to compensate for the deviations of the printheads from the presumed conditions.
During operation, individual inkjets in the printheads eject patterns of ink drops to form printed images, including text and graphics, on the image receiving surface. An individual inkjet includes a fluid pressure chamber that holds ink prior to ejecting each ink drop and a larger ink reservoir replenishes the pressure chamber after the ejection of each ink drop. When printing patterns of multiple ink drops during a print job, the transient motion of ink may result in variations of the mass and velocity of the ink drops that are ejected from the inkjet. Since the printhead is located at a substantially fixed distance from the moving image receiving surface, the variations in the ink drop velocity also affect the locations of where the ink drops land on the image receiving surface. The variations can lead to errors in the placement of ink drops that degrade the quality of the printed image.
Because the variations in the ink drop masses and velocities vary over time based on the pattern of operation for the inkjet, traditional registration processes are not suitable for correcting the drop placement errors. In many printer embodiments, the electrical firing signals that operate inkjets in a printhead are generated in a synchronous manner based on a clock signal that is generated at a predetermined frequency. During each period of the clock signal, the inkjet either receives the electrical firing signal to eject an ink drop, or does not receive the electrical firing signal and does not eject an ink drop. One existing solution that adjusts the relative locations of ink drops from a single inkjet adjusts the time of generation for the electrical firing signals forward or backward in time by one or more cycles of the clock signal. Commonly owned U.S. Pat. No. 8,004,714 describes a process for modifying image data to adjust the timing for generation of firing signals for ink drops by one or more cycles of the clock signal to correct for ink drop placement errors for different patterns of ink drops that the inkjet ejects during operation.
While the existing solutions for drop placement adjustment correct for some drop placement errors due to variations in the velocity of the ink drops, other drop placement errors are not well suited to correction by adjusting the time of ink drop ejection. For example, in some printed ink drop patterns, changing the clock cycle during which the inkjet ejects an ink drop includes selecting a clock cycle when the inkjet is already scheduled to eject an ink drop during a print job. Thus, the existing techniques would either print only one ink drop when the image data specify that two ink drops should be printed, or the inkjet ejects two ink drops, but at least one ink drop is not ejected during the optimal clock cycle to correct the position error. Another drawback of the existing correction process is that the printer is only capable of adjusting the time for ejection of the ink drops by an integer number of cycles in the clock signal. In some instances, the position error for the printed ink drop lies within the distance that the image receiving surface moves during a full cycle of the clock signal. Thus, changing the clock cycle during which an ink drop is ejected, which is referred to as a full-pixel adjustment, cannot compensate for sub-pixel errors that are not aligned with full-pixel intervals of the image receiving surface. Consequently, improved systems and methods for the operation of inkjets to reduce drop placement errors while printing patterns of ink drops would be beneficial.
In one embodiment, a method of operating an inkjet printer that reduces placement errors for printed ink drops has been developed. The method includes identifying a pattern of ink drops for ejection from an inkjet in the printer with reference to image data for a printed image, identifying a first waveform component for a first electrical signal to operate the inkjet to eject a first ink drop in the pattern of ink drops with reference to at least a portion of the image data corresponding to the pattern of printed ink drops, and generating the first electrical signal with the first identified waveform component to operate the inkjet to eject the first ink drop in the pattern of ink drops at a first velocity onto a first location of an image receiving surface.
In another embodiment, an inkjet printer that is configured to eject ink drops with reduced placement errors has been developed. The inkjet printer includes an inkjet configured to eject drops of ink in response to receiving electrical signals, an image receiving surface configured to move past the inkjet in a print zone, a memory configured to store image data corresponding to a printed image formed, at least in part, by the inkjet on the image receiving surface, and a controller operatively connected to the inkjet and the memory. The controller is configured to identify data corresponding to a first waveform component for a first electrical signal to operate the inkjet to eject a first ink drop in a pattern of printed ink drops with reference to at least a portion of the image data corresponding to the pattern of printed ink drops, and generate the first electrical signal with the first identified waveform component to operate the inkjet to eject the first ink drop in the pattern of ink drops at a first velocity onto a first location of an image receiving surface.
The foregoing aspects and other features of a printer that is configured to waveform component adjustments of firing signals for an inkjet to correct for drop position errors when printing patterns of ink drops are described below.
For a general understanding of the present embodiments, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate like elements. As used herein, the terms “printer” generally refer to an apparatus that applies an ink image to print media and can encompass any apparatus, such as a digital copier, bookmaking machine, facsimile machine, multi-function machine, etc., which performs a print outputting function for any purpose. The printer prints ink images on an image receiving member, and the term “image receiving member” as used herein refers to print media or an intermediate member, such as a drum or belt, which carries an ink image and transfers the ink image to a print medium. “Print media” can be a physical sheet of paper, plastic, or other suitable physical substrate suitable for receiving ink images, whether precut or web fed. As used in this document, “ink” refers to a colorant that is liquid when applied to an image receiving member. For example, ink can be aqueous ink, ink emulsions, melted phase change ink, or gel ink that has been heated to a temperature that enables the ink to be liquid for application or ejection onto an image receiving member and then return to a gelatinous state. A printer can include a variety of other components, such as finishers, paper feeders, and the like, and can be embodied as a copier, printer, or a multifunction machine. An image generally includes information in electronic form, which is to be rendered on print media by a marking engine and can include text, graphics, pictures, and the like.
The term “printhead” as used herein refers to a component in the printer that is configured to eject ink drops onto the image receiving member. A typical printhead includes a plurality of inkjets that are configured to eject ink drops of one or more ink colors onto the image receiving member. The inkjets are arranged in an array of one or more rows and columns. In some embodiments, the inkjets are arranged in staggered diagonal rows across a face of the printhead. Various printer embodiments include one or more printheads that form ink images on the image receiving member. Some printer embodiments include a plurality of printheads arranged in a print zone. An image receiving member, such as a print medium or an intermediate member that holds a latent ink image, moves past the printheads in a process direction through the print zone. The inkjets in the printheads eject ink drops in rows in a cross-process direction, which is perpendicular to the process direction across the image receiving member. An individual inkjet in a printhead ejects ink drops that form a line extending in the process direction as the image receiving surface moves past the printhead in the process direction.
As used herein, the terms “electrical firing signal,” “firing signal,” and “electrical signal” are used interchangeably to refer to an electrical energy waveform that triggers an actuator in an inkjet to eject an ink drop. Examples of actuators in inkjets include, but are not limited to, piezoelectric, and electrostatic actuators. A piezoelectric actuator includes a piezoelectric transducer that changes shape when the firing signal is applied to the transducer. The transducer proximate to a pressure chamber that holds liquid ink, and the change in shape of the transducer urges some of the ink in the pressure chamber through an outlet nozzle in the form of an ink drop that is ejected from the inkjet. In an electrostatic actuator, the ink includes electrically charged particles. The electrical firing signal generates an electrostatic charge on an actuator with the same polarity as the electrostatic charge in the ink to repel ink from the actuator, to eject an ink drop from the inkjet.
As used herein, the term “peak voltage level” refers to a maximum amplitude level of an electrical firing signal. As described in more detail below, some firing signals include a waveform with both positive and negative peak voltage levels. The positive peak voltage level and negative peak voltage level in a firing signal waveform may have the same amplitude or different amplitudes. In some inkjet embodiments, the peak voltage level of the firing signal affects the mass and velocity of the ink drop that is ejected from the inkjet in response to the firing signal. For example, higher peak voltage levels for the firing signal increase the mass and velocity of the ink drop that is ejected from the inkjet, while lower peak voltage levels decrease the mass and velocity of the ejected ink drop. Since the image receiving surface moves in a process direction relative to the inkjet at a substantially constant rate and typically remains at a fixed distance from the inkjet, changes in the velocity of the ejected ink drops affect the relative locations of where the ink drops land on the image receiving surface in the process direction.
As used herein, the term “peak voltage duration” refers to a time duration of the peak voltage level during a firing signal. The peak voltage duration can refer to the duration of both a positive peak voltage level and negative peak voltage level in a signal. Different electrical firing signal waveforms include positive peak voltage durations and negative peak voltage durations that are either equally long or of different durations. In one embodiment, an increase in the duration of the peak voltage level in the firing signal increases the ejection velocity of the ink drop while a decrease in the duration of the peak voltage level decreases the ejection velocity of the ink drop.
As used herein, the term “waveform component” refers to any parameter in the shape or magnitude of an electrical firing signal waveform that is adjusted to affect the velocity of an ink drop that is ejected from an inkjet in response to the generation of the waveform with the adjusted component parameter. The peak voltage level and peak voltage duration are examples of waveform components in electrical firing signals. As described below, an inkjet printer adjusts one or more waveform components including either or both of the peak voltage level and peak voltage duration to adjust the ejection velocities of ink drops on a drop-by-drop basis during an imaging operation. Since different ink drop ejection patterns result in variations of the ink drop velocity due to the characteristics of the inkjet and printhead, the adjustments to the waveform components enable more accurate placement of ink drop patterns on the image receiving surface during the imaging operation.
The phase change ink printer 10 also includes a phase change ink delivery subsystem 20 that has multiple sources of different color phase change inks in solid form. Since the phase change ink printer 10 is a multicolor printer, the ink delivery subsystem 20 includes four (4) sources 22, 24, 26, 28, representing four (4) different colors CMYK (cyan, magenta, yellow, and black) of phase change inks. The phase change ink delivery subsystem also includes a melting and control apparatus (not shown) for melting the solid form of the phase change ink into a liquid form. Each of the ink sources 22, 24, 26, and 28 includes a reservoir used to supply the melted ink to the printhead assemblies 32 and 34. In the example of
The phase change ink printer 10 includes a substrate supply and handling subsystem 40. The substrate supply and handling subsystem 40, for example, includes sheet or substrate supply sources 42, 44, 48, of which supply source 48, for example, is a high capacity paper supply or feeder for storing and supplying image receiving substrates in the form of a cut sheet print medium 49. The phase change ink printer 10 as shown also includes an original document feeder 70 that has a document holding tray 72, document sheet feeding and retrieval devices 74, and a document exposure and scanning subsystem 76. A media transport path 50 extracts print media, such as individually cut media sheets, from the substrate supply and handling system 40 and moves the print media in a process direction P. The media transport path 50 passes the print medium 49 through a substrate heater or pre-heater assembly 52, which heats the print medium 49 prior to transfixing an ink image to the print medium 49 in the transfix nip 18.
Media sources 42, 44, 48 provide image receiving substrates that pass through media transport path 50 to arrive at transfix nip 18 formed between the image receiving member 12 and transfix roller 19 in timed registration with the ink image formed on the image receiving surface 14. As the ink image and media travel through the nip, the ink image is transferred from the surface 14 and fixedly fused to the print medium 49 within the transfix nip 18. In a duplexed configuration, the media transport path 50 passes the print medium 49 through the transfix nip 18 a second time for transfixing of a second ink image to a second side of the print medium 49.
Operation and control of the various subsystems, components and functions of the printer 10 are performed with the aid of a controller or electronic subsystem (ESS) 80. The ESS or controller 80, for example, is a self-contained, dedicated mini-computer having a central processor unit (CPU) 82 with a digital memory 84, and a display or user interface (UI) 86. The ESS or controller 80, for example, includes a sensor input and control circuit 88 as well as an ink drop placement and control circuit 89. In one embodiment, the ink drop placement control circuit 89 is implemented as a field programmable gate array (FPGA). In addition, the CPU 82 reads, captures, prepares and manages the image data flow associated with print jobs received from image input sources, such as the scanning system 76, or an online or a work station connection 90. As such, the ESS or controller 80 is the main multi-tasking processor for operating and controlling all of the other printer subsystems and functions.
The controller 80 can be implemented with general or specialized programmable processors that execute programmed instructions, for example, printhead operation. The instructions and data required to perform the programmed functions are stored in the memory 84 that is associated with the processors or controllers. The processors, their memories, and interface circuitry configure the printer 10 to form ink images, and, more particularly, to control the operation of inkjets in the printhead assemblies 32 and 34 to eject ink drops to form printed images. These components are provided on a printed circuit card or provided as a circuit in an application specific integrated circuit (ASIC). Each of the circuits can be implemented with a separate processor or multiple circuits are implemented on the same processor. In alternative configurations, the circuits are implemented with discrete components or circuits provided in very large scale integration (VLSI) circuits. Also, the circuits described herein can be implemented with a combination of processors, FPGAs, ASICs, or discrete components.
In operation, the printer 10 ejects a plurality of ink drops from inkjets in the printhead assemblies 32 and 34 onto the surface 14 of the image receiving member 12. The controller 80 generates electrical firing signals to operate individual inkjets in one or both of the printhead assemblies 32 and 34. As described in more detail below, the controller 80 identifies image data that corresponding to a predetermined number of pixels that are processed before and after the generation of a firing signal to operate each inkjet in the printhead assemblies 32 and 34. The controller 80 identifies a waveform component adjustment with reference to the patterns of image data using a lookup table that is stored in the memory 84. The controller 80 adjusts the waveform components for the firing signals that are provided to each of the inkjets on a drop-by-drop basis to reduce or eliminate the drop placement errors on the image receiving surface 12 that are caused by the variations in ink drop velocity when the inkjet ejects different patterns of ink drops. While
The printer 10 is an illustrative embodiment of a printer that adjusts the waveform components of firing signals to reduce or eliminate ink drop placement errors, but the processes described herein are also applicable to alternative inkjet printer configurations. For example, while the printer 10 depicted in
Process 100 begins as the printer receives image data corresponding to patterns of printed ink drops that are used to form a printed image (block 104). In the printer 10, the controller 80 receives image data in one or more digital formats. The controller 80 performs half-tone and other image operations to generate binary image data for the printheads and individual inkjets in the printhead assemblies 32 and 34. Binary image data refer to a series of data including two values (e.g. on/off, 1/0, etc.) that specify whether the controller 80 should generate a firing signal to operate the inkjet at a predetermined time, or if the inkjet should remain inactive. As described above, the printheads operate in conjunction with a synchronous clock signal at a predetermined frequency, which is typically on the order of 30-100 KHz. During each cycle of the clock signal, the controller 80 either generates a firing signal for the inkjet or does not generate a firing signal for the inkjet based on the content of the binary image data.
In
Different patterns of image data and corresponding patterns of ink drops, including sequences of repeated ejections of ink drops and sequences where the inkjet ejects ink drops intermittently, generate different variations in the velocities of printed ink drops. During process 100, the printer 10 adjusts the waveform components of individual firing signals that are generated to eject the individual ink drops to adjust the velocities of the ink drops. The adjustment of the ink drop velocity corrects for sub-pixel placement errors and corrects for some full-pixel errors if the magnitude of the full pixel error is within a predetermined range, such as up to two full pixels Larger full-pixel positional errors may be corrected more effectively through adjustment of the time of operation for the inkjet using the methods described in U.S. Pat. No. 8,004,714 in conjunction with the waveform adjustment described in this patent. Thus, process 100 enables the printer 10 to eject ink drops in the intended locations as depicted by the printed ink drops 224 to correct the individual drop placement errors that are depicted by the printed ink drops 248.
Referring again to
After identifying the next ink drop to be printed from the inkjet in the image data, the controller 80 identifies a predetermined waveform component adjustment settings for the firing signal that is used to eject the next ink drop. The controller 80 identifies the waveform component adjustment settings based one or both of a previous history of image data and upcoming image data for the inkjet (block 112). In the printer 10, the memory 84 includes a buffer storing a portion of the image data corresponding to the inkjet including image data from previous cycles of the clock signal for the printhead, the identified image data for the identified cycle of the clock signal when the controller generates the firing signal, and a portion of the image data from upcoming portions of the image that are printed at later times during the print job. The memory 84 also stores a lookup table data structure that associates the pattern of image data in the memory buffer with a predetermined waveform component adjustment setting that the controller 80 uses to adjust the waveform of the firing signal. As described above, in an alternative embodiment the printheads in the printhead assemblies 32 and 34 include individual memory modules that store the waveform component adjustment data in association with printhead controllers that generate the electrical firing signal waveforms using the adjusted waveform components.
In
In the embodiment of
The waveform adjustment values 336 in the lookup table 324 are predetermined values that are identified empirically prior to the commencement of imaging operations for the printer 10. In one embodiment, the characteristics of inkjets in the printhead are measured during the manufacture of the printhead to identify variations in the velocity of the ink drops that are ejected from the inkjet for different printed patterns of ink drops. The waveform components, which include the peak voltage levels and durations of the firing signals, are adjusted in an iterative manner to correct the variations in the ink drop velocity and corresponding identified drop placement errors that result from the variations in the velocity of ink drops for each pattern of drops. Decreasing either or both of the peak voltage level and duration of the firing signal enables ejection of the ink drop with a lower velocity, and increasing either or both of the peak voltage level and duration of the firing signal enables ejection of the ink drop with a higher velocity. The adjustment to the waveform components is made within a predetermined minimum and maximum effective peak voltage levels and durations for the printhead. If the identified error for the location of the printed ink drop is in the process direction, then the waveform adjustment is used to decrease the velocity of the ink drop to adjust the location of the printed ink drop “downstream” in the process direction. If the identified error for the location of the printed ink drops is against the process direction, then the waveform adjustment is used to increases the velocity of the ink drop to adjust the location of the printed ink drop “upstream” in the process direction.
In some configurations, the adjustment to waveform components normalize the velocities of different ink drops in the printed patterns so that the effective ejection velocity is the same for multiple ink drops in the printed pattern. The different peak voltage level and durations compensate for the variations in ejection velocity due to the physical characteristics of the inkjet and printhead while printing the pattern of ink drops. In the printer 10, the controller 80 applies up to 64 levels of voltage adjustment to the peak voltage, which enables correction of the locations of pixels with sub-pixel precision on the image receiving surface. The controller 80 similarly applies different incremental changes to the duration of the voltage peaks for the firing signal waveforms to normalize the velocity of the ejected ink drops.
In some configurations, the voltage levels are adjusted to correct the relative process direction distance between printed ink drops in a printed pattern of ink drops. Thus, the ink drops can be ejected at different velocities to position the ink drops on the image receiving surface 12 at predetermined distances in the printed pattern. To correct a positioning error where the process direction distance between two printed ink drops in a printed pattern of ink drops is too small, the waveform component adjustments increase the velocity of the first printed ink drop, decrease the velocity of the second printed ink drop, or include a combination of velocity adjustments for both ink drops to reduce the drop positioning error. Ejecting different ink drops in a printed pattern from the inkjet with different ink drop velocities also enables ejection of the ink drops without excess pressurized air and prevents the contamination of the ink with air bubbles in some embodiments. Similarly, the waveform component adjustments decrease the velocity of the first printed ink drop, increase the velocity of the second printed ink drop, or include a combination of velocity adjustments for both ink drops to reduce the drop positioning error when the distance between the process direction distance between the two ink drops is too large. In the printer 10, the memory 84 stores the lookup table 324 including the patterns of binary image data and the predetermined voltage adjustment values 336 for use in adjusting the waveform components of the firing signals during process 100.
During an imaging operation, an inkjet may remain idle for an extended time prior to being activated to eject a single ink drop or to begin ejection of a sequence of multiple ink drops. In the lookup table 304, the image data pattern for an individual ink drop includes a series of binary pixels with the value of 0 preceding the image data pixel that indicates the inkjet should eject an ink drop after a period of inactivity. In some embodiments, the waveform component adjustment for the firing signal increases either or both of the peak voltage level and peak voltage duration to eject the ink drop. The increased peak voltage level and peak voltage duration assist in clearing quiescent ink from the inkjet when the inkjet has remained idle for a prolonged time prior to ejecting the ink drop.
During process 100, the controller 80 identifies an entry in the lookup table 324 that corresponds to the image data in the image data buffer 304. In the example of
Referring again to
Referring again to
It will be appreciated that variants of the above-disclosed and other features, and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. 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.
