PREDICTIVE INK DELIVERY SYSTEM AND METHODS OF USE
20240100842 ยท 2024-03-28
Inventors
- Angus CONDIE (Huntingdon, Cambridgeshire, GB)
- David SPEED (Huntingdon, Cambridgeshire, GB)
- Renzo TRIP (Huntingdon, Cambridgeshire, GB)
Cpc classification
B41J2/175
PERFORMING OPERATIONS; TRANSPORTING
B41J2/17566
PERFORMING OPERATIONS; TRANSPORTING
B41J3/4073
PERFORMING OPERATIONS; TRANSPORTING
B41J2/04508
PERFORMING OPERATIONS; TRANSPORTING
B41J2/04586
PERFORMING OPERATIONS; TRANSPORTING
International classification
B41J2/175
PERFORMING OPERATIONS; TRANSPORTING
B41J3/407
PERFORMING OPERATIONS; TRANSPORTING
B41M5/00
PERFORMING OPERATIONS; TRANSPORTING
B41J2/045
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A sub-controller (20), controller (30), fluid supply system and apparatus for printing and a method for printing. Provided is a processor controlled sub-controller (20) for controlling the fluid pressure in one or more droplet ejection heads (60); wherein said controller (30) is configured to receive a droplet ejection head movement profile for each of said one or more droplet ejection heads (60), determine a respective induced fluid pressure profile at one or more predetermined locations for each of said one or more droplet ejection heads (60) using the respective droplet ejection head movement profile; and generate respective pressure correction data for each of said one or more droplet ejection heads based on the respective induced fluid pressure profile and a predetermined pressure window to be maintained at said one or more droplet ejection heads (60). Also provided is a method of printing using one or more droplet ejection heads (60) fluidically connected to a fluid supply system wherein said method comprises the steps of receiving droplet ejection head movement profile(s); determining a respective induced fluid pressure profile at one or more predetermined locations for each of said one or more droplet ejection heads using the respective droplet ejection head movement profile(s); generating respective pressure correction file(s) at said one or more predetermined locations based on said induced fluid pressure profile(s) and said predetermined pressure window.
Claims
1. (canceled)
2. (canceled)
3. (canceled)
4. (canceled)
5. (canceled)
6. (canceled)
7. (canceled)
8. A processor controlled controller configured to control a printing process comprising controlling the fluid pressure in one or more droplet ejection heads; wherein said controller is configured to: receive a printing strategy; and calculate a respective droplet ejection head movement profile for each of said one or more droplet ejection heads using said printing strategy.
9. The controller according to claim 8, further configured to send said droplet ejection head movement profile to a sub-controller, or wherein said controller is further configured to receive a droplet ejection head movement profile for each of said one or more droplet ejection heads; the controller being further configured to determine a respective induced fluid pressure profile at one or more predetermined locations for each of said one or more droplet ejection heads using the respective droplet ejection head movement profile, and to generate respective pressure correction data for each of said one or more droplet ejection heads based on the respective induced fluid pressure profile and a predetermined pressure window to be maintained at said one or more droplet ejection heads.
10. The controller according to claim 9, further configured to control one or more movement devices so as to move said one or more droplet ejection heads in accordance with said droplet ejection head movement profile, wherein said one or more droplet ejection heads are mounted on said one or more movement devices.
11. The controller according to claim 8, wherein said printing strategy comprises printing commands and wherein said controller is further configured to control said one or more droplet ejection heads so as to execute said printing commands, and wherein said printing strategy comprises fluid requirements and wherein said controller is further configured to control a fluid supply so as to meet said fluid requirements.
12. A fluid supply system incorporating the controller according to claim to 8, the fluid supply comprises a fluid supply, a fluid reservoir and one or more fluid supply paths, wherein said one or more fluid supply paths are connected to said fluid reservoir at a first end and are configured so as to connect to one or more droplet ejection heads at a second end.
13. The fluid supply system according to claim 12, wherein said fluid supply system further comprises one or more control devices located at said one or more predetermined locations and wherein said one or more control devices are in communication with said controller, and wherein said one or more control devices are configured to be controllable so as to dynamically adjust the fluid pressure within a part or all of the fluid supply system when in operation; wherein said control devices are controlled by said controller.
14. The fluid supply system according to claim 12, wherein said fluid supply system is configured as a through-flow system comprising one or more fluid supply paths and one or more fluid return paths.
15. The fluid supply system according to claim 12, wherein said one or more predetermined locations comprise one or more of: adjacent and fluidically connected to said fluid reservoir; and/or located within said fluid reservoir and/or within or fluidically connected to one of said one or more fluid supply paths and/or located adjacent to or fluidically connected to said second end of said one or more fluid supply paths.
16. The fluid supply system according to claim 12, further comprising one or more pressure sensors located so as to measure the pressure at said one or more predetermined locations in said fluid supply system and wherein said one or more sensors are in communication with said controller so as to provide pressure measurements thereto.
17. (canceled)
18. A method of printing using one or more droplet ejection heads fluidically connected to the fluid supply system according to claim 12, wherein said method comprises the steps of: receiving a droplet ejection head movement profile; determining a respective induced fluid pressure profile at one or more predetermined locations for each of said one or more droplet ejection heads using the droplet ejection head movement profile; generating respective pressure correction data based on the respective induced fluid pressure profile and a predetermined pressure window to be maintained at said one or more droplet ejection heads; and generating a respective pressure correction file for said one or more predetermined locations based on said pressure correction data.
19. The method of printing according to claim 18, wherein generating said respective pressure correction file further comprises adjusting for further predictable pressure variations in said fluid supply system.
20. The method of printing according to claim 18, wherein generating said pressure correction data comprises performing a calculation and/or wherein generating said pressure correction data comprises using a lookup table and/or wherein generating said pressure correction data comprises using a comparator and/or wherein generating said induced fluid pressure profile and/or said respective pressure correction data comprises performing a pre-printing calibration process.
21. The method of printing according claim 18, further comprising controlling the fluid pressure within the fluid supply system during operation and thereby maintaining a predetermined pressure window.
22. The method of printing according to claim 21, wherein said fluid supply system further comprises one or more control devices located at said one or more predetermined locations and wherein said one or more control devices are in communication with said controller, and wherein said one or more control devices are configured to be controllable so as to dynamically adjust the fluid pressure within a part or all of the fluid supply system when in operation; wherein said control devices are controlled by said controller, wherein controlling the fluid pressure within the fluid supply system during operation comprises dynamically adjusting the pressure in the fluid supply system using said one or more control devices and said pressure correction file.
23. The method of printing according to claim 18, wherein said fluid supply system comprises one or more pressure sensors located so as to measure the pressure at said one or more predetermined locations in said fluid supply system and wherein said one or more sensors are in communication with said controller so as to provide pressure measurements thereto, wherein said method comprises sensing the pressure in the fluid supply system at said one or more predetermined locations and wherein said method further comprises adjusting the pressure in the fluid supply system if there is a difference between the sensed pressure and the predetermined pressure window.
24. The method of printing according to claim 18, wherein said method further comprises receiving printing commands and executing said printing commands and further comprises moving said one or more droplet ejection heads according to said droplet ejection head movement profile.
25. The method of printing according to claim 18, wherein calculating a droplet ejection head movement profile for each of said one or more droplet ejection heads comprises one or more of: calculating the droplet ejection head path and/or the droplet ejection head velocity and/or the droplet ejection head acceleration or deceleration and/or the droplet ejection head orientation.
26. The controller according to claim 9, wherein said sub-controller is configured to: receive a droplet ejection head movement profile for each of said one or more droplet ejection heads; determine a respective induced fluid pressure profile at one or more predetermined locations for each of said one or more droplet ejection heads using the respective droplet ejection head movement profile; and generate respective pressure correction data for each of said one or more droplet ejection heads based on the respective induced fluid pressure profile and a predetermined pressure window to be maintained at said one or more droplet ejection heads.
27. The controller according to claim 26, wherein said sub-controller is configured to perform a calculation to generate said respective pressure correction data and/or wherein said sub-controller is configured to use a look-up table to generate said respective pressure correction data and/or wherein said sub-controller is configured to use a comparator to generate said respective pressure correction data.
28. The controller according to claim 26, wherein said sub-controller is configured to generate respective pressure correction files using said respective pressure correction data for each of said one or more droplet ejection heads, and wherein said sub-controller is further configured to control one or more control devices located at said one or more predetermined locations using said pressure correction file(s) so as to dynamically adjust the fluid pressure in part or all of a fluid supply system in order to maintain said predetermined pressure window at said one or more droplet ejection heads when said droplet ejection heads and said control device are fluidically connected to said fluid supply system.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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[0047] It should be noted that the drawings are not to scale and that certain features may be shown with exaggerated sizes so that these are more clearly visible.
DETAILED DESCRIPTION OF THE DRAWINGS
[0048] Embodiments and their various implementations will now be described with reference to the drawings. Throughout the following description, like reference numerals are used for like elements where appropriate.
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[0050] The control device 10 is part of the fluid supply system located in or adjacent to the fluid supply path 42 so as to be fluidically connected to the fluid supply path 42 so as to be able to control the pressure in the fluid supply 46. In this implementation, the control device 10 is located in close proximity to the droplet ejection head 60. The sub-controller 20 is configured so as to control the control device 10. The sub-controller may be a system-on-chip module. The sub-controller may comprise software elements and/or FPGA logic.
[0051] Turning now to
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[0053] As previously described, whilst methods exist to adjust the fluid supply in response to measurements of induced pressure changes, in applications where the induced pressure is changing rapidly (due to changes in orientation and/or position and/or velocity) such methods may be too slow to respond and therefore unable to control the induced pressure sufficiently to maintain the pressure at the nozzle plate 61 within the predetermined pressure window 150 so as to prevent weeping/air ingestion or undesirable variations in droplet size and velocity, and hence print quality/appearance. The present application describes a method of compensating for some/all induced pressure changes by determining (predicting) them in advance of executing the print strategy and then using the predicted induced pressure changes and the predetermined pressure window 150 to calculate a desired pressure compensation regime. An apparatus such as that depicted in
[0056] The sub-controller 20 is then configured to generate a pressure correction file 180 (step 125) for the droplet ejection head 60 and then to provide the pressure correction file 180 to an external device, or to use the pressure correction file 180 to directly control the control device 10 (step 126), or to supply the pressure correction file to the control device 10, which may have internal controllers, so as to adjust and control the pressure in the fluid supply 46 over time. Locating the sub-controller 20 in close proximity to the control device 10 may be desirable to ensure that communications sent to/from the control device are conveyed and received in short time-scales.
[0057] It may be understood that the predetermined pressure window 150 may be the meniscus pressure window, whereby the upper limit is the pressure for which the nozzle plate 61 starts to wet (Pm=0 mbar) and the lower limit is the pressure at which air is ingested through the nozzles. These limits depend on a variety of factors, such as the type of droplet ejection head being used, the nozzle size and shape (nozzle layout), and the properties of the fluid being used. It may also be understood that a predetermined pressure window 150 narrower than the meniscus pressure window may be used if, for example, pressure fluctuations within the meniscus pressure window are significant enough to lead to undesirable variations in droplet size and velocity and hence the print appearance.
[0058] It may further be understood that the predetermined location 51 is the position at which the control will be applied to adjust the fluid pressure so as to maintain the predetermined pressure window 150 at the droplet ejection head 60. It may further be understood that depending on where and how such control is to be applied, the predetermined location 51 may be at a fixed location or may be at a moving position. For example, the control device 10 may be located on a movement device 70 and move with the droplet ejection head 60, or the two may move independently of each other, or only the droplet ejection head may move whilst the control device's position is fixed. However, as previously explained, with reference to
[0059] It may be understood that there are a number of ways in which the pressure correction data may be determined, for example the sub-controller 20 may perform a calculation to generate the pressure correction data. This may be calculated using the laws of physics; alternatively the sub-controller 20 may use a look-up table or may have a comparator to generate said respective pressure correction data. The comparator may compare the determined induced fluid pressure with the predetermined or pre-stored induced pressure and based on the comparison, output the pressure correction data. Further, where the sub-controller uses a look-up table, this may be pre-determined and encoded into the sub-controller 20, or provided to the sub-controller with the movement profile 111. Alternatively the sub-controller 20 may use a pre-calibration process to generate the induced pressure profile 170 and/or the pressure correction data, for example the apparatus may be used to perform calibration sweep(s) to generate a look-up table, or the apparatus may be used to trace the droplet ejection head path using the movement profile 111 so as to measure and record the induced pressure profile 170, compare that with the predetermined induced pressure profile and from this the pressure correction data can be calculated or determined. As an example one or more pressure sensors 50 may be moved along the path the droplet ejection head(s) will take and the pressure variations measured. It may be understood that when using one or more pressure sensors 50 in this manner to perform such calibration sweeps, the sensors must be integrated in such a way that the measured pressure represents the pressure in the nozzle(s). Alternatively, any other suitable method may be used to determine the pressure correction data. The pressure correction data may then be used to generate a pressure correction file 180 and the sub-controller 20 may be further configured to control the control device 10 located at the predetermined location 51 using the pressure correction file 180 so as to dynamically adjust the fluid pressure in part or all of the fluid supply system 40 in order to maintain the predetermined pressure window 150 at the droplet ejection head 60 when the droplet ejection head 60 and the control device 10 are fluidically connected to the fluid supply 46.
[0060] It may be understood that in many implementations, it may be convenient to locate the control device 10 close to the droplet ejection head 60. However, in other implementations, it may be suitable to locate a control device 10b in the fluid reservoir 41 as depicted with dotted lines in
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[0062] Turning now to
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[0066] The controller 30 is then configured to send the droplet ejection head movement profile 111 to a sub-controller 20 which may be substantially as described herein.
In the apparatus 90 of
[0072] Considering now
[0073] Turning now to
[0074] The arrangements and implementations as described herein may be used with a method of printing onto a vertical or non-planar or three-dimensional surface or onto a complex shape such as a three-dimensional shape or body. Such a method may use one or more droplet ejection heads 60 fluidically connected to a fluid supply system 40 as described herein; wherein said method comprises the steps of: [0075] receiving one or more droplet ejection head movement profiles 111; [0076] determining a respective induced fluid pressure profile at one or more predetermined locations for each of said one or more droplet ejection heads using the respective droplet ejection head movement profiles 111; [0077] generating pressure correction data at said one or more predetermined locations based on said induced fluid pressure profile and a predetermined pressure window.
[0078] The predetermined pressure window may depend on the droplet ejection head being used, the fluid being used, distance and/or angle between the fluid supply system 40 and the droplet ejection head 60, fluid supply pipe diameter and any other components that the fluid supply system 40 may comprise, further, the predetermined pressure window may be the meniscus pressure window or a (possibly narrower) pressure range so as to optimise the print performance. The method of printing may further comprise controlling the fluid pressure within the fluid supply system 40 during operation and thereby maintaining a predetermined pressure window 150 at said one or more droplet ejection heads 60 whilst receiving printing commands and executing said printing commands such that the droplet ejection head (or heads) 60 print the image onto the substrate whilst moving the one or more droplet ejection heads 60 according to the droplet ejection head 60 movement profile 111.
[0079] It may be understood that where there are other, predictable pressure variations in the fluid supply system 40, the generation of the pressure correction data may therefore further comprise adjusting for further predictable pressure variations in the fluid supply system 40. Depending on the implementation, one or more ways of calculating the pressure correction data may be implemented, for example the method of printing may comprise one or more of the following: [0080] generating the pressure correction data comprises performing a calculation, for example using a formula and/or the laws of physics; [0081] generating the pressure correction data comprises using a lookup table; [0082] generating the pressure correction data comprises using a comparator; [0083] generating the pressure correction data comprises performing a pre-printing calibration process.
[0084] Once the pressure correction data has been determined, the method of printing may comprise controlling the fluid pressure within the fluid supply system 40 during operation by dynamically adjusting the pressure in the fluid supply system 40 using one or more control devices 10 and the pressure correction data, which may be provided as a pressure correction file.
[0085] The method of printing may further comprise sensing the pressure in the fluid supply system 40 at one or more locations, for example, at the one or more predetermined locations 51, using one or more sensors 50. This may be performed as a check that the control devices are correcting the induced pressure in the fluid supply system correctly, or, the sensors may additionally/instead be used to measure unpredictable pressure fluctuations in the fluid supply system 40, for example due to environmentally-induced vibrations, or vibrations from component parts of the apparatus 90. The method of printing may therefore further comprise adjusting the pressure in the fluid supply system 40 if there is a difference between the sensed pressure and the predetermined pressure window.
[0086] It may be understood that in order to determine the movement profile 111, the printing strategy may need to be determined; this may be calculated/defined in the processor 35. For example, the method of printing may involve determining or receiving the print job data, and using the print job data such that determining the printing strategy comprises using one or more of the printing grid, the print resolution, the swath profile, number of layers, and stitching. Having determined what is to be printed, and where, the method of printing further comprises determining the printing strategy wherein determining the printing strategy comprises calculating a droplet ejection head movement profile 111 for the one or more droplet ejection heads 60. It may be understood that such calculations may comprise calculating the droplet ejection head path, the droplet ejection head velocity, the droplet ejection head acceleration or deceleration and/or the droplet ejection head orientation. Determining the printing strategy may also comprise determining printing commands and fluid requirements.
[0087] The controller and/or sub-controller may be a computing device, a microprocessor, an application-specific integrated circuit (ASIC), system on chip modules including processor elements and FPGA logic, or any other suitable device to control the functions of the various components of the fluid supply system and/or the droplet ejection head. The processor may be, for example, a microprocessor or a computer.