WEB MEDIUM ORIENTATION DETECTION
20170344842 · 2017-11-30
Assignee
Inventors
- Juan C. PÉREZ MUÑOZ (Venlo, NL)
- Lodewijk T. HOLTMAN (Venlo, NL)
- Wilhelmus J.E.G. VERHOFSTAD (Venlo, NL)
Cpc classification
B65H2601/272
PERFORMING OPERATIONS; TRANSPORTING
B65H2301/331
PERFORMING OPERATIONS; TRANSPORTING
B65H23/16
PERFORMING OPERATIONS; TRANSPORTING
B41J15/16
PERFORMING OPERATIONS; TRANSPORTING
B65H2511/24
PERFORMING OPERATIONS; TRANSPORTING
B65H23/0204
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
In a method for high speed printing of web-based media, a medium is pulled along a media transport path to a pulling transport mechanism. The orientation of the medium with respect to the media transport path is sensed and this orientation is compared to a reference orientation to detect an orientation error. If an orientation error is detected, one or more of the following steps is performed: adjusting a print job for an image to be printed on the web medium; adjusting the transport speed; emitting a communication signal; and stopping the pulling transport mechanism and the image forming unit. It is the insight of the inventor that productivity may be increased by allowing a “tight winding” printing system to start printing at relatively high speed and reduce this speed only when significantly large deviations in the orientation of the web are detected.
Claims
1. Printing system for printing web media, comprising: a take-out roller; a take-up roller for pulling a web medium along a media transport path from the take-out roller to the take-up roller; an image forming unit positioned along the media transport path, characterized by: an orientation sensor for sensing an orientation of the web medium, the orientation sensor comprising: a curved medium support surface defining a turn in the media transport path, which curved medium support surface is tiltable around a tilting axis, which tilting axis extends in a transport direction substantially tangentially to the curved medium support surface in a reference orientation; a tilting sensor for determining tilting data proportional to a tilting angle by which the curved medium support surface is tilted from its reference orientation around the tilting axis; a controller configured to: receive the tilting data from the orientation sensor; compare the tilting data to the reference orientation to determine an orientation error; and compare the orientation error to a deviation threshold.
2. Printing system according to claim 1, wherein: the tilting sensor comprises a displacement sensor attached to the curved medium support surface for detecting a displacement of a section of the curved medium support surface in a direction substantially perpendicular to the curved medium support surface; and the controller is configured to compare the detected displacement to the reference orientation to determine the tilting data.
3. Printing system according to claim 2, wherein: the tilting sensor comprises a pair of displacement sensors attached to opposing lateral sides of the curved medium support surface, each displacement sensor configured for detecting a displacement of a respective side of the curved medium support surface in a direction substantially perpendicular to the curved medium support surface; and the controller is configured to compare the detected displacements to one another to determine the tilting data.
4. Printing system according to claim 1, wherein the controller is further configured to emit an error signal for initiating an appropriate action of the printing system if the orientation error exceeds the deviation threshold.
5. Printing system according to claim 1, wherein the curved medium support surface is positioned upstream of the image forming unit.
6. Printing system according to claim 1, wherein the error signal is configured for reducing the transport speed of the web medium on the transport path.
7. Printing system according to claim 1, wherein the error signal is configured for initiating at least one of the following: controlling the image forming unit to adjust a print job for an image to be printed on the web medium; and emitting a communication signal prompt to an operator.
8. Printing system according to claim 1, wherein the controller is arranged for: classifying the orientation error into an error level by comparing the orientation error to an error level reference; and selecting one of the following steps determined by the error level: controlling the image forming unit to adjust a print job for an image to be printed on the web medium; reducing the transport speed; emitting an communication signal prompt to an operator; and stopping the image forming unit, take-out roller, and the take-up roller.
9. Printing system according to claim 1, further comprising a buffer plate defining the curved medium support surface and urging elements for urging the buffer plate against the web medium, wherein the orientation sensor comprises a tilting angle sensor for determining an tilting angle around the tilting axis between the buffer plate and a buffer plate reference orientation.
10. Method for printing of web-based media, the method comprising the steps of: pulling a web medium at a predefined transport speed over a media transport path, which media transport path extends along an orientation sensor comprising a curved medium support surface defining a turn in the media transport path and along an image forming unit to a pulling transport mechanism; sensing the tilting of the curved medium support surface around a tilting axis, which tilting axis extends in a transport direction substantially tangential to the curved medium support surface in a reference orientation; comparing the sensed tilting to the reference orientation to determine an orientation error; and comparing the orientation error to a deviation threshold.
11. Method according to claim 10, further comprising the step of: sensing a displacement of a section of the curved medium support surface in a direction substantially perpendicular to the curved medium support surface; and determining the tilting of the curved medium support surface around a tilting axis from said displacement.
12. Method according to claim 10, further comprising the step of: sensing a displacement of a two opposing lateral sides of the curved medium support surface in a direction substantially perpendicular to the curved medium support surface; and determining the tilting of the curved medium support surface around a tilting axis from said displacements.
13. Method according to claim 10, further comprising the step of emitting an error signal if orientation error exceeds the deviation threshold.
14. Method according to claim 13, further comprising at least one of the following steps: adjusting a print job for an image to be printed on the web medium; adjusting the transport speed; emitting a communication signal; and stopping transport of the web medium.
15. Method according to claim 10, wherein the step of comparing the orientation data to a reference orientation further comprises determining a rotation angle parameter, which rotation angle parameter corresponds to an angle between a longitudinal direction of the web medium and a transport direction of the media transport path.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0095] The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
[0096]
[0097]
[0098]
[0099]
[0100]
[0101]
[0102]
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0103] The present invention will now be described with reference to the accompanying drawings, wherein the same reference numerals have been used to identify the same or similar elements throughout the several views.
[0104]
[0105] Images are printed on an image receiving member, for example paper, supplied by a roll 3, 4. The roll 3 is supported on the roll support R1, while the roll 4 is supported on the roll support R2. Alternatively, cut sheet image receiving members may be used instead of rolls 3, 4 of image receiving member. Printed sheets of the image receiving member, cut off from the roll 3, 4, are deposited in the delivery tray 6.
[0106] Each one of the marking materials for use in the printing assembly are stored in four containers 5 arranged in fluid connection with the respective print heads for supplying marking material to said print heads.
[0107] The local user interface unit 8 is integrated to the print engine and may comprise a display unit and a control panel. Alternatively, the control panel may be integrated in the display unit, for example in the form of a touch-screen control panel. The local user interface unit 8 is connected to a control unit 7 placed inside the printing apparatus 1. The control unit 7, for example a computer, comprises a processor adapted to issue commands to the print engine, for example for controlling the print process. The printing system 1 may optionally be connected to a network N. The connection to the network N is diagrammatically shown in the form of a cable 9, but nevertheless, the connection could be wireless. The printing system 1 may receive printing jobs via the network. Further, optionally, the controller of the printer may be provided with a USB port, so printing jobs may be sent to the printer via this USB port.
[0108]
[0109] The image receiving member 3 may be a medium in web or in sheet form and may be composed of e.g. paper, cardboard, label stock, coated paper, plastic or textile. Alternatively, the image receiving member 3 may also be an intermediate member, endless or not. Examples of endless members, which may be moved cyclically, are a belt or a drum. The image receiving member 3 is moved in the sub-scanning direction A by the platen 11 along four print heads 12a-12d provided with a fluid marking material.
[0110] A scanning print carriage 13 carries the four print heads 12a-12d and may be moved in reciprocation in the main scanning direction B parallel to the platen 11, such as to enable scanning of the image receiving member 3 in the main scanning direction B. Only four print heads 12a-12d are depicted for demonstrating the invention. In practice an arbitrary number of print heads may be employed. In any case, at least one print head 12a-12d per color of marking material is placed on the scanning print carriage 13. For example, for a black-and-white printer, at least one print head 12a-12d, usually containing black marking material is present. Alternatively, a black-and-white printer may comprise a white marking material, which is to be applied on a black image-receiving member 3. For a full-color printer, containing multiple colors, at least one print head 12a-12d for each of the colors, usually black, cyan, magenta and yellow is present. Often, in a full-color printer, black marking material is used more frequently in comparison to differently colored marking material. Therefore, more print heads 12a-12d containing black marking material may be provided on the scanning print carriage 13 compared to print heads 12a-12d containing marking material in any of the other colors. Alternatively, the print head 12a-12d containing black marking material may be larger than any of the print heads 12a-12d, containing a differently colored marking material.
[0111] The carriage 13 is guided by guiding means 14, 15. These guiding means 14, 15 may be rods as depicted in
[0112] Each print head 12a-12d comprises an orifice surface 16 having at least one orifice 17, in fluid communication with a pressure chamber containing fluid marking material provided in the print head 12a-12d. On the orifice surface 16, a number of orifices 17 is arranged in a single linear array parallel to the sub-scanning direction A. Eight orifices 17 per print head 12a-12d are depicted in
[0113] Upon ejection of the marking material, some marking material may be spilled and stay on the orifice surface 16 of the print head 12a-12d. The ink present on the orifice surface 16, may negatively influence the ejection of droplets and the placement of these droplets on the image receiving member 3. Therefore, it may be advantageous to remove excess of ink from the orifice surface 16. The excess of ink may be removed for example by wiping with a wiper and/or by application of a suitable anti-wetting property of the surface, e.g. provided by a coating.
[0114]
[0115] The web medium 3 provided from the roll R1 has a low plane stiffness, which causes the web 3 to buckle easily. Examples of such media are thin media, textile, or certain types of banner media. When sliding over the print surface 11′, the web 3 experiences a friction force which causes the web 3 to buckle, even though a suction force is applied via vacuum holes in the print surface 11′ to hold the medium 3 against the print surface 11′. The buckled web 3 may come into contact with the print heads 12a-d, resulting in the smearing of ink across the web 3 or damage to the print heads 12a-d. To prevent buckling, the medium 3 requires a pulling force to flatten the web 3 over the print surface 11′. This pulling force or tension is provided by a pulling transport mechanism R3 downstream of the inkjet printing assembly 10. Said pulling transport mechanism R3 may be a transport pinch along the transport path P, but is preferably formed as a take-up roller R3. The take-up roller R3 comprises an actuator for rotating the roll R3 and pulling on the web 3, such that the web 3 is under tension along the entire transport path P, or at least between the inkjet printing assembly 10 and the take-up roller R3.
[0116] Prior to printing the leading edge of the web 3 is attached to the take-up roller R3, as shown in
[0117] The present invention allows for high speed printing without additional effort to the operator by monitoring for the occurrence of the above described rotational effects and automatically taking appropriate action. Thereto, the printing system 1 comprises a sensor 20, 30 for detecting the tilting of the curved surface of the buffer plate 31.
[0118] In a preferred embodiment, the orientation sensor 30 comprises a curved buffer plate 31, as shown in
[0119]
[0120] The tilting of the buffer plate 32 is cross-sectionally shown in
[0121] It will be appreciated that in an alternate embodiment, the tilting sensor 20 may be in the form of an optical camera system 20 to determine the orientation of the buffer plate 31.
[0122] The controller 40 compares the difference between the sensed orientation O and the reference orientation OR to a deviation threshold. Said threshold defines a distinction between errors which do affect image quality (visible artifacts) and invisible ones do not reduce print quality. The threshold is preferably a value for a threshold angle or a lateral shift threshold. Orientation errors below the threshold are so small that these do not show up in the printed image, at least not visible by eye. Since such negligible deviations do not visually affect print quality, these are preferably not corrected. This reduces the amount of operations performed by the printing system 1 and ensures smooth operation. Orientation errors above the threshold require compensating or correcting to prevent the image Im from becoming disturbed. In either case, during operation, the printing system 1 keeps monitoring the orientation O of the web 3.
[0123] Once substantial tilting S and in consequence rotation R of the web 3 above the deviation threshold have been determined, the controller 40 initiates the appropriate corrective action, which is shown in the method diagram in
[0124] While printing the sensor 30 determines the orientation of the buffer plate 31. This sensed orientation O is compared to a reference orientation OR of the web 3 or the buffer plate 31, wherefrom a deviation or tilting angle α. Since deviations a may occur which are so small that these do not significantly affect the image quality, the deviation α is compared to a threshold. The threshold may be an upper limit, for example a maximum value for an orientation angle α or a lateral shift. The upper limits defines which deviations a are allowable without requiring correction by the printing system 1. i.e. which do not show up in the printed image. If the detected deviation α in the buffer plate's orientation O is below the threshold, printing is continued at the initially selected high speed and the orientation O of the web 3 is continually monitored by the sensor 30. Further, from this tilting angle α, the rotation of the web 3 with respect to the transport direction D can be derived. Said rotation may be further used to determine the amount of deviation in the web's position.
[0125] In case the controller 40 determines a significantly large deviation α of the web's orientation O with respect to its desired position OR on the transport path P, the controller 40 determines that the deviation α exceeds the predefined threshold. The appropriate error level for the deviation α is then determined by the controller 40. Thereby the controller 40 classifies the deviation α into one of a plurality of error levels, such as minor, medium, and critical deviations. This is done by comparing the deviation, for example the size or magnitude of the deviation angle, or the magnitude and frequency of the oscillations in the web's orientation, to an error level reference stored in the memory of the controller 40. The error level reference comprises criteria for classifying a deviation into an error level, for example by defining bottom and/or upper limits or ranges for matching the determined deviations to one of the error levels.
[0126] When a deviation has been selected or classified by the controller 40 as a specific class of error level, the controller 40 instructs the printing system 1 to perform one or more actions linked to said error level. The memory of the controller 40 stores for each error level instructions for performing corrective actions. The error level determines the corrective action(s) to be taken. For example, for minor deviations, the image to be printed may be repositioned or adjusted, either by adjusting the digital bitmap or by repositioning the print heads 12a-d to correct for the determined deviation of the web 3. When the determined deviations are too large to be corrected by adjusting the image, these deviations are classified into a different class. A different corrective action is also required. When selecting a class of such deviations of the web 3, especially in the case of determined periodic oscillations in the web's orientation O, the controller 40 adjusts the transport speed. The speed may be set to a predefined speed wherein oscillations of the web 3 were known to be minimal or absent. Alternatively the speed may be adjusted stepwise while continuously monitoring the deviation α of the web 3 to stepwise reduce or eliminate the deviations or oscillations in the web's orientation. Very large deviations which may cause damaged media or paper jams are classified as critical deviations. When this latter class is selected the controller 40 instructs the printing system 1 to halt the print operation, stopping both the transport mechanism R1-R3 and the inkjet printing assembly 10. Further, the controller 40 may, when selecting any of the error levels, instruct a communication device to send a signal to an operator. The communication device may be a light on the printer, a user interface for prompting the user, or an emitter for sending a wireless signal to a receiver held by the operator. The communication signal may be used to inform the operator of the status of the printing system 1 or to instruct the operator to attend the printing system 1, for example when an increase in deviations or certain class of deviations has been determined. This allows the operator to leave the system 1 unattended. It will be appreciated that apart from magnitude deviations in the web's positions may be classified by type, such as periodic oscillations, lateral shifts, rotations etc.
[0127] Although specific embodiments of the invention are illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations exist. It should be appreciated that the exemplary embodiment or exemplary embodiments are examples only and are not intended to limit the scope, applicability, or configuration in any way. Rather, the foregoing summary and detailed description will provide those skilled in the art with a convenient road map for implementing at least one exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope as set forth in the appended claims and their legal equivalents. Generally, this application is intended to cover any adaptations or variations of the specific embodiments discussed herein.
[0128] It will also be appreciated that in this document the terms “comprise”, “comprising”, “include”, “including”, “contain”, “containing”, “have”, “having”, and any variations thereof, are intended to be understood in an inclusive (i.e. non-exclusive) sense, such that the process, method, device, apparatus or system described herein is not limited to those features or parts or elements or steps recited but may include other elements, features, parts or steps not expressly listed or inherent to such process, method, article, or apparatus. Furthermore, the terms “a” and “an” used herein are intended to be understood as meaning one or more unless explicitly stated otherwise. Moreover, the terms “first”, “second”, “third”, etc. are used merely as labels, and are not intended to impose numerical requirements on or to establish a certain ranking of importance of their objects.
[0129] The present invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the present invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.