# Patent

## Title
Droplet ejection apparatus and a method of detecting and judging head failure in the same

## Abstract

It is an object of the invention to provide a droplet ejection apparatus and a method of detecting and judging a head failure that can detect an ejection failure and carry out appropriate recovery processing according to a cause thereof. The droplet ejection apparatus of the invention includes a plurality of droplet ejection heads, each of the droplet ejection heads including a diaphragm and an actuator which displaces the diaphragm; a driving circuit which drives the actuator of each droplet ejection head; residual vibration detector 16 for detecting a residual vibration of the diaphragm displaced by the actuator after the actuator has been driven by the driving circuit; pulse generator for generating reference pulses; information processor 17 for carrying out a computation for the number of reference pulses generated by the pulse generator on the basis of the residual vibration of the diaphragm detected by the residual vibration detector; time measurer for measuring a lapsed time since the actuator has been driven by the driving circuit; and head failure judge 20 for judging a head failure in the droplet ejection heads on the basis of the computation result of the information processor 17 and the lapsed time measured by the time measurer.

## Background
This application is a divisional patent application of U.S. Ser. No. 10/824,335 filed Apr. 14, 2004, claiming priority to Japanese Patent Application No. 2003-112232 filed Apr. 16, 2003 all of which are hereby incorporated by reference.


BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a droplet ejection apparatus and a method of detecting and judging a head failure.
2. Background Art
An ink jet printer, which is one type of droplet ejection apparatus, forms an image on a predetermined sheet of paper by ejecting ink drops (droplets) via a plurality of nozzles of a printing head of the ink jet printer. The printing head (ink jet head) of the ink jet printer is provided with a number of nozzles. However, there is a case where some of the nozzles are blocked due to an increase of ink viscosity, intrusion of air bubbles, adhesion of dust or paper dust, or the like, and therefore these nozzles become unable to eject ink droplets. When the nozzles are blocked, missing dots occur within a printed image, which results in deterioration of image quality.
As far, a method of optically detecting a state where no ink droplets are ejected through the nozzles of the ink jet head (a state of failing ink droplet ejection) for each nozzle of the ink jet head was devised as a method of detecting such an ejection failure of an ink droplet (hereinafter, also referred to as the missing dot) (for example, see Japanese Laid-Open Patent Application No. Hei. 8-309963 or the like). This method makes it possible to identify a nozzle causing the missing dot (ejection failure).
In the optical missing dot (droplet ejection failure) detecting method described above, however, a detector including a light source and an optical sensor is attached to a droplet ejection apparatus (for example, an ink jet printer). Hence, this detecting method generally has a problem that the light source and the optical sensor have to be set (or provided) with exact accuracy (high degree of accuracy) so that droplets ejected through the nozzles of the droplet ejection head (ink jet head) pass through a space between the light source and the optical sensor and therefore intercept light from the light source to the optical sensor. In addition, since such a detector is generally expensive, the droplet ejection apparatus having the detector has another problem that the manufacturing costs of the ink jet printer are increased. Further, since an output portion of the light source or a detection portion of the optical sensor may be smeared by ink mist through the nozzles or paper dust from printing sheets or the like, there is a possibility that the reliability of the detector becomes a matter of concern.
Further, although the optical missing dot detecting method described above can detect the missing dot, that is, an ejection failure (non-ejection) of ink droplets from the nozzles, the cause of the missing dot (ejection failure) cannot be identified (judged) on the basis of the detection result. Hence, there is another problem that it is impossible to select and carry out appropriate recovery processing depending on the cause of the missing dot (ejection failure). For this reason, sequential recovery processing is carried out independently of the cause of the missing dot in the conventional missing dot detecting method. For example, ink may be pump-sucked (vacuumed) from the ink jet head under circumstances where a wiping process might be sufficient for, recovery. This increases discharged ink (wasted ink), or causes several types of recovery processing to be carried out because appropriate recovery processing is not carried out, and thereby reduces or deteriorates throughput of the ink jet printer (droplet ejection apparatus).
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a droplet ejection apparatus and a method of detecting and judging a head failure that can detect an ejection failure (head failure) in droplet ejection heads and carry out appropriate recovery processing according to a cause thereof.
In order to achieve the above object, in one aspect of the invention, the invention is directed to a droplet ejection apparatus. The droplet ejection apparatus in one embodiment includes:

    
    
        a plurality of droplet ejection heads, each of the droplet ejection heads including:
        
            a diaphragm;
            an actuator which displaces the diaphragm;
            a cavity filled with a liquid, an internal pressure of the cavity being increased and decreased in response to displacement of the diaphragm; and
            a nozzle communicated with the cavity, through which the liquid is ejected in the form of droplets in response to the increase and decrease of the internal pressure of the cavity;
        
        
        a driving circuit which drives the actuator of each droplet ejection head;
        residual vibration detecting means for detecting a residual vibration of the diaphragm displaced by the actuator after the actuator has been driven by the driving circuit;
        pulse generating means for generating reference pulses;
        computation means for carrying out a computation for the number of reference pulses generated by the pulse generating means on the basis of the residual vibration of the diaphragm detected by the residual vibration detecting means;
        time measuring means for measuring a lapsed time since the actuator has been driven by the driving circuit; and
        head failure judging means for judging a head failure in the droplet ejection heads on the basis of the computation result of the computation means and the lapsed time measured by the time measuring means.
    
    


According to the droplet ejection apparatus in the one embodiment of the invention, when the ejection operation in which the liquid is ejected in the form of droplets (it may be the driving of the actuator to an extent that the liquid is not ejected) is carried out by the driving of the actuator, the pulses generated in the predetermined time period are counted and the lapsed time is measured since the previous driving of the actuator, and it is detected whether the droplet has been ejected normally or not on the basis of the counted value and the lapsed time.
Therefore, according to the droplet ejection apparatus of the invention, in comparison with the conventional droplet ejection apparatus capable of detecting an ejection failure, the droplet ejection apparatus of the invention does not need other parts (for example, optical missing dot detecting device or the like). As a result, not only an ejection failure (including a head failure, “head failure” will be described later) of the droplets can be detected without increasing the size of the droplet ejection head, but also the manufacturing costs of the droplet ejection apparatus capable of carrying out an ejection failure (missing dot) detecting operation can be reduced. In addition, because the droplet ejection apparatus of the invention detects an ejection failure of the droplets through the use of the residual vibration of the diaphragm after the droplet ejection operation, an ejection failure of the droplets can be detected even during the recording operation.
Further, a droplet ejection failure in another embodiment of the invention includes:

    
    
        a plurality of droplet ejection heads, each of the droplet ejection heads including:
        
            a cavity filled with a liquid;
            a nozzle communicated with the cavity; and
            an actuator which changes an internal pressure of the cavity to eject the liquid in the form of droplets through the nozzle in response to the pressure changes;
        
        
        a driving circuit which drives the actuator of each droplet ejection head;
        residual vibration detecting means for detecting a residual vibration of an electromotive voltage generated from the actuator after the actuator has been driven by the driving circuit;
        pulse generating means for generating reference pulses;
        computation means for carrying out a computation for the number of reference pulses generated by the pulse generating means on the basis of the residual vibration of the electromotive voltage detected by the residual vibration detecting means;
        time measuring means for measuring a lapsed time since the actuator has been driven by the driving circuit; and
        head failure judging means for judging a head failure in the droplet ejection heads on the basis of the computation result of the computation means and the lapsed time measured by the time measuring means.
    
    


According to the droplet ejection apparatus in another embodiment of the invention, in place of the residual vibration of the diaphragm described above, by detecting the residual vibration of the electromotive voltage generated from the actuator, it is possible to achieve the operation and effect similar to the droplet ejection apparatus in one embodiment described above. In this way, the droplet ejection apparatus of the invention can adopt the similar structure using the electromotive voltage of the piezoelectric actuator.
The residual vibration of the diaphragm referred to herein means a state in which the diaphragm keeps vibrating while damping due to the droplet ejection operation (including the operation to an extent that the liquid is not ejected) after the actuator carried out the droplet ejection operation according to a driving signal (voltage signal) from the driving circuit until the actuator carries out the droplet ejection operation again in response to input of the following driving signal. Further, the residual vibration of the electromotive voltage referred to herein means a state in which the electromotive voltage generated by the actuator keeps vibrating while damping due to the droplet ejection operation (including the operation to an extent that the liquid is not ejected) after the actuator carried out the droplet ejection operation according to a driving signal (voltage signal) from the driving circuit until the actuator carries out the droplet ejection operation again in response to input of the following driving signal.
In the droplet ejection apparatus of the invention, it is preferable that the computation means includes timing generating means for generating predetermined timing on the basis of the residual vibration detected by the residual vibration detecting means, a counter which counts the number of reference pulses generated by the pulse generating means for a predetermined time period, and holding means which holds the count value of the counter at the timing generated by the timing generating means. In this case, it is preferable that the counter subtracts the number of reference pulses generated for the predetermined time period from a predetermined reference value. Moreover, it is preferable that the droplet ejection apparatus of the invention further includes a memory for storing the predetermined reference value.
It is preferable that the droplet ejection apparatus of the invention further includes a temperature sensor for measuring ambient temperature of the plurality of droplet ejection heads. In this case, it is preferable that the predetermined reference value is corrected on the basis of the ambient temperature measured by the temperature sensor. This makes it possible to detect the head failure in the droplet ejection heads more accurately.
Further, in the droplet ejection apparatus of the invention, it is preferable that the predetermined time period is any one of a time period until the residual vibration is generated after driving the actuator, a time period corresponding to a first half cycle of the residual vibration, and a time period corresponding to a first one cycle of the residual vibration. Furthermore, in the droplet ejection apparatus of the invention, it is preferable that the head failure judging means judges presence or absence of the head failure in the droplet ejection heads and a cause thereof on the basis of the computation result by the computation means and the lapsed time. Moreover, in the droplet ejection apparatus of the invention, it is preferable that the head failure judging means judges a cause of the head failure on the basis of the count value held by the holding means and the lapsed time.
In this case, in the droplet ejection apparatus of the invention, it is preferable that the head failure judging means judges that an air bubble has been intruded into the cavity as the cause of the head failure in the case where the held count value is larger than a first count threshold. Further, in the droplet ejection apparatus of the invention, it is preferable that the head failure judging means judges the cause of the head failure according to the lapsed time in the case where the held count value is smaller than a first count threshold. In this case, it is preferable that the head failure judging means judges that much paper dust is adhering in the vicinity of the outlet of the nozzle as the cause of the head failure in the case where the held count value is smaller than a third count threshold and the lapsed time is smaller than a first time threshold. In this regard, in the invention, “paper dust” is not limited to mere paper dust generated from a recording sheet or the like. For example, the “paper dust” includes all the substances that could adhere in the vicinity of the nozzles and impede ejection of droplets, such as pieces of rubber from the advancing roller (feeding roller) and dust afloat in air.
Further, in the droplet ejection apparatus of the invention, it is preferable that the head failure judging means judges that little paper dust is adhering in the vicinity of the outlet of the nozzle as the cause of the head failure in the case where the held count value is in the range between a second count threshold and a third count threshold and the lapsed time is smaller than a first time threshold. In the droplet ejection apparatus of the invention, it is preferable that the head failure judging means judges that the head failure does not occur in the case where the held count value is in the range between the first count threshold and a second count threshold and the lapsed time is smaller than a first time threshold. In the droplet ejection apparatus of the invention, it is preferable that the head failure judging means judges that much paper dust is adhering in the vicinity of the outlet of the nozzle as the cause of the head failure in the case where the held count value is smaller than a third count threshold and the lapsed time is in the range between first and second time thresholds. In the droplet ejection apparatus of the invention, it is preferable that the head failure judging means judges that the liquid in the vicinity of the nozzle has somewhat thickened due to drying as the cause of the head failure in the case where the held count value is in the range between a second count threshold and a third count threshold and the lapsed time is in the range between first and second time thresholds. In the droplet ejection apparatus of the invention, it is preferable that the head failure judging means judges that the head failure does not occur in the case where the held count value is in the range between the first count threshold and a second count threshold and the lapsed time is in the range between first and second time thresholds.
Moreover, in the droplet ejection apparatus of the invention, it is preferable that the head failure judging means judges that the liquid in the vicinity of the nozzle has considerably thickened due to drying as the cause of the head failure in the case where the held count value is smaller than a third count threshold and the lapsed time is larger than a second time threshold. In the droplet ejection apparatus of the invention, it is preferable that the head failure judging means judges that little paper dust is adhering in the vicinity of the outlet of the nozzle as the cause of the head failure in the case where the held count value is in the range between a second count threshold and a third count threshold and the lapsed time is larger than a second time threshold. In the droplet ejection apparatus of the invention, it is preferable that the head failure judging means judges that the head failure does not occur in the case where the held count value is in the range between the first count threshold and a second count threshold and the lapsed time is larger than a second time threshold.
Here, it is preferable that the droplet ejection apparatus of the invention further includes recovery means for carrying out recovery processing to eliminate the cause of the head failure judged by the head failure judging means. In this case, in the droplet ejection apparatus of the invention, it is preferable that the recovery means includes: wiping means for carrying out a wiping process in which a nozzle surface of the plurality of droplet ejection heads where the nozzles are arranged is wiped with a wiper; flushing means for carrying out a flushing process by which the droplets are preliminarily ejected through the predetermined nozzle by driving the actuator; and pumping means for carrying out a pump-suction process with the use of a pump connected to a cap that covers the nozzle surface of the plurality of droplet ejection heads.
Further, in the droplet ejection apparatus of the invention, it is preferable that the recovery means carries out the flushing process or the pump-suction process in the case where it is judged that the cause of the head failure is the little thickening of the liquid due to drying. In the droplet ejection apparatus of the invention, it is preferable that the recovery means carries out the pump-suction process in the case where it is judged that the cause of the head failure is the considerable thickening of the liquid due to drying. In the droplet ejection apparatus of the invention, it is preferable that the recovery means changes the number of ejections in the flushing process or a suction time of the pump in the pump-suction process according to the degree of the thickening of the liquid due to drying and carries out the flushing process or the pump-suction process in the case where it is judged that the cause of the head failure is the thickening of the liquid due to drying. In the droplet ejection apparatus of the invention, it is preferable that the recovery means carries out the wiping process in the case where it is judged that the cause of the head failure is the adhesion of paper dust. In the droplet ejection apparatus of the invention, it is preferable that the recovery means changes the number of wiping operations in the wiping process according to the degree of the adhesion of paper dust and carries out the wiping process in the case where it is judged that the cause of the head failure is the adhesion of paper dust. In this case, in the droplet ejection apparatus of the invention, it is preferable that the recovery means changes the number of wiping operations in the wiping process according to the degree of the ejection operations in the flushing process in response to the lapsed time and carries out the flushing process in the case where it is judged that the cause of the head failure is the little thickening of the liquid due to drying when the flushing process is to be carried out.
In the droplet ejection apparatus of the invention, it is preferable that the recovery means carries out the pump-suction process in the case where the cause of the head failure is the intrusion of air bubble. In this case, in the droplet ejection apparatus of the invention, it is preferable that the recovery means changes a suction time of the pump in the pump-suction process according to the computation result and carries out the pump-suction process in the case where it is judged that the cause of the head failure is the intrusion of air bubble.
Further, in the droplet ejection apparatus of the invention, it is preferable that the recovery means carries out the recovery processing until the cause of the head failure judged by the head failure judging means is eliminated. It is preferable that the droplet ejection apparatus of the invention further includes informing means for informing that the head failure is not recovered in the case where the cause of the head failure is not eliminated even though the recovery means carried out the recovery processing. In this case, in the droplet ejection apparatus of the invention, it is preferable that the droplet ejection apparatus of the invention further includes liquid storage means for storing the liquid to be supplied to the cavities of the plurality of droplet ejection heads, and that the informing means informs that the liquid storage means is to be exchanged in the case where the cause of the head failure is not eliminated even though the recovery means carried out the recovery processing. Moreover, in the droplet ejection apparatus of the invention, it is preferable that the droplet ejection apparatus is constructed so as to stop a printing operation when carrying out a printing operation in the case where the cause of the head failure is not eliminated even though the recovery means carried out the recovery processing.
It is preferable that the droplet ejection apparatus of the invention further includes storage means for storing the judgment result judged by the head failure judging means in association with the nozzle for which the judgment was carried out.
Further, it is preferable that the droplet ejection apparatus of the invention further includes switching means for switching a connection of the actuator from the driving circuit to the residual vibration detecting means after carrying out the droplet ejection operation by driving the actuator. In this case, in the droplet ejection apparatus of the invention, it is preferable that the droplet ejection apparatus comprises a plurality of residual vibration detecting means, a plurality of computation means, a plurality of head failure judging means and a plurality of switching means, and that the switching means corresponding to the droplet ejection head in which the actuator has carried out the driving operation switches the connection of the actuator from the driving circuit to the corresponding residual vibration detecting means, and then the head failure judging means corresponding to the switched residual vibration detecting means judges the head failure of the corresponding droplet ejection head.
Alternatively, in the droplet ejection apparatus of the invention, it is preferable that the droplet ejection apparatus of the invention further includes a plurality of switching means which respectively correspond to the plurality of droplet ejection heads; and detection determining means that determines for which droplet ejection head the residual vibration detecting means detects the residual vibration, in which the corresponding switching means switches a connection of the actuator from the driving circuit to the residual vibration detecting means after carrying out the driving operation of the actuator of the droplet ejection head determined by the detection determining means.
In the droplet ejection apparatus of the invention, it is preferable that the residual vibration detecting means includes an oscillation circuit and the oscillation circuit oscillates in response to an electric capacitance component of the actuator that varies with the residual vibration of the diaphragm or in response to an electromotive voltage component of the actuator. In this case, in the droplet ejection apparatus of the invention, it is preferable that the ejection failure detecting means includes a resistor element connected to the actuator, and the oscillation circuit forms a CR oscillation circuit based on the electric capacitance component of the actuator and a resistance component of the resistor element.
Further, in the droplet ejection apparatus of the invention, it is preferable that the ejection failure detecting means includes an F/V converting circuit that generates a voltage waveform in response to the residual vibration of the diaphragm from a predetermined group of signals generated based on changes in an oscillation frequency of an output signal from the oscillation circuit. In this case, in the droplet ejection apparatus of the invention, it is preferable that the ejection failure detecting means includes a waveform shaping circuit that shapes the voltage waveform in response to the residual vibration of the diaphragm generated by the F/V converting circuit into a predetermined waveform. Furthermore, in the droplet ejection apparatus of the invention, it is preferable that the waveform shaping circuit includes: DC component eliminating means for eliminating a direct current component from the voltage waveform of the residual vibration of the diaphragm generated by the F/V converting circuit; and a comparator that compares the voltage waveform from which the direct current component thereof has been eliminated by the DC component eliminating means with a predetermined voltage value, in which wherein the comparator generates and outputs a rectangular wave based on this voltage comparison.
Moreover, the actuator may be an electrostatic actuator, or a piezoelectric actuator using a piezoelectric effect of a piezoelectric element. In addition, it is preferable that the droplet ejection apparatus of the invention further includes storage means for storing a cause of the ejection failure of the droplets detected by the ejection failure detecting means in association with the nozzle for which the detection was carried out. Moreover, it is preferable that the droplet ejection apparatus of the invention includes an ink jet printer.
Further, in another aspect of the invention, the invention is directed to a method of detecting and judging a head failure in a droplet ejection apparatus. The method in one embodiment includes the steps of:
detecting a residual vibration of a diaphragm displaced by an actuator in a droplet ejection head after the actuator has been driven by a driving circuit;
generating reference pulses at the same time when detecting the residual vibration of the diaphragm;
carrying out an operation for the number of reference pulses generated on the basis of the residual vibration of the diaphragm;
measuring a lapsed time since the actuator has been driven by the driving circuit; and
judging a head failure in the droplet ejection head on the basis of the computation result and the measured lapsed time.
Moreover, in another embodiment of the invention, a method of detecting and judging a head failure in a droplet ejection apparatus includes the steps of:
detecting a residual vibration of an electromotive voltage generated from an actuator in a droplet ejection head after the actuator has been driven by a driving circuit;
generating reference pulses at the same time when detecting the residual vibration of the electromotive voltage;
carrying out an operation for the number of reference pulses generated on the basis of the residual vibration of the electromotive voltage;
measuring a lapsed time since the actuator has been driven by the driving circuit; and
judging a head failure in the droplet ejection head on the basis of the computation result and the measured lapsed time.
Here, in any method of detecting and judging a head failure in a droplet ejection apparatus, it is preferable that the method includes the step of:
carrying out recovery processing to eliminate a cause of the head failure in response to the judged cause of the head failure.



BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features, and the advantages of the invention will readily become more apparent from the following detailed description of preferred embodiments of the invention with reference to the accompanying drawings.
FIG. 1 is a schematic view showing the configuration of an ink jet printer as one type of droplet ejection apparatus of the invention.
FIG. 2 is a block diagram schematically showing a major portion of the ink jet printer (droplet ejection apparatus) of the invention.
FIG. 3 is a schematic cross sectional view of a head unit (ink jet head) in the ink jet printer shown in FIG. 1.
FIG. 4 is an exploded perspective view showing the configuration of the head unit shown in FIG. 3.
FIG. 5 shows one example of a nozzle arrangement pattern in a nozzle plate of the head unit using four colors of inks.
FIG. 6 is a state diagram showing respective states of a cross section taken along the line III-III of FIG. 3 when a driving signal is inputted.
FIG. 7 is a circuit diagram showing a computation model of simple harmonic vibration on the assumption of residual vibration of the diaphragm shown in FIG. 3.
FIG. 8 is a graph showing the relationship between an experimental value and computed value of residual vibration of the diaphragm shown in FIG. 3 in the case of normal ejection.
FIG. 9 is a conceptual view in the vicinity of the nozzle in a case where an air bubble has intruded into the cavity shown in FIG. 3.
FIG. 10 is a graph showing the computed value and the experimental value of residual vibration in a state where ink droplets cannot be ejected due to intrusion of an air bubble into the cavity.
FIG. 11 is a conceptual view in the vicinity of the nozzle in a case where ink has fixed due to drying in the vicinity of the nozzle shown in FIG. 3.
FIG. 12 is a graph showing the computed value and the experimental value of residual vibration in a state where ink has thickened due to drying in the vicinity of the nozzle.
FIG. 13 is a conceptual view in the vicinity of the nozzle in a case where paper dust is adhering in the vicinity of the outlet of the nozzle shown in FIG. 3.
FIG. 14 is a graph showing the computed value and the experimental value of residual vibration in a state where paper dust is adhering to the outlet of the nozzle.
FIG. 15 shows pictures of the nozzle states before and after adhesion of paper dust in the vicinity of the nozzle.
FIG. 16 is a schematic block diagram of the ejection failure detecting means.
FIG. 17 is a conceptual view in the case where the electrostatic actuator shown in FIG. 3 is assumed as a parallel plate capacitor.
FIG. 18 is a circuit diagram of an oscillation circuit including the capacitor constituted from the electrostatic actuator shown in FIG. 3.
FIG. 19 is a circuit diagram of an F/V converting circuit in the ejection failure detecting means shown in FIG. 16.
FIG. 20 is a timing chart showing the timing of output signals from respective portions and the like based on an oscillation frequency outputted from the oscillation circuit.
FIG. 21 is a drawing used to explain a setting method of fixed times tr and t1.
FIG. 22 is a circuit diagram showing the circuitry of a waveform shaping circuit shown in FIG. 16.
FIG. 23 is a block diagram schematically showing switching means for switching between a driving circuit and a detection circuit.
FIG. 24 is a block diagram showing one example of computation means according to the invention.
FIG. 25 is a timing chart of the subtraction processing of the subtraction counter shown in FIG. 24.
FIG. 26 is a flowchart showing head failure detection and judgment processing of the invention.
FIG. 27 is a flowchart showing ejection failure detection processing in one embodiment according to the invention.
FIG. 28 is a flowchart showing residual vibration detection processing of the invention.
FIG. 29 is a flowchart showing one example of computation processing according to the invention.
FIG. 30 is a flowchart showing another example of computation processing according to the invention.
FIG. 31 is a graph showing the relationship between a degree of ink viscosity and ambient temperature.
FIG. 32 is a flowchart partially showing ejection failure (head failure) judgment processing of the invention.
FIG. 33 is a flowchart partially showing ejection failure (head failure) judgment processing of the invention.
FIG. 34 is a flowchart partially showing ejection failure (head failure) judgment processing of the invention.
FIG. 35 is a graph showing the relationship between a lapsed time (waiting time) and a degree of ink viscosity and the relationship between vibration frequency of the residual vibration and a degree of ink viscosity.
FIG. 36 shows one example of detection timing of an ejection failure for a plurality of ink jet heads (in the case where there is one ejection failure detecting means).
FIG. 37 shows another example of detection timing of an ejection failure for a plurality of ink jet heads (in the case where the number of ejection failure detecting means is equal to the number of ink jet heads).
FIG. 38 shows still another example of detection timing of an ejection failure for a plurality of ink jet heads (in the case where the number of ejection failure detecting means is equal to the number of ink jet heads, and detection of an ejection failure is carried out when printing data is inputted).
FIG. 39 shows yet still another example of detection timing of an ejection failure for a plurality of ink jet heads (in the case where the number of switching means is equal to the number of ink jet heads, and detection of an ejection failure is carried out by making the rounds of the respective ink jet heads).
FIG. 40 is a flowchart showing the detection timing of an ejection failure during a flushing operation by the ink jet printer shown in FIG. 36.
FIG. 41 is a flowchart showing the detection timing of an ejection failure during a flushing operation by the ink jet printers shown in FIGS. 37 and 38.
FIG. 42 is a flowchart showing the detection timing of an ejection failure during a flushing operation by the ink jet printer shown in FIG. 39.
FIG. 43 is a flowchart showing the detection timing of an ejection failure during a printing operation by the ink jet printers shown in FIGS. 37 and 38.
FIG. 44 is a flowchart showing the detection timing of an ejection failure during a printing operation by the ink jet printer shown in FIG. 39.
FIG. 45 is a drawing schematically showing the structure (part of which is omitted) when viewed from the top of the ink jet printer shown in FIG.1.
FIG. 46 is a drawing showing the positional relationship between a wiper and head unit shown in FIG. 45.
FIG. 47 is a drawing showing the relationship between the head unit (ink jet heads), a cap and a pump during a pump-suction process.
FIG. 48 is a schematic view showing the configuration of a tube pump shown in FIG. 47.
FIG. 49 is a flowchart showing ejection failure recovery processing in the ink jet printer (droplet ejection apparatus) of the invention.
FIG. 50 is a flowchart showing ejection failure recovery processing in the ink jet printer (droplet ejection apparatus) of the invention (in consideration of the count value and lapsed time).
FIG. 51 is a cross sectional view schematically showing an example of another configuration of the ink jet head of the invention.
FIG. 52 is a cross sectional view schematically showing an example of still another configuration of the ink jet head of the invention.
FIG. 53 is a cross sectional view schematically showing an example of still another configuration of the ink jet head of the invention.
FIG. 54 is a cross sectional view schematically showing an example of still another configuration of the ink jet head of the invention.
FIG. 55 is a block diagram schematically showing switching means between the driving circuit and the detecting circuit in the case of using a piezoelectric actuator.
FIG. 56 is a flowchart showing the residual vibration detection processing in another embodiment according to the invention.



DETAILED DESCRIPTION OF THE INVENTION
Preferred embodiments of a droplet ejection apparatus and a method of detecting and judging a head failure of the invention will now be described in detail with reference to FIGS. 1-56. It is to be understood that these embodiments are mentioned for the purpose of illustration of the invention and interpretations of the content of the invention are not limited to these embodiments. It should be noted that, in the embodiments described below, an ink jet printer that prints an image on a recording sheet (droplet receptor) by ejecting ink (liquid material) will be described as one example of the droplet ejection apparatus of the invention.
FIRST EMBODIMENT
FIG. 1 is a schematic view showing the configuration of an ink jet printer 1 as one type of droplet ejection apparatus according to a first embodiment of the invention. Now, in following explanations using FIG. 1, an upper side and lower side are referred to as “upper” and “lower,” respectively. First, the configuration of the ink jet printer 1 will be described.
The ink jet printer 1 shown in FIG. 1 includes a main body 2. A tray 21 on which recording sheets P may be placed, a sheet discharge port 22, through which the recording sheet P is discharged, and an operation panel 7 are respectively provided in the rear of the top, in the front of the bottom, and on the top surface, of the main body 2.
The operation panel 7 is provided with a display portion (not shown) for displaying an error message or the like, such as a liquid crystal display, an organic EL display, an LED lamp or the like, and an operation portion (not shown) comprising various kinds of switches or the like. The display portion of the operation panel 7 functions as informing means that informs that effect in the case where an ejection failure (head failure) is detected in ejection failure detection processing described later. In this regard, the informing means (informing method) is not limited to display on the display portion. For example, the informing means includes means by outputting voice or an alarm, lighting of a lamp, or one that can respectively transmit information on an ejection failure to a host computer 8 or a print server via an IF 9 or a network, and the like.
The informing means may inform that effect in the case where a cause of a head failure cannot be eliminated even though the recovery processing by recovery means 24 (described later) has been carried out, and may inform that an ink cartridge (liquid storage means) 31 that stores the ink to be supplied to cavities 141 of a plurality of droplet ejection heads 100 is to be exchanged in the case where the cause of the head failure is not eliminated even though the recovery means carried out the recovery processing. The droplet ejection apparatus (ink jet printer) of the invention may be constituted so as to stop a printing operation when carrying out the printing operation in the case where the cause of the head failure is not eliminated even though the recovery means carried out the recovery processing.
Further, the main body 2 mainly includes a printing device 4 equipped with printing means (moving element) 3 which undergoes a reciprocating motion, a feeder (droplet receptor transporting means) 5 which feeds and discharges a recording sheet P to/from the printing device 4 one by one, and a control section (control means) 6 which controls the printing device 4 and the feeder 5.
The feeder 5 intermittently feeds recording sheets P one by one under the control of the control section 6. The recording sheet P passes by the vicinity of the bottom of the printing means 3. In this instance, the printing means 3 reciprocates in a direction substantially perpendicular to the feeding direction of the recording sheet P, thereby carrying out a printing operation on the recording sheet P. In other words, the printing operation by the ink jet method is carried out so that the reciprocating motion of the printing means 3 and the intermittent feeding of the recording sheet P constitute the main scanning and the sub scanning of printing, respectively.
The printing device 4 is provided with the printing means 3, a carriage motor 41 serving as a driving source for moving the printing means 3 (making it to reciprocate) in the main scanning direction, and a reciprocating mechanism 42 which receives rotations of the carriage motor 41 and making the printing means 3 to reciprocate in the main scanning direction.
The printing means 3 includes a plurality of head units 35 on which a plurality of nozzles 110 are provided in accordance with ink types, a plurality of ink cartridges (I/C) 31 each respectively supplying the head units 35 with inks, a carriage 32 on which the head units 35 and ink cartridges 31 are mounted.
Further, as will be described in FIG. 3, the head unit 35 is provided with a number of ink jet recording heads (i.e., ink jet heads or droplet ejection heads) 100 each comprising a nozzle 110, a diaphragm 121, an electrostatic actuator 120, a cavity 141, an ink supply port 142, and the like. In this regard, although FIG. 1 shows the configuration in which the head units 35 and the ink cartridges 31 are included, the invention is not limited to this configuration. For example, the invention may include a configuration in which the ink cartridges 31 are provided in another place instead of being mounted on the carriage 32, and communicates with the head units 35 via tubes or the like to supply inks thereto (not shown in the drawings). Hereinafter, the configuration in which the plurality of ink jet heads 100, each of which comprises the nozzle 110, the diaphragm 121, the electrostatic actuator 120, the cavity 141, the ink supply port 142, and the like, are provided will be referred to as the “head unit 35”.
By using cartridges respectively filled with four colors of inks, including yellow, cyan, magenta, and black, as the ink cartridges 31, full-color printing becomes possible. In this case, the head units 35 respectively corresponding to the colors are provided in the printing means 3. Here, FIG. 1 shows four ink cartridges 31 respectively corresponding to four colors of inks, but the printing means 3 may be configured to further include an ink cartridge or ink cartridges 31 for other ink such as light cyan, light magenta, or dark yellow a special color or the like.
The reciprocating mechanism 42 includes a carriage guide shaft 422 supported by a frame (not shown) at both ends thereof, and a timing belt 421 extending in parallel with the carriage guide shaft 422.
The carriage 32 is supported by the carriage guide shaft 422 of the reciprocating mechanism 42 so as to be able to reciprocate and is fixed to a part of the timing belt 421.
When the timing belt 421 is run forward and backward via a pulley by the operation of the carriage motor 41, the printing means 3 is guided by the carriage guide shaft 422 and starts to reciprocate. During this reciprocating motion, ink droplets are ejected through the nozzles 110 of the plurality of ink jet heads 100 in the head units 35 as needed in response to image data (printing data) to be printed, thereby carrying out printing operation onto the recording sheet P.
The feeder 5 includes a feeding motor 51 serving as a driving source thereof, and a feeding roller 52 which is rotated in association with the operation of the feeding motor 51.
The feeding roller 52 comprises a driven roller 52a and a driving roller 52b which vertically face across a transportation path of a recording sheet P (i.e., a recording sheet P). The driving roller 52b is connected to the feeding motor 51. This allows the feeding roller 52 to feed a number of recording sheets P placed on the tray 21 to the printing device 4 one by one, and discharge the recording sheets P from the printing device 4 one by one. Instead of the tray 21, a feeding cassette in which the recording sheets P can be housed may be removably attached.
The control section 6 carries out a printing operation on a recording sheet P by controlling the printing device 4, the feeder 5 and the like according to the printing data inputted from a host computer 8 such as a personal computer (PC), a digital camera (DC) or the like. The control section 6 also controls the display portion of the operation panel 7 to display an error message or the like, or an LED lamp or the like to be turned ON/OFF, and controls the respective portions to carry out corresponding processes according to press signals of various switches inputted from the operation portion.
FIG. 2 is a block diagram schematically showing a major portion of the ink jet printer of the invention. Referring to FIG. 2, the ink jet printer 1 of the invention is provided with an interface portion (IF) 9 for receiving printing data or the like inputted from the host computer 8, the control section 6, the carriage motor 41, a carriage motor driver 43 for controlling the driving of the carriage motor 41, the feeding motor 51, a feeding motor driver 53 for controlling the driving of the feeding motor 51, the head units 35, a head driver 33 for controlling the driving of the head units 35, ejection failure detecting means 10, the operation panel 7, recovery means 24, time measuring means 25, and a temperature sensor 37. In this regard, the ejection failure detecting means 10, the head driver 33, and the recovery means 24 will be described later in detail.
Referring to FIG. 2, the control section 6 is provided with a CPU (Central Processing Unit) 61 which carries out various types of processes such as a printing process, ejection failure detection processing or the like, an EEPROM (Electrically Erasable Programmable Read-Only Memory) (storage means) 62 as one kind of nonvolatile semiconductor memory for storing the printing data inputted from the host computer 8 via the IF 9 in a data storage region (not shown), a RAM (Random Access Memory) 63 for temporarily storing various kinds of data when the ejection failure detection processing or the like (described later) is carried out or temporarily opening up application programs for printing processes or the like, and a PROM 64 as one kind of nonvolatile semiconductor memory in which control programs and the like for controlling the respective portions are stored. The components of the control section 6 are electrically connected to each other via a bus (not shown).
As described above, the printing means 3 is provided with the plurality of head units 35 respectively corresponding to the colors of inks. Further, each head unit 35 is provided with a plurality of nozzles 110 and the plurality of electrostatic actuators 120 respectively corresponding to the nozzles 110 (that is, the plurality of ink jet heads 100). In other words, each head unit 35 is configured to include a plurality of ink jet heads 100 (droplet ejection heads) each comprising a set including a nozzle 110 and an electrostatic actuator 120. The head driver 33 comprises a driving circuit 18 for driving the electrostatic actuators 120 of the respective ink jet heads 100 to control ejection timing of inks, and switching means 23 (see FIG. 16). In this regard, the configuration of the ink jet head 100 and the electrostatic actuator 120 will be described later.
Although it is not shown in the drawings, various kinds of sensors capable of detecting, for example, a remaining quantity of ink in each of the ink cartridges 31, the position of the printing means 3, printing environments such as temperature, humidity and the like are electrically connected to the control section 6.
When the control section 6 receives printing data from the host computer 8 via the IF 9, the control section 6 stores the printing data in the EEPROM 62. The CPU 61 then executes a predetermined process on the printing data, and outputs driving signals to each of the drivers 33, 43, and 53 according to the processed data and input data from the various kinds of sensors. When these driving signals are respectively inputted through the drivers 33, 43, and 53, the plurality of electrostatic actuators 120 corresponding to the plurality of ink jet heads 100 in the respective head units 35, the carriage motor 41 of the printing device 4, and the feeder 5 start to operate individually. In this way, a printing operation is effected on a recording sheet P.
The time measuring means 25 measures a driving halt period of the ink jet heads 100, that is, a lapsed time since the last ejection operation has been carried out, and is constituted from a timer or the like, for example. The lapsed time (time data) measured by the time measuring means 25 is outputted to the control section 6. As will be described later, when carrying out head failure detection and judgment processing, the judging means (head failure judging means) 20 judges presence or absence of a head failure (ejection failure) and a cause thereof on the basis of the outputted time data (lapsed time) and a computation result outputted from computation means 17 (see FIG. 24).
The temperature sensor 37 measures ambient temperature of the ink jet heads 100. A measuring result of the temperature sensor 37 is used for correcting a normal count value (count value data) held in a normal count value memory 46 of the computation means 17 in the computation processing described later as well as a temperature data table (see FIG. 24).
Next, the structure of the ink jet head 100 in each head unit 35 in the printing means 3 will now be described. FIG. 3 is a schematic cross sectional view of the head unit 35 (ink jet head 100) shown in FIG. 1 (including common components such as the ink cartridge 31). FIG. 4 is an exploded perspective view schematically showing the configuration of the head unit 35 corresponding to one color of ink. FIG. 5 is a plan view showing an example of a nozzle surface of the head unit 35 shown in FIG. 3 on which the plurality of ink jet heads 100 are provided. It should be noted that FIGS. 3 and 4 are shown upside down from the normally used state and FIG. 5 is a plan view when the ink jet head 100 shown in FIG. 3 is viewed from the top of the drawing.
As shown in FIG. 3, the head unit 35 is connected to the ink cartridge 31 via an ink intake port 131, a damper chamber 130, and an ink supply tube 311. The damper chamber 130 is provided with a damper 132 made of rubber. The damper chamber 130 makes it possible to absorb fluctuation of ink and a change in ink pressure when the carriage 32 reciprocates, whereby it is possible to supply the respective ink jet heads 100 of the head unit 35 with a predetermined quantity of ink in a stable manner.
Further, the head unit 35 has a triple-layer structure, in which a silicon substrate 140 in the middle, a nozzle plate 150 also made of silicon, which is layered on the upper side of the silicon substrate 140 in FIG. 3, and a borosilicate glass substrate (glass substrate) 160 having a coefficient of thermal expansion close to that of silicon, which is layered on the lower side of the silicon substrate 140. A plurality of independent cavities (pressure chambers) 141 (seven cavities are shown in FIG. 4), one reservoir (common ink chamber) 143, and grooves each serving as an ink supply port (orifice) 142 that allows communication between the reservoir 143 and each of the cavities 141 are formed in the silicon substrate 140 of the middle layer. Each groove may be formed, for example, by applying an etching process from the surface of the silicon substrate 140. The nozzle plate 150, the silicon substrate 140, and the glass substrate 160 are bonded to each other in this order, whereby each of the cavities 141, the reservoir 143 and each of the ink supply ports 142 are defined therein.
Each of these cavities 141 is formed in the shape of a strip (rectangular prism), and is configured in such a manner that a volume thereof is variable with vibration (displacement) of a diaphragm 121 described later and this change in volume makes ink (liquid material) to be ejected through the nozzle (ink nozzle) 110. The nozzles 110 are respectively formed in the nozzle plate 150 at positions corresponding to the portions on the tip side of the cavities 141, and communicate with the respective cavities 141. Further, the ink intake port 131 communicating with the reservoir 143 is formed in the glass substrate 160 at a portion where the reservoir 143 is located. Ink is supplied from the ink cartridge 31 to the reservoir 143 by way of the ink supply tube 311 and the damper chamber 130 through the ink intake port 131. The ink supplied to the reservoir 143 passes through the respective ink supply ports 142 and is then supplied to the respective cavities 141 that are independent from each other. In this regard, the cavities 141 are respectively defined by the nozzle plate 150, sidewalls (partition walls) 144, and bottom walls 121.
The bottom wall 121 of each of the independent cavity 141 is formed in a thin-walled manner, and the bottom wall 121 is formed to function as a diaphragm that can undergo elastic deformation (elastic displacement) in the out-of-plane direction (its thickness direction), that is, in the vertical direction of FIG. 3. Consequently, hereinafter, the portion of this bottom wall 121 will be occasionally referred to as the diaphragm 121 for ease of explanation (in other words, the same reference numeral 121 is used for both the “bottom wall” and the “diaphragm”).
Shallow concave portions 161 are respectively formed in the surface of the glass substrate 160 on the silicon substrate 140 side, at the positions corresponding to the cavities 141 in the silicon substrate 140. Thus, the bottom wall 121 of each cavity 141 faces, with a predetermined clearance in between, the surface of an opposing wall 162 of the glass substrate 160 in which the concave portions 161 are formed. In other words, a clearance (air gap) having a predetermined thickness (for example, approximately 0.2 microns) exists between the bottom wall 121 of each cavity 141 and a segment electrode 122 described later. In this case, the concave portions 161 can be formed by an etching process, for example.
The bottom wall (diaphragm) 121 of each cavity 141 forms a part of a common electrode 124 on the respective cavities 141 side for accumulating charges by a driving signal supplied from the head driver 33. In other words, the diaphragm 121 of each cavity 141 also serves as one of the counter electrodes (counter electrodes of the capacitor) in the corresponding electrostatic actuator 120 described later. The segment electrodes 122 each serving as an electrode opposing the common electrode 124 are respectively formed on the surfaces of the concave portions 161 in the glass substrate 160 so as to face the bottom walls 121 of the cavities 141. Further, as shown in FIG. 3, the surfaces of the bottom walls 121 of the respective cavities 141 are covered with an insulating layer 123 made of a silicon dioxide (SiO2) film. In this manner, the bottom wall 121 of each cavity 141, that is, the diaphragm 121 and the corresponding segment electrode 122 form (constitute) the counter electrodes (counter electrodes of the capacitor) via the insulating layer 123 formed on the surface of the bottom wall 121 of the cavity 141 on the lower side of FIG. 3 and the clearance within the concave portion 161. Therefore, the diaphragm 121, the segment electrode 122, and the insulating layer 123 and the clearance therebetween form the major portion of the electrostatic actuator 120.
As shown in FIG. 3, the head driver 33 including the driving circuit 18 for applying a driving voltage between these counter electrodes carries out charge and discharge of these counter electrodes in response to a printing signal (printing data) inputted from the control section 6. One output terminal of the head driver (voltage applying means) 33 is connected to the respective segment electrodes 122, and the other output terminal is connected to an input terminal 124a of the common electrode 124 formed in the silicon substrate 140. Because the silicon substrate 140 is doped with impurities and therefore has conductive property by itself, it is possible to supply the common electrode 124 of the bottom walls 121 with a voltage from the input terminal 124a of the common electrode 124. Alternatively, for example, a thin film made of an electrically conductive material such as gold, copper, or the like may be formed on one surface of the silicon substrate 140. This makes it possible to supply a voltage (electric charges) to the common electrode 124 at low electric resistance (efficiently). This thin film may be formed, for example, by vapor deposition, sputtering, or the like. In this embodiment, for example, because the silicon substrate 140 and the glass substrate 160 are coupled (bonded) to each other through anode bonding, an electrically conductive film used as an electrode in this anode bonding is formed on the silicon substrate 140 on the channel forming surface side (i.e., on the top side of the silicon substrate 140 shown in FIG. 3). This electrically conductive film is directly used as the input terminal 124a of the common electrode 124. It should be appreciated, however, that in the invention, for example, the input terminal 124a of the common electrode 124 may be omitted and the bonding method of the silicon substrate 140 and the glass substrate 160 is not limited to the anode bonding.
As shown in FIG. 4, the head unit 35 is provided with the nozzle plate 150 in which a plurality of nozzles 110 corresponding to the plurality of ink jet heads 100 are formed, the silicon substrate (ink chamber substrate) 140 in which a plurality of cavities 141, a plurality of ink supply ports 142, and one reservoir 143 are formed, and the insulating layer 123, all of which are accommodated in a base body 170 containing the glass substrate 160. The base body 170 is made of, for example, various kinds of resin materials, various kinds of metal materials, or the like, and the silicon substrate 140 is fixed to and supported by the base body 170.
The plurality of nozzles 110 formed in the nozzle plate 150 are aligned linearly and substantially parallel to the reservoir 143 in FIG. 4 to make the illustration simple. However, the alignment pattern of the nozzles 110 is not limited to this pattern, and they are normally arranged in a manner that steps are shifted as in the nozzle alignment pattern shown in FIG. 5, for example. Further, the pitch between the nozzles 110 can be set appropriately depending on the printing resolution (dpi: dot per inch). In this regard, FIG. 5 shows the alignment pattern of the nozzles 110 in the case where four colors of ink (ink cartridges 31) are applied.
FIG. 6 shows respective states of the cross section taken along the line III-III of FIG. 3 when a driving signal is inputted. When a driving voltage is applied between the counter electrodes from the head driver 33, Coulomb force is generated between the counter electrodes, whereby the bottom wall (diaphragm) 121 then bends (is attracted) towards the segment electrode 122 from the initial state (FIG. 6(a)) so that the volume of the cavity 141 is increased (FIG. 6(b)). When the electric charges between the counter electrodes are discharged abruptly at this state under the control of the head driver 33, the diaphragm 121 restores upward in the drawing due to its elastic restoring force, whereby the diaphragm 121 moves upwards above its initial position at the initial state so that the volume of the cavity 141 is contracted abruptly (FIG. 6(c)). At this time, a part of the ink (liquid material) filled in the cavity 141 is ejected through the nozzle 110 communicating with this cavity 141 in the form of ink droplets due to the compression pressure generated within the cavity 141.
The diaphragm 121 in each cavity 141 undergoes damped vibration continuately by this series of operations (the ink ejection operation by the driving signal from the head driver 33) until an ink droplet is ejected again when the following driving signal (driving voltage) is inputted. Hereinafter, this damped vibration is also referred to as the residual vibration. The residual vibration of the diaphragm 121 is assumed to have an intrinsic vibration frequency that is determined by the acoustic resistance r given by the shapes of the nozzle 110 and the ink supply port 142, a degree of ink viscosity and the like, the acoustic inertance m given by a weight of ink within the channel (cavity 141), and compliance Cm of the diaphragm 121.
The computation model of the residual vibration of the diaphragm 121 based on the above assumption will now be described. FIG. 7 is a circuit diagram showing the computation model of simple harmonic vibration on the assumption of the residual vibration of the diaphragm 121. In this way, the computation model of the residual vibration of the diaphragm 121 can be represented by a sound pressure P, and the acoustic inertance m, compliance Cm and acoustic resistance r mentioned above. Then, by computing a step response in terms of a volume velocity u when the sound pressure P is applied to the circuit shown in FIG. 7, following equations are obtained.




  
    
      
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The computation result obtained from the equations described above is compared with the experiment result from an experiment carried out separately as to the residual vibration of the diaphragm 121 after ejection of ink droplets. FIG. 8 is a graph showing the relationship between the experimental value and the computed value of the residual vibration of the diaphragm 121. As can be understood from the graph shown in FIG. 8, two waveforms of the experimental value and the computed value substantially correspond with each other.
In the meantime, a phenomenon, which ink droplets are not ejected normally through the nozzle 110 even when the above-mentioned ejection operation is carried out, that is, the occurrence of an ejection failure of droplets, may occur in any of the ink jet heads 100 of the head unit 35. As for causes of the occurrence of the ejection failure, as will be described below, (1) intrusion of an air bubble into the cavity 141, (2) drying and thickening (fixing) of ink in the vicinity the nozzle 110, (3) adhesion of paper dust in the vicinity the outlet of the nozzle 110, or the like may be mentioned.
Once the ejection failure occurs, it typically results in non-ejection of droplets through the nozzle 110, that is, the advent of a droplet non-ejection phenomenon, which gives rise to missing dots in pixels forming an image printed (drawn) on a recording sheet P. Further, in the case of the ejection failure, even when droplets are ejected through the nozzle 110, the ejected droplets do not land on the recording sheet P adequately because a quantity of droplets is too small or the flying direction (trajectory) of droplets is deviated, which also appears as missing dots in pixels. For this reason, hereinafter, an ejection failure of droplets may also be referred to simply as the “missing dot”.
Hereinafter, in the case where an ink droplet is not ejected through a nozzle 110 even though an actuator (electrostatic actuator 120) of the droplet ejection apparatus (ink jet printer 1) has carried out an ejection driving operation, such a failure is referred to as “ejection failure”. On the other hand, in the case where a failure is detected when the actuator (electrostatic actuator 120) is driven by a driving circuit to such an extent that a droplet is not ejected, this failure and the above-mentioned failure (ejection failure) are referred to as “head failure”. However, the failure that is detected when the actuator is driven to such an extent that a droplet is not ejected may be also referred to as “ejection failure”.
In the following, values of the acoustic resistance r and/or the acoustic inertance m are adjusted on the basis of the comparison result shown in FIG. 8 for each cause of the missing dot (ejection failure) phenomenon (i.e., droplet non-ejection phenomenon) during the printing process, which occurs in the nozzle 110 of the ink jet head 100, so that the computed value and the experimental value of the residual vibration of the diaphragm 121 match (or substantially correspond) with each other. In this regard, three types of causes including intrusion of an air bubble, thickening due to drying, and adhesion of paper dust will be discussed herein.
First, intrusion of an air bubble into the cavity 141, which is one of the causes of the missing dot, will be discussed. FIG. 9 is a conceptual view in the vicinity of the nozzle 110 in a case where an air bubble B has intruded into the cavity 141 of FIG. 3. As shown in FIG. 9, the air bubble B thus generated is assumed to be generated and adhering to the wall surface of the cavity 141 (FIG. 9 shows a case where the air bubble B is adhering in the vicinity of the nozzle 110, as one example of the adhesion position of the air bubble B).
When the air bubble B has intruded into the cavity 141 in this manner, a total weight of ink filling the cavity 141 is thought to decrease, which in turn lowers the acoustic inertance m. Because the air bubble B is adhering to the wall surface of the cavity 141, the nozzle 110 is thought to become in a state where its diameter is increased in size by the diameter of the air bubble B, which in turn lowers the acoustic resistance r.
Thus, by setting both the acoustic resistance r and the acoustic inertance m smaller than in the case of FIG. 8 where ink is ejected normally, to be matched with the experimental value of the residual vibration in the case of intrusion of an air bubble, the result (graph) as shown in FIG. 10 was obtained. As can be understood from the graphs of FIGS. 8 and 10, in the case of intrusion of an air bubble into the cavity 141, a residual vibration waveform, characterized in that the frequency becomes higher than in the case of normal ejection, is obtained. In this regard, it can also be confirmed that the damping rate of amplitude of the residual vibration becomes smaller as the acoustic resistance r is lowered, and the amplitude of the residual vibration thus becomes smaller slowly.
Next, drying (fixing and thickening) of ink in the vicinity of the nozzle 110, which is another cause of the missing dot, will be discussed. FIG. 11 is a conceptual view in the vicinity of the nozzle 110 in a case where ink has fixed due to drying in the vicinity of the nozzle 110 of FIG. 3. As shown in FIG. 11, in a case where ink has fixed due to drying in the vicinity of the nozzle 110, ink within the cavity 141 is in a situation that the ink is trapped within the cavity 141. When ink dries and thickens in the vicinity of the nozzle 110 in this manner, the acoustic resistance r is thought to increase.
Thus, by setting the acoustic resistance r larger than in the case of FIG. 8 where ink is ejected normally, to be matched with the experimental value of the residual vibration in the case of fixing (thickening) of ink caused by drying in the vicinity of the nozzle 110, the result (graph) as shown in FIG. 12 was obtained. In this case, the experimental values shown in FIG. 12 are those obtained by measuring the residual vibration of the diaphragm 121 in a state where the head unit 35 was allowed to stand for a few days without attaching a cap (not shown), so that ink could not be ejected because the ink had dried and thickened (the ink had fixed) in the vicinity of the nozzle 110 within the cavity 141. As can be understood from the graphs of FIGS. 8 and 12, in the case where ink has thickened due to drying in the vicinity of the nozzle 110, a residual vibration waveform, characterized in that not only the frequency becomes extremely low compared with the case of normal ejection, but also the residual vibration is over-damped, is obtained. This is because, when the diaphragm 121 moves upward in FIG. 3 after the diaphragm 121 is attracted downward in FIG. 3 in order to eject an ink droplet and ink thereby flows into the cavity 141 from the reservoir 143, there is no escape for the ink within the cavity 141 and the diaphragm 121 suddenly becomes unable to vibrate anymore (i.e., the diaphragm 121 becomes over-damped).
Next, adhesion of paper dust in the vicinity of the outlet of the nozzle 110, which is still another cause of the missing dot, will be described. FIG. 13 is a conceptual view in the vicinity of the nozzle 110 in the case of adhesion of paper dust in the vicinity of the outlet of the nozzle 110 of FIG. 3. As shown in FIG. 13, in the case where paper dust is adhering in the vicinity of the outlet of the nozzle 110, not only ink seeps out from the cavity 141 via paper dust, but also it becomes impossible to eject ink through the nozzle 110. In the case where paper dust is adhering in the vicinity of the outlet of the nozzle 110 and ink seeps out from the nozzle 110 in this manner, a quantity of ink within the cavity 141 and ink seeping out when viewed from the diaphragm 121 is thought to increase compared with the normal state, which in turn causes the acoustic inertance m to increase. Further, fibers of the paper dust adhering in the vicinity of the outlet of the nozzle 110 are thought to cause the acoustic resistance r to increase.
Thus, by setting both the acoustic inertance m and the acoustic resistance r larger than in the case of FIG. 8 where ink is ejected normally, to be matched with the experimental value of the residual vibration in the case of adhesion of paper dust in the vicinity of the outlet of the nozzle 110, the result (graph) as shown in FIG. 14 was obtained. As can be understood from the graphs of FIGS. 8 and 14, in the case where paper dust is adhering in the vicinity of the outlet of the nozzle 110, a residual vibration waveform, characterized in that the frequency becomes lower than in the case of normal ejection, is obtained (it is also understood from the graphs of FIGS. 12 and 14 that the frequency of the residual vibration in the case of adhesion of paper dust is higher than that in the case of thickening ink). FIG. 15 shows pictures of the states of the nozzle 110 before and after adhesion of paper dust. It can be seen from FIG. 15(b) that once paper dust adheres in the vicinity of the outlet of the nozzle 110, ink seeps out along the paper dust.
Note that in both the cases where ink has thickened due to drying in the vicinity of the nozzle 110 and where paper dust is adhering in the vicinity of the outlet of the nozzle 110, the frequency of the damped vibration is lower than in the case where ink droplets are ejected normally. Hence, a comparison is made, for example, with a predetermined threshold in the frequency, the cycle or the phase of the damped vibration to identify these two causes of the missing dot (non-ejection of ink, i.e., ejection failure) from the waveform of the residual vibration of the diaphragm 121, or alternatively the causes can be identified from a change of the cycle of the residual vibration (damped vibration) or the damping rate of a change in amplitude. In this way, an ejection failure of the respective ink jet heads 100 can be detected from a change of the residual vibration of the diaphragm 121, in particular, a change of the frequency thereof, when ink droplets are ejected through the nozzle 110 of each of the ink jet heads 100. Further, by comparing the frequency of the residual vibration in this case with the frequency of the residual vibration in the case of normal ejection, the cause of the ejection failure can be identified.
Further, in the case where a driving signal (voltage signal) to such an extent that a droplet (ink droplet) is not ejected is inputted to an electrostatic actuator 120 from the driving circuit 18 of the head driver 33, a similar residual vibration waveform of a diaphragm 121 can be obtained (however, the amplitude of the residual vibration waveform becomes smaller). Thus, by enlarging the vertical axis of a graph that shows a residual vibration of a diaphragm 121, that is, the amplitude thereof, the computed value and the experimental value of the residual vibration of the diaphragm 121 similar to FIGS. 10, 12 and 14 corresponding to the respective causes of ejection failure can be obtained. Therefore, by detecting the residual vibration of the diaphragm 121 when the electrostatic actuator 120 is driven to such an extent that an ink droplet is not ejected, it is possible to detect an ejection failure (head failure) in the ink jet heads 100. Hereinafter, as described above, since there is a case in which a failure of the ink jet heads 100 can be detected without ejecting a droplet, the failure detected in such a manner may be referred to as “head failure”.
Next, the ejection failure detecting means 10 of the invention will now be described. FIG. 16 is a schematic block diagram of the ejection failure detecting means 10 shown in FIG. 2. As shown in FIG. 16, the ejection failure detecting means 10 is provided with residual vibration detecting means 16 comprising an oscillation circuit 11, an F/V (frequency-to-voltage) converting circuit 12 and a waveform shaping circuit 15, computation means 17 for measuring the cycle, amplitude or the like of the residual vibration from the residual vibration waveform data detected in the residual vibration detecting means 16, and judging means (head failure judging means) 20 for judging an ejection failure of the ink jet head 100 on the basis of the cycle, a subtraction count value or the like measured by the computation means 17, a lapsed time (time data) measured by the time measuring means 25, and the like. In the ejection failure detecting means 10, the residual vibration detecting means 16 detects the vibration waveform, which is formed in the F/V converting circuit 12 and the waveform shaping circuit 15 from the oscillation frequency of the oscillation circuit 11 that oscillates on the basis of the residual vibration of the diaphragm 121 of the electrostatic actuator 120. In the residual vibration detecting means 16, the computation means 17 then measures the cycle or the like of the residual vibration on the basis of the vibration waveform thus detected and count the number of reference pulses generated for a predetermined time period, and the judging means 20 detects and judges an ejection failure of each of the ink jet heads 100 provided to each head unit 35 in the printing means 3, on the basis of the cycle, the subtraction count value, and the like of the residual vibration thus measured. In the following, each component of the ejection failure detecting means 10 will be described.
First, a method of using the oscillation circuit 11 to detect the frequency (the number of vibration) of the residual vibration of the diaphragm 121 of the electrostatic actuator 120 will be described. FIG. 17 is a conceptual view in the case where the electrostatic actuator 120 of FIG. 3 is assumed as a parallel plate capacitor. FIG. 18 is a circuit diagram of the oscillation circuit 11 including the capacitor constituted from the electrostatic actuator 120 of FIG. 3. In this case, the oscillation circuit 11 shown in FIG. 18 is a CR oscillation circuit using the hysteresis characteristic of a schmitt trigger. However, in the invention, the oscillation circuit is not limited to such a CR oscillation circuit, and any oscillation circuit can be used provided that it is an oscillation circuit using an electric capacitance component (capacitor C) of the actuator (including the diaphragm). The oscillation circuit 11 may comprise, for example, the one using an LC oscillation circuit. Further, this embodiment describes an example case using a schmitt trigger inverter; however, a CR oscillation circuit using inverters in three stages may be formed.
In the ink jet head 100 shown in FIG. 3, as described above, the diaphragm 121 and the segment electrode 122 spaced apart therefrom by an extremely small interval (clearance) together form the electrostatic actuator 120 that forms the counter electrodes. The electrostatic actuator 120 can be deemed as the parallel plate capacitor as shown in FIG. 17. In the case where C is the electric capacitance of the capacitor, S is the surface area of each of the diaphragm 121 and the segment electrode 122, g is a distance (gap length) between the two electrodes 121 and 122, and ∈ is a dielectric constant of the space (clearance) sandwiched by both electrodes (if ∈0 is a dielectric constant in vacuum and ∈r is a specific dielectric constant in the clearance, then ∈=∈0×∈r), then an electric capacitance C(x) of the capacitor (electrostatic actuator 120) shown in FIG. 17 can be expressed by the following equation.




  
    
      
        
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        )
      
    
  




As shown in FIG. 17, x in Equation (4) above indicates a displacement quantity of the diaphragm 121 from the reference position thereof, caused by the residual vibration of the diaphragm 121.
As can be understood from Equation (4) above, the smaller the gap length g (i.e., gap length g−displacement quantity x) is, the larger the electric capacitance C(x) becomes, and conversely, the larger the gap length g (gap length g−displacement quantity x) is, the smaller the electric capacitance C(x) becomes. In this manner, the electric capacitance C(x) is inversely proportional to (gap length g−displacement quantity x) (the gap length g when x is 0). In this regard, for the electrostatic actuator 120 shown in FIG. 3, a specific dielectric constant, ∈r=1, because the clearance is fully filled with air.
Further, because ink droplets (ink dots) to be ejected become finer with an increase of the resolution of the droplet ejection apparatus (the ink jet printer 1 in this embodiment), the electrostatic actuator 120 is increased in density and decreased in size. The surface area S of the diaphragm 121 of the ink jet head 100 thus becomes smaller and a smaller electrostatic actuator 120 is assembled. Furthermore, the gap length g of the electrostatic actuator 120 that varies with the residual vibration caused by ink droplet ejection is approximately one tenth of the initial gap g0. Hence, as can be understood from Equation (4) above, a quantity of change of the electric capacitance of the electrostatic actuator 120 takes an extremely small value.
In order to detect a quantity of change of the electric capacitance of the electrostatic actuator 120 (which varies with the vibration pattern of the residual vibration), a method as follows is used, that is, a method of forming an oscillation circuit as the one shown in FIG. 18 on the basis of the electric capacitance of the electrostatic actuator 120, and analyzing the frequency (cycle) of the residual vibration on the basis of the oscillated signal. The oscillation circuit 11 shown in FIG. 18 comprises a capacitor (C) constituted from the electrostatic actuator 120, a schmitt trigger inverter 111, and a resistor element (R) 112.
In the case where an output signal from the schmitt trigger inverter 111 is in the high level, the capacitor C is charged via the resistor element 112. When the charged voltage in the capacitor C (a potential difference between the diaphragm 121 and the segment electrode 122) reaches an input threshold voltage VT+ of the schmitt trigger inverter 111, the output signal from the schmitt trigger inverter 111 inverts to a low level. Then, when the output signal from the schmitt trigger inverter 111 shifts to the low level, electric charges charged in the capacitor C via the resistor element 112 are discharged. When the voltage of the capacitor C reaches the input threshold voltage VT− of the schmitt trigger inverter 111 through this discharge, the output signal from the schmitt trigger inverter 111 inverts again to the high level. Thereafter, this oscillation operation is carried out repetitively.
Here, in order to detect a change with time of the electric capacitance of the capacitor C in each of the above-mentioned phenomena (intrusion of an air bubble, drying, adhesion of paper dust, and normal ejection), it is required that the oscillation frequency of the oscillation circuit 11 is set to an oscillation frequency at which the frequency in the case of intrusion of an air bubble (see FIG. 10), where the frequency of the residual vibration is the highest, can be detected. For this reason, the oscillation frequency of the oscillation circuit 11 has to be increased, for example, to a few or several tens of times or more than the frequency of the residual vibration to be detected, that is, it has to be set to one or more orders of magnitude higher than the frequency in the case of intrusion of an air bubble. In this case, it is preferable to set the oscillation frequency to an oscillation frequency at which the residual vibration frequency in the case of intrusion of an air bubble can be detected, because the frequency of the residual vibration in the case of intrusion of an air bubble shows a high frequency in comparison with the case of normal ejection. Otherwise, it is impossible to detect the frequency of the residual vibration accurately for the phenomenon of the ejection failure. In this embodiment, therefore, a time constant of the CR in the oscillation circuit 11 is set in accordance with the oscillation frequency. By setting the oscillation frequency of the oscillation circuit 11 high in this manner, it is possible to detect the residual vibration waveform more accurately on the basis of a minute change of the oscillation frequency.
The digital information on the residual vibration waveform for each oscillation frequency can be obtained by counting pulses of the oscillation signal outputted from the oscillation circuit 11 in every cycle (pulse) of the oscillation frequency with the use of a measuring count pulse (counter), and by subtracting a count quantity of the pulses of the oscillation frequency when the oscillation circuit 11 is oscillated with an electric capacitance of the capacitor C at the initial gap g0 from the count quantity thus measured. By carrying out D/A (digital-to-analog) conversion on the basis of the digital information, a schematic residual vibration waveform can be generated. The method as described above may be used; however, the measuring count pulse (counter) having a high frequency (high resolution) that can measure a minute change of the oscillation frequency is needed. Such a count pulse (counter) increases the cost, and for this reason, the ejection failure detecting means 10 of the invention uses the F/V converting circuit 12 shown in FIG. 19.
FIG. 19 is a circuit diagram of the F/V converting circuit 12 in the ejection failure detecting means 10 shown in FIG. 16. As shown in FIG. 19, the F/V converting circuit 12 comprises three switches SW1, SW2 and SW3, two capacitors C1 and C2, a resistor element R1, a constant current source 13 from which a constant current Is is outputted, and a buffer 14. The operation of the F/V converting circuit 12 will be described with the use of the timing chart of FIG. 20 and the graph of FIG. 21.
First, a method of generating a charging signal, a hold signal, and a clear signal shown in the timing chart of FIG. 20 will be described. The charging signal is generated in such a manner that a fixed time tr is set from the rising edge of the oscillation pulse of the oscillation circuit 11 and the signal remains in the high level for the fixed time tr. The hold signal is generated in such a manner that the signal rises in sync with the rising edge of the charging signal, and falls to the low level after it is held in the high level for a predetermined fixed time. The clear signal is generated in such a manner that the signal rises in sync with the falling edge of the hold signal and falls to the low level after it is held in the high level for a predetermined fixed time. In this regard, as will be described later, because electric charges move from the capacitor C1 to the capacitor C2 instantaneously and the capacitor C1 discharges instantaneously, in regard to pulses of the hold signal and the clear signal, it is sufficient for each signal to include one pulse until the following rising edge of the output signal from the oscillation circuit 11 occurs, and the rising edge and the falling edge are not limited to those described above.
In this regard, a driving signal (broken line) when carrying out an ink droplet ejection operation to detect an ejection failure of droplets and a driving signal (solid line) to an extent that an ink droplet is not ejected are shown in the timing chart of FIG. 20. Even though any driving signal is inputted to the electrostatic actuator 120, a similar timing chart can be obtained. For this reason, Hereinbelow, a description will be given based on the driving signal during an ink droplet ejection operation (broken line). A chain line in the timing chart of FIG. 20 shows a driving limit of the electrostatic actuator 120. This “driving limit” means a voltage value applied to the electrostatic actuator 120 at a limit where an ink droplet cannot be ejected. Thus, the driving circuit 18 can set a power of the driving signal to at least a low power in which an ink droplet is not ejected and a high power to carry out an ejection driving operation.
In this regard, the driving voltage having an extent that an ink droplet is not ejected depends on the type of droplet ejection head (ink jet head 100) or a structure thereof. For example, in the case where a driving voltage for normal ejection of droplets is 100%, this driving voltage having an extent that an ink droplet is not ejected is in the range of about 10 to 50%. When the driving voltage is lowered, the voltage signal of a residual vibration for detecting a head failure of the ink jet heads 100 is also lowered. Hence, it is preferable that the driving voltage for detecting a head failure is set to such an extent slightly smaller than the limit at which an ink droplet cannot be ejected. A method of driving an actuator to such an extent that a droplet is not ejected is not limited to such a method of driving an actuator by becoming the driving voltage lower than normal. Otherwise, in the case of a thermal jet type of droplet ejection head that uses film-boiling phenomenon, a driving current may be lowered.
With reference to FIG. 21, a method of setting the fixed times tr and t1 in obtaining a sharp waveform (voltage waveform) of the residual vibration will be described. The fixed time tr is adjusted from the cycle of the oscillation pulse oscillated with the electric capacitance C when the electrostatic actuator 120 is at the initial gap length g0, and is set so that a charged potential for the charging time t1 becomes about half of the chargeable range of the capacitor C1. Further, a gradient of the charged potential is set so as not to exceed the chargeable range of the capacitor C1 from a charging time t2 at the position at which the gap length g becomes the maximum (Max) to a charging time t3 at the position at which the gap length g becomes the minimum (Min). In other words, because the gradient of the charged potential is determined by dV/dt=Is/C1, it is sufficient to set the output constant current Is from the constant current source 13 to an appropriate value. By setting the output constant current Is of the constant current source 13 as high as possible within the range, a minute change of the electric capacitance of the capacitor comprising the electrostatic actuator 120 can be detected with high sensitivity, and this makes it possible to detect a minute change of the diaphragm 121 of the electrostatic actuator 120.
The configuration of the waveform shaping circuit 15 shown in FIG. 16 will now be described with reference to FIG. 22. FIG. 22 is a circuit diagram showing the circuitry of the waveform shaping circuit 15 of FIG. 16. The waveform shaping circuit 15 outputs the residual vibration waveform to the judging means 20 in the form of a rectangular wave. As shown in FIG. 22, the waveform shaping circuit 15 comprises two capacitors C3 (DC component eliminating means) and C4, two resistor elements R2 and R3, two direct current voltage sources Vref1 and Vref2, an operational amplifier 151, and a comparator 152. In this regard, the waveform shaping circuit 15 may be configured to measure the amplitude of the residual vibration waveform by directly outputting a wave height value detected in the waveform shaping processing of the residual vibration waveform.
The output from the buffer 14 in the F/V converting circuit 12 includes electric capacitance components of DC components (direct current components) based on the initial gap g0 of the electrostatic actuator 120. Because the direct current components vary with each ink jet head 100, the capacitor C3 is used to eliminate the direct current components of the electric capacitance. The capacitor C3 thus eliminates the DC components from an output signal from the buffer 14, and outputs only the AC components of the residual vibration to the inverting input terminal of the operational amplifier 151.
The operational amplifier 151 inverts and amplifies the output signal from the buffer 14 in the F/V converting circuit 12, from which the direct current components have been eliminated, and also forms a low-pass filter to remove a high band of the output signal. In this case, the operational amplifier 151 is assumed to be a single power source circuit. The operational amplifier 151 forms an inverting amplifier based on the two resistor elements R2 and R3, and the residual vibration (alternating current components) inputted therein is therefore amplified by a factor of −R3/R2.
Further, because of the single power source operation, the operational amplifier 151 outputs an amplified residual vibration waveform of the diaphragm 121 that vibrates about the potential set by the direct current voltage source Vref1 connected to the non-inverting input terminal thereof. Here, the direct current voltage source Vref1 is set to about half the voltage range within which the operational amplifier 151 is operable with a single power source. Furthermore, the operational amplifier 151 forms a low-pass filter, having a cut-off frequency of 1/(2π×C4×R3), from the two capacitors C3 and C4. Then, as shown in the timing chart of FIG. 20, the residual vibration waveform of the diaphragm 121, which is amplified after the direct current components are eliminated therefrom, is compared with the potential of the other direct current voltage source Vref2 in the comparator 152 in the following stage, and the comparison result is outputted from the waveform shaping circuit 15 in the form of a rectangular wave. In this case, the direct current voltage source Vref1 may be commonly used as the other direct current voltage source Vref2.
Next, the operations of the F/V converting circuit 12 and the waveform shaping circuit 15 of FIG. 19 will now be described with reference to the timing chart shown in FIG. 20. The F/V converting circuit 12 shown in FIG. 19 operates according to the charging signal, the clear signal and the hold signal, which are generated as described above. Referring to the timing chart of FIG. 20, when the driving signal of the electrostatic actuator 120 is inputted into the ink jet head 100 of the head unit 35 via the head driver 33, the diaphragm 121 of the electrostatic actuator 120 is attracted toward the segment electrode 122 as shown in FIG. 6(b), and abruptly contracts upward in FIG. 6 in sync with the falling edge of the driving signal (see FIG. 6(c)).
A driving/detection switching signal that switches the connection of the ink jet head 100 between the driving circuit 18 and the ejection failure detecting means 10 shifts to the high level in sync with the falling edge of the driving signal. The driving/detection switching signal is held in the high level during the driving halt period of the corresponding ink jet head 100, and shifts to the low level before the following driving signal is inputted. While the driving/detection switching signal remains in the high level, the oscillation circuit 11 of FIG. 18 keeps oscillating while changing the oscillation frequency in response to the residual vibration of the diaphragm 121 of the electrostatic actuator 120.
As described above, the charging signal is held in the high level from the falling edge of the driving signal, that is, the rising edge of the output signal from the oscillation circuit 11 until the elapse of the fixed time tr, which is set in advance so that the waveform of the residual vibration will not exceed the chargeable range of the capacitor C1. It should be noted that the switch SW1 remains OFF while the charging signal is held in the high level.
When the fixed time tr elapses and the charging signal shifts to the low level, the switch SW1 is switched ON in sync with the falling edge of the charging signal (see FIG. 19). The constant current source 13 and the capacitor C1 are then connected to each other, and the capacitor C1 is charged with the gradient Is/C1 as described above. Namely, the capacitor C1 is kept charged while the charging signal remains in the low level, that is, until it shifts to the high level in sync with the rising edge of the following pulse of the output signal from the oscillation circuit 11.
When the charging signal shifts to the high level, the switch SW1 is switched OFF (i.e., opened), and the capacitor C1 is isolated from the constant current source 13. At this time, the capacitor C1 holds a potential charged during the period t1 during which the charging signal remained in the low level (that is, ideally speaking, Is×t1/C1 (Volt)). When the hold signal shifts to the high level in this state, the switch SW2 is switched ON (see FIG. 19), and the capacitors C1 and C2 are connected to each other via the resistor element R1. After the switch SW2 is switched ON, charging and discharging operations are carried out due to a charged potential difference between the two capacitors C1 and C2, and the electric charges move from the capacitor C1 to the capacitor C2 so that the potential differences in the two capacitors C1 and C2 become almost equal.
Herein, the electric capacitance of the capacitor C2 is set to approximately one tenth or less of the electric capacitance of the capacitor C1. For this reason, a quantity of electric charges that move (are used) due to the charging and discharging caused by a potential difference between the two capacitors C1 and C2 is one tenth or less of the electric charges charged in the capacitor C1. Hence, after the electric charges moved from the capacitor C1 to the capacitor C2, a potential difference in the capacitor C1 varies little (drops little). In the F/V converting circuit 12 of FIG. 19, a primary low-pass filter is formed from the resistor element R1 and the capacitor C2 in preventing the charged potential from rising abruptly by the inductance or the like of the wiring in the F/V converting circuit 12 when the capacitor C2 is charged.
After the charged potential, which is substantially equal to the charged potential in the capacitor C1, is held in the capacitor C2, the hold signal shifts to the low level, and the capacitor C1 is isolated from the capacitor C2. Further, when the clear signal shifts to the high level and the switch SW3 is switched ON, the capacitor C1 is connected to the ground terminal GND, and a discharge operation is carried out so that the electric charges charged in the capacitor C1 is reduced to 0. After the capacitor C1 is discharged, when the clear signal shifts to the low level, and the switch SW3 is switched OFF, then the electrode of the capacitor C1 at the top in FIG. 19 is isolated from the ground terminal GND, and the F/V converting circuit 12 stands by (waits) until the following charging signal is inputted, that is, until the charging signal shifts to the low level.
The potential held in the capacitor C2 is updated at each rising time of the charging signal, that is, at each timing at which the charging to the capacitor C2 is completed, and this potential is outputted to the waveform shaping circuit 15 of FIG. 22 in the form of the residual vibration waveform of the diaphragm 121 via the buffer 14. Hence, by setting the electric capacitance of the electrostatic actuator 120 (in this case, a variation width of the electric capacitance due to the residual vibration has to be taken into consideration) and the resistance value of the resistor element 112 so that the oscillation frequency of the oscillation circuit 11 becomes high, each step (step difference) in the potential in the capacitor C2 (output from the buffer 14) shown in the timing chart of FIG. 20 can become more in detail, and this makes it possible to detect a change with time of the electric capacitance due to the residual vibration of the diaphragm 121 more in detail.
Thereafter, the charging signal repeatedly shifts between the low level and the high level, and the potential held in the capacitor C2 is outputted to the waveform shaping circuit 15 via the buffer 14 at the predetermined timing described above. In the waveform shaping circuit 15, the direct current components are eliminated by the capacitor C3 from the voltage signal (the potential in the capacitor C2 in the timing chart of FIG. 20) inputted from the buffer 14, and the resulting signal is inputted into the inverting input terminal of the operational amplifier 151 via the resistor element R2. The alternating current (AC) components of the residual vibration thus inputted are inverted and amplified in the operational amplifier 151, and outputted to one input terminal of the comparator 152. The comparator 152 compares the potential (reference voltage) set in advance by the direct current voltage source Vref2 with the potential of the residual vibration waveform (alternating current components) to output a rectangular wave (output from the comparator in the timing chart of FIG. 20).
Next, the switching timing between an ink droplet ejection operation (i.e., driving state) and an ejection failure detection operation (i.e., driving halt state) of the ink jet head 100 will now be described. FIG. 23 is a block diagram schematically showing the switching means 23 for switching the connection of the ink jet head 100 between the driving circuit 18 and the ejection failure detecting means 10. Referring to FIG. 23, the driving circuit 18 in the head driver 33 shown in FIG. 16 will be described as the driving circuit of the ink jet head 100. As shown in the timing chart of FIG. 20, the head failure detection and judgment processing (ejection failure detection processing) of the invention is carried out in a period between the driving signals for the ink jet head 100, that is, during the driving halt period.
Referring to FIG. 23, the switching means 23 is initially connected to the driving circuit 18 side to drive the electrostatic actuator 120 thereof. As described above, when the driving signal (voltage signal) is inputted from the driving circuit 18 to the diaphragm 121, the electrostatic actuator 120 starts to be driven, and the diaphragm 121 is attracted toward the segment electrode 122. Then, when the applied voltage drops to 0, the diaphragm 121 displaces abruptly in a direction to move away from the segment electrode 122 and starts to vibrate (residual vibration). At this time, an ink droplet is ejected through the nozzle 110 of the ink jet head 100.
When the pulse of the driving signal falls, the driving/detection switching signal is inputted into the switching means 23 in sync with the falling edge thereof (see the timing chart of FIG. 20), and the switching means 23 switches the connection of the diaphragm 121 from the driving circuit 18 to the ejection failure detecting means (detection circuit) 10, so that the electrostatic actuator 120 (used as the capacitor of the oscillation circuit 11) is connected to the ejection failure detecting means 10.
Then, the ejection failure detecting means 10 carries out the detection processing of an ejection failure (missing dot) as described above, and generates a predetermined group of signals on the basis of the residual vibration waveform data (rectangular wave data) of the diaphragm 121 outputted from the comparator 152 in the waveform shaping circuit 15 by means of timing generating means 36 (described later) of the computation means 17 to count the number of reference pulses. In this embodiment, the computation means 17 measures (or detects) a particular vibrational cycle (a half cycle, one cycle or the like) from the residual vibration waveform data, and outputs a count value counted on the basis of the group of signals (mentioned above) to the judging means 20. In this regard, the computation means 17 may measure a predetermined time from the residual vibration waveform, such as a time from the falling edge of the driving signal (or the rising edge of the driving/detection switching signal) to the time when the residual vibration occurs, a first half cycle after the occurrence of the residual vibration (or every half cycle), a first quarter cycle after the occurrence of the residual vibration (or every quarter cycle), and the like, in addition to the cycle of the residual vibration. Alternatively, the computation means 17 may measure a time from the first rising edge to the following falling edge, and output a time two times longer than the measured time (that is, a half cycle thereof) to the judging means 20 as the cycle of the residual vibration.
FIG. 24 is a block diagram showing one example of the computation means 17. In order to judge whether or not a time until the first rising edge of the waveform (rectangular wave) of the output signal from the comparator 152, a time (cycle of the residual vibration) from the first rising edge to the following rising edge of the waveform of the output signal from the comparator 152, or the like is the cycle or the like at the normal ejection state, the computation means 17 subtracts the number of reference pulses from a normal count value by means of a subtraction counter 45, and carries out computation processing for judging a state of the residual vibration on the basis of the subtraction result. Referring to FIG. 24, the computation means 17 is constituted from an AND circuit AND, a subtraction counter 45, holding means 48 and timing generating means 36. In this case, the reference pulses are generated by pulse generating means (not shown). This pulse generating means may be constituted in the computation means 17, the control section or the like.
The normal count value is inputted to the subtraction counter 45 from a normal count value memory 46. The holding means 48 temporarily holds the subtraction result of the subtraction counter 45, and outputs the held subtraction result (holding result) to the judging means 20 and the storage means 62. The holding result may be, for example, constituted so as to be transferred to the judging means 20 and the storage means 62 every one ejection operation, or so that the holding results for arbitrary times of ejection operations are held and outputted to the judging means 20 and the storage means 62 at a time.
As shown in FIG. 24, the AND circuit AND outputs a logical multiply between the driving/detection switching signal and the reference pulses to the subtraction counter 45. In other words, when the driving/detection switching signal is in the high level, the reference pulses are outputted to the subtraction counter 45. When a predetermined count value (normal count value) is inputted from the normal count value memory 46, the subtraction counter 45 holds the value. Then, when the reference pulses are inputted to the subtraction counter 45, the subtraction counter 45 subtracts the number of reference pulses generated for a predetermined time period (a predetermined time, which is determined by the timing generating means 36) from the predetermined count value. In this regard, the predetermined time period is, for example, a time period until the residual vibration of the diaphragm 121 is generated when an ink droplet is normally ejected from the inkjet head 100; a time period until a half cycle of the residual vibration of the diaphragm 121; a time period until one cycle of the residual vibration of the diaphragm 121; or the like. Further, the predetermined count value stored in the normal count value memory 46 is the number of pulses counted using the reference pulses for the predetermine time period mentioned above at a normal ejection operation.
FIG. 25 is a timing chart of the subtraction processing of the subtraction counter shown in FIG. 24. In this timing chart, the number of reference pulses is subtracted from the normal count value for a Ts time period of the residual vibration waveform. This Ts time period is a time period until the diaphragm 121 returns to an initial position (original position) thereof after carrying out the ejection operation of the electrostatic actuator 120, that is, a time period until the residual vibration of the diaphragm 121 starts after the ejection operation.
As described above, the reference pulses are inputted into the computation means 17 from the control section 6 for the driving halt period (see FIG. 24). However, the reference pulses may be continuously outputted from the control section 6 in spite of this state. Alternatively, the ink jet printer 1 may be constructed so as to output the reference pulses in sync with a rising edge of the driving/detection switching signal and stop outputting the reference pulses in sync with a falling edge of the Ls signal. Because the ink jet printer 1 is constructed so that the subtraction counter 45 dose not operate when the CLR signal does not becomes a Low level, a method of outputting the reference pulses is not limited thereto.
The CLR signal becomes a Low level in sync with a rising edge of the driving/detection switching signal, and becomes a High level at timing of a falling edge of the Ls signal. The subtraction counter 45 is allowed to operate for a time period in the Low level. The Load signal is a pulse that becomes a High level only for a short time in sync with the rising edge of the driving/detection switching signal. The subtraction counter 45 obtains a predetermined count value (normal count value) from the normal count value memory 46 at timing of the falling edge of the pulse of the Load signal. When the normal count value is loaded to the subtraction counter 45 (the subtraction counter 45 obtains the normal count value) in this manner, the subtraction counter 45 subtract the number of reference pulses inputted for a time period (Ts time period, herein) in which the CLR signal is in a Low level.
The Ls signal is a signal that becomes a High level for a short time in sync with the first rising edge of the waveform (rectangular wave) of the output signal from the comparator 52. The subtraction counter 45 continually outputs the subtraction result to the holding means 48, and the holding means 48 holds (stores) the output of the subtraction counter 45 (subtraction count value) at timing of the rising edge of the Ls signal at which the Ls signal becomes a High level. Then, the CLR signal becomes a Low level from a High level in sync with the falling edge of the Ls signal at which the Ls signal becomes a Low level, the count value (subtraction count value) of the subtraction counter 45 is cleared and the subtraction count operation (subtraction count processing) of the subtraction counter 45 is terminated (banned).
At timing when the subtraction count operation is banned, the held result (subtraction count value) of the holding means 48, time data, and judgment result of the judging means 20 are stored into the storage means 62. In this regard, the storage timing of the data into the storage means 62 is a time point when the ejection failure judgment processing is terminated. The timing may be the same time as occurrence of an Ls signal (rewriting of the holding means 48). Alternately, in the case of obtaining some pieces of data from a residual vibration cycle one time, the timing is a time point when the ejection failure judgment processing is terminated on the basis of the data after some pieces of cycle data (data on Ts, a half cycle and the like) at one ejection operation has been held to the holding means 48. Further, this timing may be a time point when the halt time period of the driving/detection switching signal is terminated (that is, the timing of the falling edge of the driving/detection switching signal).
The timing generating means 36 generates the Load signal, the CLR signal and the Ls signal described above on the basis of the residual vibration waveform (rectangular wave) inputted from the residual vibration detecting means 16 and the driving/detection switching signal, and outputs the Load signal and the CLR signal to the subtraction counter 45 and outputs the Ls signal to the holding means 48.
The judging means 20 compares the subtraction result obtained by the subtraction processing of the subtraction counter 45 with predetermined count reference values (N1, P1, and N2) inputted from a comparison reference value memory 47, and compares the lapsed time measured by the time measuring means 25 with predetermined time reference values (T1 and T2). Then, the judgment result is outputted to the storage means 62. In this regard, the predetermined count reference values may be set up from some count reference values (thresholds) (see the timing chart of FIG. 25), and it is possible to detect and judge a cause of the ejection failure described above (i.e., intrusion of an air bubble, adhesion of paper dust and thickening due to drying) by comparing the subtraction result of the subtraction counter 45 with each of these count reference values and comparing the lapsed time with each of the some time reference values. The operation in detail will be described later.
It should be noted that the normal count value memory 46 and the comparison reference value memory 47 may be respectively provided in the ink jet printer 1 as separate memories, and may be shared with the EEPROM (storage means) 62 in the control section 6. Further, such subtraction count processing (computation) may be carried out at a driving halt period at which the electrostatic actuators 120 in the ink jet printer 1 are not driven. This makes it possible to carry out detection of an ejection failure without deteriorating the throughput of the ink jet printer 1.
As described above, the judging means 20 judges the presence or absence of an ejection failure in the nozzles 110 of the ink jet heads 100, the cause of the ejection failure, a comparative deviation, and the like on the basis of the particular vibration cycle (computation result) of the residual vibration waveform obtained by carrying out the computation by the computation means 17 and the lapsed time measured by the time measuring means 25, and outputs the judgment result to the control section 6. The control section 6 then saves the judgment result in a predetermined storage region of the EEPROM (storage means) 62.
The driving/detection switching signal is inputted into the switching means 23 again at the timing at which the following driving signal is inputted from the driving circuit 18, and the driving circuit 18 and the electrostatic actuator 120 are thereby connected to each other. Because the driving circuit 18 holds the ground (GND) level once the driving voltage is applied thereto, the switching means 23 carries out the switching operation as described above (see the timing chart of FIG. 20). This makes it possible to detect the residual vibration waveform of the diaphragm 121 of the electrostatic actuator 120 accurately without being influenced due to a disturbance or the like from the driving circuit 18.
In this regard, in the invention, the residual vibration waveform data is not limited to that made into a rectangular wave by the comparator 152. For example, as the structure shown in FIG. 24 described above, it may be arranged in such a manner that the residual vibration amplitude data outputted from the operational amplifier 151 is converted into numerical forms by means of the computation means 17 that carries out the A/D (analog-to-digital) conversion without carrying out the comparison processing by the comparator 152, then the presence or absence of an ejection failure or the like is judged by the judging means 20 on the basis of the data converted into the numerical forms in this manner, and the judgment result is stored into the storage means 62.
Further, because the meniscus (the surface on which ink within the nozzle 110 comes in contact with air) of the nozzle 110 vibrates in sync with the residual vibration of the diaphragm 121, each of the ink jet heads 100 waits for the residual vibration of the meniscus to be damped in a time substantially determined based on the acoustic resistance r after the ink droplet ejection operation (stand by for a predetermined time), and then starts the following ink droplet ejection operation. In the present invention, because the residual vibration of the diaphragm 121 is detected by effectively using this stand-by time, detection of an ejection failure can be carried out without influencing the driving of the ink jet head 100. In other words, it is possible to carry out the ejection failure detection processing for the nozzle 110 of the ink jet head 100 without reducing the throughput of the ink jet printer 1 (droplet ejection apparatus).
As described above, in the case where an air bubble has intruded into the cavity 141 of the ink jet head 100, because the frequency becomes higher than that of the residual vibration waveform of the diaphragm 121 in the case of normal ejection, the cycle thereof conversely becomes shorter than the cycle of the residual vibration in the case of normal ejection. Further, in the case where ink has thickened or fixed due to drying in the vicinity of the nozzle 110, the residual vibration is over-damped. Hence, because the frequency becomes extremely low in comparison with that of the residual vibration waveform in the case of normal ejection, the cycle thereof becomes markedly longer than the cycle of the residual vibration in the case of normal ejection. Furthermore, in the case where paper dust is adhering in the vicinity of the outlet of the nozzle 110, the frequency of the residual vibration is lower than the frequency of the residual vibration in the case of normal ejection and higher than the frequency of the residual vibration in the case of drying/thickening of ink. Hence, the cycle thereof becomes longer than the cycle of the residual vibration in the case of normal ejection and shorter than the cycle of the residual vibration in the case of drying of ink.
Therefore, by setting a predetermined range Tr as the cycle of the residual vibration in the case of normal ejection, and by setting a predetermined threshold T1 to differentiate the cycle of the residual vibration when paper dust is adhering in the vicinity of the outlet of the nozzle 110 from the cycle of the residual vibration when ink has dried in the vicinity of the nozzle 110, it is possible to determine the cause of such an ejection failure of the ink jet head 100. In the invention, the judging means 20 judges the cause of an ejection failure depending on the count value for the predetermined time period of the residual vibration waveform detected in the ejection failure detection processing described above.
Next, the operation of the ejection failure detecting means 10 of the invention will be described with reference to the timing chart of FIG. 25. A method of generating a Load signal, an Ls signal and a CLR signal shown in FIGS. 24 and 25 will be first described. As shown in the timing chart of FIG. 25, the Load signal is a signal that becomes a high level for a short time right before a rising edge of the driving signal outputted from the driving circuit 18. The Ls signal is a signal that becomes a high level in sync with a falling edge of the driving/detection switching signal inputted to the switching means 23 and the AND circuit AND, and holds in the high level for a predetermined time (enough time to store the judgment result into the storage means 62). Further, it is not shown in the timing chart of FIG. 25, but the CLR signal is a signal to clear the subtraction result held in the subtraction counter 45 in the subtraction processing, and is inputted to the subtraction counter 45 at predetermined timing until the Load signal is inputted after the output of the Ls signal. This group of signals is generated by the timing generating means 36 on the basis of the rectangular wave generated by the residual vibration detecting means 16.
The computation means 17 of the ejection failure detecting means 10 operates in response to a group of signals generated in this way. When the Load signal is inputted to the subtraction counter 45 from the timing generating means 36 right before the rising edge of the driving signal outputted from the driving circuit 18, a normal count value is inputted from the normal count value memory 46 to the subtraction counter 45 and held therein at this timing. When the ejection driving operation of the ink jet head 100 (driving period) is terminated, the driving/detection switching signal is inputted to the switching means 23 and the AND circuit AND in sync with the falling edge of the driving signal. Then, the switching means 23 switches the connection of the electrostatic actuator 120 from the driving circuit 18 to the oscillation circuit 11 in response to the driving/detection switching signal (see FIG. 23).
The capacitance C in the oscillation circuit 11 is varied in response to the residual vibration of the diaphragm 121, whereby the oscillation circuit 11 starts to oscillate. The subtraction counter 45 opens the gate in sync with the rising edge of the driving/detection switching signal (in this case, because the reference pulses are inputted to the subtraction counter 45 only when the driving/detection switching signal is in the high level by means of the AND circuit AND, the gate may be held in the open state), and carries out the subtraction processing, in which the number of reference pulses is subtracted from the normal count value, while the driving/detection switching signal remains in the high level (i.e., for the time period Ts). The time period Ts is a time period until the residual vibration of the diaphragm 121 occurs (the residual vibration is generated) after an ejection operation, and more specifically, it is a time period until the diaphragm 121 returns to the position, where the diaphragm 121 is positioned when the electrostatic actuator 120 is not driven, after an ink droplet was ejected from the ink jet head 100.
In the timing chart of FIG. 25, after switching the connection from the driving circuit 18 to the ejection failure detecting means 10, the judgment of the presence or absence of an ejection failure and a cause thereof is carried out on the basis of the normal count value in the time period until the residual vibration of the diaphragm 121 occurs. The driving/detection switching signal falls to the low level and the Ls signal is generated at the timing when the residual vibration occurs (i.e., at the timing when the diaphragm 121 returns to a initial state position). Then, the judging means 20 carries out predetermined judgment processing on the basis of the subtraction result of the subtraction counter 45, and the judgment result is stored into the storage means 62. In this regard, each of the reference values N1, N2, and P1 (that is, comparison reference values) in FIG. 25 is a predetermined threshold (that is, first to third count thresholds). The cause of an ejection failure (including a head failure) is judged on the basis of differences between these count thresholds and the subtraction result (subtraction count value) and the differences between the lapsed time measured by the time measuring means 25 and each of the predetermined time reference values (that is, first and second time thresholds).
Next, a method of detecting and judging a head failure in the droplet ejection apparatus (ink jet printer 1) of the invention (head failure detection and judgment processing and head failure recovery processing) will now be described. FIG. 26 is a flowchart showing head failure detection and judgment processing of the invention. When the ink jet printer 1 is powered on, for example, this head failure detection and judgment processing is started.
For example, when the ink jet printer 1 is turned on, a timer of the time measuring means 25 start timing (Step S101). At Step S102, the control section 6 judges whether or not a printing instruction is inputted from the host computer 8 via IF 9. In the case where it is judged that the printing instruction is not inputted, the ink jet printer 1 waits until the timer is up (Step S103). In this regard, a time when the timer is up (time when an ejection operation has been carried out, that is, lapsed time) may be set to a predetermined threshold at which there is a possibility that a head failure occurs.
When the timer is up without inputting the printing instruction, the processing proceeds to Step S104, and the ejection failure detection processing (see FIG. 27) is carried out. In this case, the ink jet heads 100 are moved (arranged) to a recovery area where a pump-suction process (an area where a cap can be capped) described later can be carried out, and a nozzle plate is capped with the cap. Hence, the ink jet printer 1 can carry out an ejection operation of ink droplets. However, in order to discharge useless ink, head failure detection processing in which the electrostatic actuator 120 is driven to an extent that an ink droplet is not ejected may be carried out.
At Step S105, it is judged whether or not there is an ejection failure or head failure (that is, an ejection failure (head failure) occurs). In the case where it is judged that an ejection failure or head failure does not occur, the control section 6 clears the measured time of the timer in the time measuring means 25 (Step S107), and proceeds to Step S101. On the other hand, in the case where it is judged that an ejection failure or head failure occurs, the recovery means 24 carries out recovery processing (described later, see FIG. 49 or 50) (Step S106), and the control section 6 clears the measured time of the timer in the time measuring means 25 (Step S107). Then, the processing proceeds to Step S101, and the same processing is repeated.
At Step S102, in the case where it is judged that a printing instruction is inputted, the processing proceeds to Step S108, and the ejection failure detection and judgment processing (ejection failure detection processing) under the printing operation is carried out (see FIG. 43 or 44). At Step 109, it is judged whether or not there is any ink jet head 100 under an ejection failure. In the case where it is judged that there is any ink jet head 100 under an ejection failure, the ink jet printer 1 stops (discontinues) the printing operation and moves the head units 35 to a recovery area (Step S110). Then, the recovery means 24 carries out the recovery processing described later (Step S106), and the control section 6 clears the measured time of the timer in the time measuring means 25 (Step S107). The processing proceeds to Step S101, and the same processing is repeated.
On the other hand, in the case where it is judged that there is no ink jet head 100 under an ejection failure, the control section 6 judges whether or not the printing operation instructed from the host computer is terminated. In the case where it is judged that the printing operation is terminated, the control section 6 clears the measured time of the timer in the time measuring means 25 (Step S107). Then, the processing proceeds to Step S101, and the same processing is repeated. In the case where it is judged that the printing operation is not terminated, the processing proceeds to Step S108, and the same processing is repeated. In this way, this processing is repeated while the ink jet printer 1 is turned on. This makes it possible to detect a head failure such as thickening of ink even when a printing operation is not carried out, and to recover the head failure detected.
Next, the head failure detection and judgment processing carried out at each of Steps S104 and S108 in the flowchart shown in FIG. 26 will now be described (see FIG. 43 or 44). FIG. 27 is a flowchart showing the head failure detection and judgment processing of the invention. In this regard, in the flowchart shown in FIG. 27, the head failure detection and judgment processing corresponding to an ink ejection operation of one ink jet head 100, that is, one nozzle 110, will be described for ease of explanation.
Initially, the driving signal corresponding to the printing data (ejection data) or driving to an extent that an ink droplet is not ejected is inputted from the driving circuit 18 of the head driver 33, whereby the driving signal (voltage signal) is applied between both electrodes of the electrostatic actuator 120 according to the timing of the driving signal as shown in the timing chart of FIG. 20 (Step S201). The control section 6 then judges whether or not the ink jet head 100 that has ejected an ink droplet is in a driving halt period on the basis of the driving/detection switching signal (Step S202). At this point, the driving/detection switching signal shifts to the high level in sync with the falling edge of the driving signal (see FIG. 20), and is inputted into the switching means 23 from the control section 6.
When the driving/detection switching signal is inputted into the switching means 23, the electrostatic actuator 120, that is, the capacitor constituting the oscillation circuit 11 is isolated from the driving circuit 18 by the switching means 23, and is connected to the ejection failure detecting means 10 (detection circuit) side, that is, to the oscillation circuit 11 of the residual vibration detecting means 16 (Step S203). Subsequently, the residual vibration detection processing described later is carried out (Step S204), and the computation means 17 carries out the computation described later on the basis of the residual vibration waveform data detected in the residual vibration detection processing (Step S205).
Subsequently, the ejection failure judgment processing described later is carried out by the judging means 20 on the basis of the computation result by the computation means 17 (Step S206), and the judgment result is saved (stored) in a predetermined storage region in the EEPROM (storage means) 62 of the control section 6 (Step S207). At the following Step S208, it is judged whether or not the ink jet head 100 is in the driving period. In other words, it is judged whether or not the driving halt period has ended and the following driving signal is inputted, and this operation is suspended at Step S208 until the following driving signal is inputted.
When the driving/detection switching signal shifts to the low level in sync with the rising edge of the driving signal at the timing at which the following driving signal is inputted (i.e., “YES” at Step S208), the switching means 23 switches the connection of the electrostatic actuator 120 from the ejection failure detecting means (detection circuit) 10 to the driving circuit 18 (Step S209), and the ejection failure detection and judgment processing is terminated.
Next, the residual vibration detection processing (sub routine) at Step S204 of the flowchart shown in FIG. 27 will now be described. FIG. 28 is a flowchart showing the residual vibration detection processing of the invention. When the electrostatic actuator 120 and the oscillation circuit 11 are connected to each other by the switching means 23 as described above (Step S203 of FIG. 27), the oscillation circuit 11 forms a CR oscillation circuit, and starts to oscillate in response to the change of the electric capacitance of the electrostatic actuator 120 (residual vibration of the diaphragm 121 of the electrostatic actuator 120) (Step S301).
As shown in the timing chart described above, the charging signal, the hold signal and the clear signal are generated in the F/V converting circuit 12 according to the output signal (pulse signal) from the oscillation circuit 11, and the F/V conversion processing is carried out according to these signals by the F/V converting circuit 12, by which the frequency of the output signal from the oscillation circuit 11 is converted into a voltage (Step S302), and then the residual vibration waveform data of the diaphragm 121 is outputted from the F/V converting circuit 12. The DC components (direct current components) are eliminated from the residual vibration waveform data outputted from the F/V converting circuit 12 in the capacitor C3 of the waveform shaping circuit 15 (Step S303), and the residual vibration waveform (AC components) from which the DC components have been eliminated is amplified in the operational amplifier 151 (Step S304).
The residual vibration waveform data after the amplification is subjected to waveform shaping in the predetermined processing and converted into pulses (Step S305). In other words, in this embodiment, the voltage value (predetermined voltage value) set by the direct current voltage source Vref2 is compared with the output voltage from the operational amplifier 151 in the comparator 152. The comparator 152 outputs the binarized waveform (rectangular wave) on the basis of the comparison result. The output signal from the comparator 152 is the output signal from the residual vibration detecting means 16, and is outputted to the computation means 17 for the ejection failure judgment processing to be carried out, upon which the residual vibration detection processing is completed (terminated).
Next, the computation processing (sub routine) at Step S205 of the flowchart shown in FIG. 27 will now be described. FIG. 29 is a flowchart showing one example of computation processing according to the invention. At the same time when the residual vibration detection processing is carried out at Step S204 of the flowchart shown in FIG. 27, as shown in the timing chart of FIG. 25, reference pulses are outputted from the pulse generating means (Step S401).
At Step S402, it is judged whether or not the ink jet head 100 is in a measurement time period for a detection output signal (output signal of detection), that is, whether or not the driving/detection switching signal is in a High level. In the case where it is judged that the ink jet head 100 is in the measurement time period, the timing generating means 36 makes the CLR signal become a Low level to allow the subtraction counter 45 to carry out a counting operation (Step S403), and the normal count value is preset to the subtraction counter 45 from the normal count value memory 46 (Step S404). Then, the subtraction counter 45 subtracts the number of reference pulses from the normal count value (Step S405).
At Step S406, the timing generating means 36 judges whether or not the measurement time period is terminated on the basis of the detection output signal, and waits until the measurement time period is terminated while the subtraction counter 45 subtracts the number of reference pulses from the normal count value. When it is judged that the measurement time period is terminated at timing of the rising edge of the detection output signal, the subtraction result (Nd value) of the subtraction counter 45 is held in the holding means 48 in response to the input of the Ls signal to the holding means 48 (Step S407). Then, the count value of the subtraction counter 45 is cleared (Step S408), and this computation processing is terminated.
Next, the computation processing (sub routine) at Step S205 of the flowchart shown in FIG. 27 on the basis of ambient temperature measured by the temperature sensor 37 will now be described. FIG. 30 is a flowchart showing another example of computation processing according to the invention. At the same time when the residual vibration detection processing is carried out at Step S204 of the flowchart shown in FIG. 27, as shown in the timing chart of FIG. 25, reference pulses are outputted from the pulse generating means (Step S501).
At Step S502, it is judged whether or not the ink jet head 100 is in a measurement time period for a detection output signal (output signal of detection), that is, whether or not the driving/detection switching signal is in a High level. In the case where it is judged that the ink jet head 100 is in the measurement time period, the timing generating means 36 makes the CLR signal become a Low level to allow the subtraction counter 45 to carry out a counting operation (Step S503). At this time, a normal count value corresponding to the ambient temperature of the ink jet head 100 that is measured by the temperature sensor 37 is selected (Step S504), and the selected normal count value is preset to the subtraction counter 45 from the normal count value memory 46 (Step S505). Then, the subtraction counter 45 subtracts the number of reference pulses from the normal count value (Step S506).
At Step S507, the timing generating means 36 judges whether or not the measurement time period is terminated on the basis of the detection output signal, and waits until the measurement time period is terminated while the subtraction counter 45 subtracts the number of reference pulses from the normal count value. When it is judged that the measurement time period is terminated at timing of the rising edge of the detection output signal, the subtraction result (Nd value) of the subtraction counter 45 is held in the holding means 48 in response to the input of the Ls signal to the holding means 48 (Step S508). Then, the count value of the subtraction counter 45 is cleared (Step S509), and this computation processing is terminated.
In this regard, the relationship between ink viscosity and temperature (graph) is shown in FIG. 31. As can be seen from this graph, in an environment where the ink jet printer 1 is used, increase in temperature (ambient temperature) reduces a degree of ink viscosity. When the degree of ink viscosity changes, as shown in FIG. 35(B), the vibration frequency of the residual vibration changes. Thus, when a normal count value is corrected on the basis of temperature, the ink jet printer 1 is constructed so that a cycle of the residual vibration corresponding to the temperature is stored into the normal count value memory 46 as a normal count value to correct an appropriate normal count value corresponding to the ambient temperature measured by the temperature sensor 37.
Next, the ejection failure judgment processing of the invention will now be described. FIGS. 32-34 are a flowchart which shows the ejection failure (head failure) judgment processing of the invention. Initially, the judging means 20 reads out the subtraction result Nd of the subtraction counter 45 from the holding means 48 (Step S601), and judges whether or not the subtraction result Nd is larger than a first count threshold P1 (Step S602). In the case where it is judged that the subtraction result Nd is larger than the first count threshold P1 (that is, Nd>P1), the judging means 20 judges that an ejection failure occurs and a cause thereof is intrusion of an air bubble into the cavity 141, and the judgment result and the subtraction result Nd are stored into the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S603, S207).
On the other hand, in the case where it is judged that the subtraction result Nd is smaller than the first count threshold P1 (that is, Nd<P1), the judging means 20 judges whether or not the lapsed time T measured by the time measuring means 25 is shorter than a first time threshold T1 (Step S604). In the case where it is judged that the lapsed time T is shorter than the first time threshold T1 (that is, T<T1), the judging means 20 further judges whether or not the subtraction result Nd is smaller than a third count threshold N2 (Step S605). In the case where it is judged that the subtraction result Nd is smaller than the third count threshold N2 (that is, Nd<N2), the judging means 20 judges that an ejection failure occurs and a cause thereof is adhesion of paper dust (L) to a nozzle surface of the head units 35, that is, much paper dust is adhering to the nozzle surface (in the vicinity of the outlet of the nozzle 110), and the judgment result is stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S606, S207).
In the case where it is judged that the subtraction result Rd is larger than the third count threshold N2 (that is, Nd>N2), the judging means 20 further judges whether or not the subtraction result Nd is smaller than a second count threshold N1 (Step S607). In the case where it is judged that the subtraction result Nd is larger than the third count threshold N2 and smaller than the second count threshold N1 (that is, N2<Nd<N1), the judging means 20 judges that an ejection failure occurs and a cause thereof is adhesion of paper dust (S) to the nozzle surface of the head units 35, that is, little (or somewhat) paper dust is adhering to the nozzle surface (in the vicinity of the outlet of the nozzle 110), and the judgment result is stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S608, S207). On the other hand, in the case where it is judged that the subtraction result Nd is larger than the second count threshold N1 (that is, N1<Nd<P1), the judging means 20 judges that an ejection failure does not occur, that is, the nozzle 110 in question is in a normal state, and the judgment result is stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S609, S207).
Subsequently, at Step S604, in the case where the lapsed time T is longer than the first time threshold T1, the judging means 20 further judges at Step S610 whether or not the lapsed time T is shorter than a second time threshold T2. In the case where the lapsed time T is longer than the first time threshold T1 and shorter than the second time threshold T2, the judging means 20 further judges whether or not the subtraction result Nd is smaller than the third count threshold N2 (Step S611). In the case where it is judged that the subtraction result Nd is smaller than the third count threshold N2 (that is, Nd<N2), the judging means 20 judges that an ejection failure occurs and a cause thereof is adhesion of paper dust (L) to the nozzle surface of the head units 35, that is, much paper dust is adhering to the nozzle surface (in the vicinity of the outlet of the nozzle 110), and the judgment result is stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S612, S207).
On the other hand, in the case where it is judged that the subtraction result Rd is larger than the third count threshold N2 (that is, Nd>N2), the judging means 20 further judges whether or not the subtraction result Nd is smaller than the second count threshold N1 (Step S613). In the case where it is judged that the subtraction result Nd is larger than the third count threshold N2 and smaller than the second count threshold N1 (that is, N2<Nd<N1), the judging means 20 judges that an ejection failure occurs and a cause thereof is thickening of ink within the cavity 141 due to drying (S), that is, the ink in the vicinity of the nozzle 110 has somewhat thickened due to drying, and the judgment result and the subtraction result Nd are stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S614, S207). On the other hand, in the case where it is judged that the subtraction result Nd is larger than the second count threshold N1 (that is, N1<Nd<P1), the judging means 20 judges that an ejection failure does not occur, that is, the nozzle 110 in question is in a normal state, and the judgment result is stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S615, S207).
Subsequently, at Step S610, in the case where the lapsed time T is longer than the second time threshold T2, the judging means 20 further judges whether or not the subtraction result is smaller than the third count threshold N2 (Step S616). In the case where it is judged that the subtraction result Nd is smaller than the third count threshold N2 (that is, Nd<N2), the judging means 20 judges that an ejection failure occurs and a cause thereof is thickening of ink within the cavity 141 due to drying (L), that is, the ink in the vicinity of the nozzle 110 has considerably thickened due to drying, and the judgment result and the lapsed time (waiting time) T are stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S617, S207).
On the other hand, in the case where it is judged that the subtraction result Rd is larger than the third count threshold N2 (that is, Nd>N2), the judging means 20 further judges whether or not the subtraction result Nd is smaller than the second count threshold N1 (Step S618). In the case where it is judged that the subtraction result Nd is larger than the third count threshold N2 and smaller than the second count threshold N1 (that is, N2<Nd<N1), the judging means 20 judges that an ejection failure occurs and a cause thereof is adhesion of paper dust (S) to the nozzle surface of the head units 35, that is, little (or somewhat) paper dust is adhering to the nozzle surface (in the vicinity of the outlet of the nozzle 110), and the judgment result is stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S619, S207). On the other hand, in the case where it is judged that the subtraction result Nd is larger than the second count threshold N1 (that is, N1<Nd<P1), the judging means 20 judges that an ejection failure does not occur, that is, the nozzle 110 in question is in a normal state, and the judgment result is stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S620, S207).
Next, in place of the flowchart in FIG. 33, the ejection failure (head failure) judgment processing in the case of correcting the subtraction result Nd on the basis of the lapsed time measured by the time measuring means 25 will now be described with reference to a flowchart of FIG. 34. At Step S604, in the case where it is judged that the lapsed time T is longer than the first time threshold T1 (that is, T>T1), the judging means 20 judges at Step S 621 whether or not the lapsed time T is shorter than the second time threshold T2. In the case where it is judged that the lapsed time T is longer than the first time threshold T1 and shorter than the second time threshold T2 (that is, T1<T<T2), the judging means 20 further judges whether or not the subtraction result Nd is smaller than the third count threshold N2 (Step S622). In the case where it is judged that the subtraction result Nd is smaller than the third count threshold N2 (that is, Nd<N2), the judging means 20 judges that an ejection failure occurs and a cause thereof is adhesion of paper dust (L) to a nozzle surface of the head units 35, that is, much paper dust is adhering to the nozzle surface (in the vicinity of the outlet of the nozzle 110), and the judgment result is stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S623, S207).
In the case where it is judged that the subtraction result Rd is larger than the third count threshold N2 (that is, Nd>N2), the judging means 20 further judges whether or not the subtraction result Nd is smaller than a second count threshold N1 (Step S624). In the case where the subtraction result Nd is larger than the third count threshold N2 and smaller than the second count threshold N1 (that is, N2<Nd<N1), the judging means 20 reads out an Ndc value calculated on the basis of the lapsed time T and an allowable error value α corresponding to the Ndc value from the comparison reference value memory 47 (Step S625), and judges whether or not the subtraction result Nd is within a predetermined range, that is, whether or not the subtraction result Nd is larger than the value Ndc−α and smaller than the value Ndc+α (that is, Ndc−α<Nd<Ndc+α) (Step S626). In the case where it is judged that the subtraction result Nd is within the predetermined range, the judging means 20 judges that an ejection failure occurs and a cause thereof is thickening of ink within the cavity 141 due to drying (S), that is, the ink in the vicinity of the nozzle 110 has somewhat thickened due to drying, and the judgment result and the subtraction result Nd are stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S627, S207). On the other hand, in the case where it is judged that the subtraction result Nd is not within the predetermined range, the judging means 20 judges that an ejection failure occurs and a cause thereof is adhesion of paper dust (S) to the nozzle surface of the head units 35, that is, little (or somewhat) paper dust is adhering to the nozzle surface (in the vicinity of the outlet of the nozzle 110), and the judgment result is stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S628, S207). On the other hand, in the case where it is judged at Step S624 that the subtraction result Nd is larger than the second count threshold N1 (that is, N1<Nd<P1), the judging means 20 judges that an ejection failure does not occur, that is, the nozzle 110 in question is in a normal state, and the judgment result is stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S629, S207).
Subsequently, at Step S621, in the case where the lapsed time T is longer than the second time threshold T2, the judging means 20 further judges whether or not the subtraction result is smaller than the third count threshold N2 (Step S630). In the case where it is judged that the subtraction result Nd is smaller than the third count threshold N2 (that is, Nd<N2), the judging means 20 judges that an ejection failure occurs and a cause thereof is thickening of ink within the cavity 141 due to drying (L), that is, the ink in the vicinity of the nozzle 110 has considerably thickened due to drying, and the judgment result and the lapsed time (waiting time) T are stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S631, S207).
On the other hand, in the case where it is judged that the subtraction result Rd is larger than the third count threshold N2 (that is, Nd>N2), the judging means 20 further judges whether or not the subtraction result Nd is smaller than the second count threshold N1 (Step S632). In the case where it is judged that the subtraction result Nd is larger than the third count threshold N2 and smaller than the second count threshold N1 (that is, N2<Nd<N1), the judging means 20 judges that an ejection failure occurs and a cause thereof is adhesion of paper dust (S) to the nozzle surface of the head units 35, that is, little (or somewhat) paper dust is adhering to the nozzle surface (in the vicinity of the outlet of the nozzle 110), and the judgment result is stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S633, S207). On the other hand, in the case where it is judged that the subtraction result Nd is larger than the second count threshold N1 (that is, N1<Nd<P1), the judging means 20 judges that an ejection failure does not occur, that is, the nozzle 110 in question is in a normal state, and the judgment result is stored in the storage means 62 in association with the nozzle 110 of the corresponding ink jet head 100 (Steps S634, S207). In this way, when the judging means 20 outputs a predetermined judgment result, the ejection failure judgment processing is terminated.
FIG. 35 is a graph showing the relationship between a lapsed time (waiting time) and a degree of ink viscosity and the relationship between vibration frequency of the residual vibration and a degree of ink viscosity. As shown in FIG. 35(A), when a lapsed time (waiting time) T is in a range under T1 (that is, T<T1), the ink jet head 100 can normally eject an ink droplet through the nozzle 100. When a lapsed time is in a range between T1 and T2 (that is, T1<T<T2), ink may be thickened due to drying to an extent that the thickening (ejection failure) can be generally recovered by a flushing process described later. Further, when a lapsed time is in a range over T2 (that is, T>T2), ink may be thickened due to drying to an extent that the thickening (ejection failure) cannot be generally recovered only by a pump-suction process.
Further, as shown in FIG. 35(B), in a vibration frequency of the residual vibration, a vibration frequency between a first count threshold P1 and a second count threshold N1 constitutes a normal ejection range, a vibration frequency between the second count threshold N1 and a third count threshold N2 constitutes a range in which a flushing process is required (frequency decreased range) because ink viscosity becomes larger than in the normal ejection range, and a vibration frequency lower than the third count threshold N2 constitutes a range in which a pump-suction process is required (over-damped range) because ink viscosity becomes larger than in the range in which a flushing process is required.
By dividing states of the ink jet head 100 into some ranges separated by some thresholds of each of two types of parameters (in this embodiment, a lapsed time and a count value) in this way, it is possible to judge a cause of an ejection failure (head failure) more precisely than in the case of only the frequency of the residual vibration. Therefore, it is possible to select recovery processing (described later) more appropriately according to the cause of the ejection failure (head failure) judged (identified). In this regard, regardless of the cause of the ejection failure, the storage means 62 may store a judgment result, that is, presence or absence of an ejection failure and a cause thereof that are judged by the judging means 20, and store all data such as a subtraction result of the subtraction counter 45, time data of the time measuring means 25, and the like by taking in them.
Next, on the assumption of the ink jet printer 1 provided with a head unit 35 including a plurality of ink jet heads (droplet ejection heads) 100, that is, a plurality of nozzles 110 (in this embodiment, the head unit 35 is provided with five ink jet heads 100a through 100e (that is, five nozzles 110), but, in the invention, both the number of the head units 35 provided to the printing means 3 and the number of the ink jet heads 100 (nozzles 110) provided to each head unit 35 are not limited to these numbers, they may be determined arbitrarily), a plurality of ejection selecting means (nozzle selector) 182 corresponding to the respective colors of inks of the ink jet printer 1 and the timing of the detection and judgment (detection and judgment timing) of an ejection failure for the respective ink jet heads 100 will now be described. FIGS. 36-39 are block diagrams showing some examples of the detection and judgment timing (in particular, timing of the ejection failure detection and judgment at a printing operation at Step S108 of the flowchart shown in FIG. 26) of an ejection failure in the ink jet printer 1 provided with the plurality of ejection selecting means 182. Examples of the configuration in the respective drawings will now be described one by one.
FIG. 36 shows one example of detection timing of an ejection failure for a plurality of (five) ink jet heads 100a through 100e (in the case where there is one ejection failure detecting means 10). As shown in FIG. 36, the ink jet printer 1 having a plurality of ink jet heads 100a through 100e is provided with driving waveform generating means 181 for generating a driving waveform, the ejection selecting means 182 capable of selecting from which nozzle 110 ink droplets are to be ejected, and the plurality of ink jet heads 100a through 100e selected by the ejection selecting means 182 and driven by the driving waveform generating means 181. In this regard, because the configuration of FIG. 36 is the same as those shown in FIG. 2, FIG. 16, and FIG. 23 except for the above-mentioned configuration, the description of the same portion is omitted.
In this example, the driving waveform generating means 181 and the ejection selecting means 182 are described as they are included in the driving circuit 18 of the head driver 33 (they are indicated as two blocks via the switching means 23 in FIG. 36; however, both of them are generally formed inside the head driver 33). The invention, however, is not limited to this configuration. For example, the driving waveform generating means 181 may be provided independently of the head driver 33.
As shown in FIG. 36, the ejection selecting means 182 is provided with a shift register 182a, a latch circuit 182b, and a driver 182c. Printing data (ejection data) outputted from the host computer 8 shown in FIG. 2 and underwent the predetermined processing in the control section 6 as well as a clock signal (CLK) are sequentially inputted into the shift register 182a. The printing data is shifted and inputted sequentially from the first stage to the latter stages in the shift register 182a in response to an input pulse of the clock signal (CLK) (each time the clock signal is inputted), and is then outputted to the latch circuit 182b as printing data corresponding to the respective ink jet heads 100a through 100e. In the ejection failure detection processing described later, ejection data used at the time of flushing (preliminary ejection) is inputted instead of the printing data. However, the ejection data referred to herein means printing data for all of the ink jet heads 100a through 100e. Alternatively, a value such that all the outputs from the latch circuit 182b will trigger ejection may be set by hardware at the time of flushing.
The latch circuit 182b latches the respective output signals from the shift register 182a by the latch signal inputted therein after printing data corresponding to the number of the nozzles 110 of the head unit 35, that is, the number of the ink jet heads 100, is stored into the shift register 182a. In the case where a CLEAR signal is inputted, the latch state is released, and the latched output signal from the shift register 182a becomes 0 (output of the latch is stopped), whereby the printing operation is stopped. In the case where no CLEAR signal is inputted, the latched printing data from the shift register 182a is outputted to the driver 182c. After the printing data outputted from the shift register 182a is latched in the latch circuit 182b, the following printing data is inputted into the shift register 182a, so that the latch signal in the latch circuit 182b is successively updated at the print timing.
The driver 182c connects the driving waveform generating means 181 to the electrostatic actuators 120 of the respective ink jet heads 100, and inputs the output signal (driving signal) from the driving waveform generating means 181 to the respective electrostatic actuators 120 specified (identified) by the latch signal outputted from the latch circuit 182b (any or all of the electrostatic actuators 120 of the ink jet heads 100a through 100e). The driving signal (voltage signal) is thus applied between both electrodes of the corresponding electrostatic actuator 120.
The ink jet printer 1 shown in FIG. 36 is provided with one driving waveform generating means 181 for driving the plurality of ink jet heads 100a through 100e, the ejection failure detecting means 10 for detecting an ejection failure (ink droplet non-ejection) for the ink jet head 100 in any of the ink jet heads 100a through 100e, storage means 62 for saving (storing) the judgment result, such as the cause of the ejection failure, obtained by the ejection failure detecting means 10, and one switching means 23 for switching the connection of the ejection selecting means 182 between the driving waveform generating means 181 and the ejection failure detecting means 10. Therefore, in this ink jet printer 1, one or more of the ink jet heads 100a through 100e selected by the driver 182c is driven according to the driving signal inputted from the driving waveform generating means 181, and the switching means 23 switches the connection of the electrostatic actuator 120 of the ink jet head 100 from the driving waveform generating means 181 to the ejection failure detecting means 10 when the driving/detection switching signal is inputted into the switching means 23 after the ejection driving operation. Then, the ejection failure detecting means 10 detects whether or not an ejection failure (ink droplet non-ejection) exists in the nozzle 110 of the ink jet head 100 in question as well as judges the cause thereof in the event of ejection failure, on the basis of the residual vibration waveform of the diaphragm 121.
Further, in the ink jet printer 1, when an ejection failure is detected and judged for the nozzle 110 of one ink jet head 100, an ejection failure is detected and judged for the nozzle 110 of the ink jet head 100 specified next, according to the driving signal subsequently inputted from the driving waveform generating means 181. Thereafter, an ejection failure is detected and judged sequentially for the nozzles 110 of the ink jet heads 100 to be driven by an output signal from the driving waveform generating means 181 in the same manner. Then, as described above, when the residual vibration detecting means 16 detects the residual vibration waveform of the diaphragm 121, the computation means 17 measures the cycle or the like of the residual vibration waveform and carries out predetermined subtraction processing on the basis of the waveform data thereof. The judging means 20 then judges normal ejection or an ejection failure on the basis of the computation result in the computation means 17, and judges the cause of the ejection failure in the event of ejection failure (head failure) to output the judgment result to the storage means 62.
In this way, because the ink jet printer 1 shown in FIG. 36 is configured in such a manner that an ejection failure is detected and judged sequentially for the respective nozzles 110 of the plurality of ink jet heads 100a through 100e during the ink droplet ejection driving operation, it is sufficient to provide one ejection failure detecting means 10 and one switching means 23, whereby it is possible to scale down the circuitry of the ink jet printer 1 capable of detecting and judging an ejection failure, and to prevent an increase of the manufacturing costs thereof.
FIG. 37 shows another example of detection timing of an ejection failure for a plurality of ink jet heads 100 (in the case where the number of the ejection failure detecting means 10 is equal to the number of the ink jet heads 100). The ink jet printer 1 shown in FIG. 37 is provided with one ejection selecting means 182, five ejection failure detecting means 10a through 10e, five switching means 23a through 23e, one driving waveform generating means 181 common for five ink jet heads 100a through 100e, and one storage means 62. In this regard, because the respective components have been described with reference to FIG. 36, the description of these components is omitted and only the connections of these components will be described.
As in the case shown in FIG. 36, the ejection selecting means 182 latches printing data corresponding to the respective ink jet heads 100a through 100e in the latch circuit 182b on the basis of the clock signal CLK and the printing data (ejection data) inputted from the host computer 8, and drives the electrostatic actuators 120 of the ink jet heads 100a through 100e corresponding to the printing data in response to the driving signal (voltage signal) inputted from the driving waveform generating means 181 into the driver 182c. The driving/detection switching signal is inputted into the respective switching means 23a through 23e corresponding to all the ink jet heads 100a through 100e. The switching means 23a through 23e then switch the connection of the ink jet heads 100 from the driving waveform generating means 181 to the ejection failure detecting means 10a through 10e according to the driving/detection switching signal regardless of the presence or absence of the corresponding printing data (ejection data), after input of the driving signal into the electrostatic actuators 120 of the ink jet heads 100.
After an ejection failure is detected and judged for the respective ink jet heads 100a through 100e by all the ejection failure detecting means 10a through 10e, the judgment results for all the ink jet heads 100a through 100e obtained in the detection processing are outputted to the storage means 62. The storage means 62 stores the presence or absence of an ejection failure and the cause of the ejection failure for the respective ink jet heads 100a through 100e into the predetermined storage region thereof.
In this way, in the ink jet printer 1 shown in FIG. 37, the plurality of ejection failure detecting means 10a through 10e are respectively provided for the nozzles 110 of the plurality of ink jet heads 100a through 100e, and an ejection failure is detected and the cause thereof is judged after carrying out the switching operation with the use of the plurality of switching means 23a through 23e corresponding to the ejection failure detecting means 10a through 10e. Therefore, it is possible to detect an ejection failure and judge the cause thereof in a short time for all the nozzles 110 at a time.
FIG. 38 shows still another example of detection timing of an ejection failure for a plurality of ink jet heads 100 (in the case where the number of the ejection failure detecting means 10 is equal to the number of the ink jet heads 100, and detection of an ejection failure is carried out when printing data is inputted). The ink jet printer 1 shown in FIG. 38 is of the same configuration as that of the ink jet printer 1 shown in FIG. 37 except that switching control means 19 is added (appended). In this example, the switching control means 19 comprises a plurality of AND circuits (logical conjunction circuits) ANDa through ANDe, and upon input of the printing data to be inputted into the respective ink jet heads 100a through 100e and the driving/detection switching signal, the switching control means 19 outputs an output signal in the high level to the corresponding switching means 23a through 23e. In this case, the switching control means 19 is not limited to AND circuits (logical conjunction circuits), and it only has to be formed in such a manner that the switching control means 19 selects one or any of the plurality of switching means 23 that corresponds to an output from the latch circuit 182b for selecting the ink jet head 100 to be driven.
The respective switching means 23a through 23e switch the connection of the electrostatic actuators 120 of the corresponding ink jet heads 100a through 100e from the driving waveform generating means 181 to the corresponding ejection failure detecting means 10a through 10e, according to the output signals from the corresponding AND circuits ANDa through ANDe of the switching control means 19. To be more specific, when the output signals from the corresponding AND circuits ANDa through ANDe are in the high level, in other words, in the case where printing data to be inputted into the corresponding ink jet heads 100a through 100e is outputted from the latch circuit 182b to the driver 182c while the driving/detection switching signal remains in the high level, the switching means 23a through 23e corresponding to the AND circuits in question switch the connections of the corresponding ink jet heads 100a through 100e from the driving waveform generating means 181 to the corresponding ejection failure detecting means 10a through 10e. 
After the presence or absence of an ejection failure for the respective ink jet heads 100 and the cause thereof in the event of ejection failure are detected by the ejection failure detecting means 10a through 10e corresponding to the ink jet heads 100 into which the printing data has been inputted, the corresponding ejection failure detecting means 10 output the judgment results obtained in the detection processing to the storage means 62. The storage means 62 stores one or more judgment result inputted (obtained) in this manner into the predetermined storage region thereof.
In this way, in the ink jet printer 1 shown in FIG. 38, a plurality of ejection failure detecting means 10a through 10e are provided to correspond to the respective nozzles 110 of a plurality of ink jet heads 100a through 100e, and when printing data corresponding to the respective ink jet heads 100a through 100e is inputted into the ejection selecting means 182 from the host computer 8 via the control section 6, an ejection failure of the ink jet head 100 is detected and the cause thereof is judged after only any of the switching means 23a through 23e specified by the switching control means 19 carry out the predetermined switching operation. Hence, the detection and judgment processing is not carried out for the ink jet heads 100 that have not carried out the ejection driving operation. It is thus possible to avoid useless detection and judgment processing in this ink jet printer 1.
FIG. 39 shows yet still another example of the detection timing of an ejection failure for a plurality of ink jet heads 100 (in the case where the number of switching means 23 is equal to the number of the ink jet heads 100, and detection of an ejection failure is carried out by making the rounds of the respective ink jet heads 100). The ink jet printer 1 shown in FIG. 39 is of the same configuration as that of the ink jet printer 1 shown in FIG. 38 except that there is only one ejection failure detecting means 10 and switching selecting means 19a for scanning the driving/detection switching signal (identifying one of the ink jet heads 100 one by one for which the detection and judgment processing is to be carried out) is added.
The switching selecting means 19a is connected to the switching control means 19 as shown in FIG. 38, and is a selector that scans (selects and switches) the input of the driving/detection switching signal into the AND circuits ANDa through ANDe corresponding to a plurality of ink jet heads 100a through 100e, according to a scanning signal (selection signal) inputted from the control section 6. The scanning (selection) order of the switching selecting means 19a may be the same as the order of printing data inputted into the shift register 182a, that is, the order of ejection by the plurality of ink jet heads 100; however, it may simply be the order of the plurality of ink jet heads 100a through 100e. In this regard, in the structure shown in FIG. 39, the switching selecting means 19a and the switching control means 19 constitute detection determining means that determines for which nozzle 110 in a plurality of ink jet heads 100a to 100e the ejection failure detecting means 10 detects an ejection failure.
In the case where the scanning order is the order of printing data inputted into the shift register 182a, when the printing data is inputted into the shift register 182a of the ejection selecting means 182, the printing data is latched in the latch circuit 182b, and outputted to the driver 182c in response to the input of the latch signal. The scanning signal to identify the ink jet head 100 corresponding to the printing data is inputted into the switching selecting means 19a in sync with the input of the printing data into the shift register 182a or the input of the latch signal into the latch circuit 182b, and the driving/detection switching signal is outputted to the corresponding AND circuit. In this regard, the switching selecting means 19a outputs a low level signal from output terminals thereof when no selection is made.
The corresponding AND circuit (in switching control means 19) carries out the logical operation AND of the printing data inputted from the latch circuit 182b and the driving/detection switching signal inputted from the switching selecting means 19a, thereby outputting an output signal in the high level to the corresponding switching means 23. When the output signal in the high level is inputted from the switching control means 19, the switching means 23 switches the connection of the electrostatic actuator 120 of the corresponding ink jet head 100 from the driving waveform generating means 181 to the ejection failure detecting means 10.
The ejection failure detecting means 10 then detects an ejection failure of the ink jet head 100 into which the printing data has been inputted, and judges the cause thereof in the event of ejection failure, after which the ejection failure detecting means 10 outputs the judgment result to the storage means 62. The storage means 62 stores the judgment result inputted (obtained) in this manner into the predetermined storage region thereof.
Further, in the case where the scanning order is simply the order of the ink jet heads 100a through 100e, when the printing data is inputted into the shift register 182a of the ejection selecting means 182, the printing data is latched in the latch circuit 182b, and outputted to the driver 182c in response to the input of the latch signal. The scanning (selection) signal to identify the ink jet head 100 corresponding to the printing data is inputted into the switching selecting means 19a in sync with the input of the printing data into the shift register 182a or the input of the latch signal into the latch circuit 182b, and the driving/detection switching signal is outputted to the corresponding AND circuit of the switching control means 19.
When the printing data corresponding to the ink jet head 100 determined by the scanning signal inputted into the switching selecting means 19a is inputted into the shift register 182a, the output signal from the corresponding AND circuit (in switching control means 19) shifts to the high level, and the corresponding switching means 23 switches the connection of the corresponding ink jet head 100 from the driving waveform generating means 181 to the ejection failure detecting means 10. However, when no printing data is inputted into the shift register 182a, the output signal from the AND circuit remains in the low level, and the corresponding switching means 23 does not carry out the predetermined switching operation. In this way, the ejection failure detection processing of the ink jet head 100 is carried out on the basis of the AND of the selection result by the switching selecting means 19a and the presence of the printing data outputted from the latch circuit 182b. 
In the case where the switching operation is carried out by the switching means 23, the ejection failure detecting means 10 detects an ejection failure of the ink jet head 100 into which the printing data has been inputted and judges the cause thereof in the event of ejection failure in the same manner as described above, and then the ejection failure detecting means 10 outputs the judgment result to the storage means 62. The storage means 62 stores the judgment result inputted (obtained) in this manner into the predetermined storage region thereof.
When there is no printing data corresponding to the ink jet head 100 specified by the switching selecting means 19a, the corresponding switching means 23 does not carry out the switching operation as described above, and for this reason, it is not necessary for the ejection failure detecting means 10 to carry out the ejection failure detection processing; however, such processing may be carried out as well. In the case where the ejection failure detection processing is carried out without carrying out the switching operation, the judging means 20 of the ejection failure detecting means 10 judges that the nozzle 110 of the corresponding ink jet head 100 is a not-yet ejected nozzle, and stores the judgment result into the predetermined storage region of the storage means 62.
In this way, the ink jet printer 1 shown in FIG. 39 is different from the ink jet printer 1 shown in FIG. 37 or FIG. 38, and in the ink jet printer 1 shown in FIG. 39, only one ejection failure detecting means 10 is provided for the respective nozzles 110 of a plurality of ink jet heads 100a through 100e. When the printing data corresponding to the respective ink jet heads 100a through 100e is inputted into the ejection selecting means 182 from the host computer 8 via the control section 6 while identified by the scanning (selection) signal, only the switching means 23, corresponding to the ink jet head 100 to carry out the ejection driving operation in response to the printing data, carries out the switching operation, so that an ejection failure is detected and the cause thereof is judged only for the corresponding ink jet head 100. This makes it possible to reduce the load on the CPU 61 of the control section 6 without the need to process a large volume of detection results at a time. Further, because the ejection failure detecting means 10 makes the rounds of the respective ink jet heads 100 at nozzle states other than the ejection operation, it is possible to recognize an ejection failure of each nozzle 110 while being driven for printing, and the state of the nozzles 110 in the entire head unit 35 can be known. Thus, because an ejection failure is detected periodically, this can reduce, for example, the steps of detecting an ejection failure nozzle by nozzle while the printing operation is halted. In view of the foregoing, it is possible to efficiently detect an ejection failure of the ink jet head 100 and judge the cause thereof.
Moreover, in contrast to the ink jet printer 1 shown in FIG. 37 or FIG. 38, because the ink jet printer 1 shown in FIG. 39 may be provided with only one ejection failure detecting means 10, in comparison with the ink jet printers 1 shown in FIGS. 37 and 38, it is possible not only to scale down the circuitry of the ink jet printer 1, but also to prevent an increase of the manufacturing costs.
Next, the operations of the ink jet printers 1 shown in FIG. 36 through FIG. 39, that is, the ejection failure detection processing (chiefly, detection timing) in the ink jet printer 1 provided with a plurality of ink jet heads 100, will now be described. In the ejection failure detection and judgment processing (multi-nozzle processing) of the invention, the residual vibration of the diaphragm 121 when the electrostatic actuators 120 of the respective ink jet heads 100 carry out the ink droplet ejection operation is detected, and the occurrence of an ejection failure (missing dot, ink droplet non-ejection) is judged for the ink jet head 100 in question on the basis of the cycle of the residual vibration; moreover, in the event of a missing dot (ink droplet non-ejection), the cause thereof is judged. In this manner, in the invention, when the ejection operation of ink droplets (droplets) by the ink jet heads 100 is carried out, the detection and judgment processing for the inkjet heads 100 can be carried out. However, the ink jet heads 100 eject ink droplets not only when the printing operation (print) is actually carried out onto a recording sheet P, but also when the flushing operation (preliminary ejection or preparatory ejection) is carried out. Hereinafter, the head failure detection and judgment processing (for multi-nozzle) of the invention in these two cases will be described.
In this regard, the flushing (preliminary ejection) process referred to herein is defined as a head cleaning operation by which ink droplets are ejected through all or only target nozzles 110 of the ink jet heads 100 while a cap (not shown in FIG. 1) is attached or in a place where ink droplets (droplets) do not reach the recording sheet P (media). The flushing process (flushing operation) is carried out, for example, when ink within the cavities 141 is discharged periodically to maintain the viscosity of ink in the nozzles 110 at a value within an adequate range, or as a recovery operation when ink has thickened. Further, the flushing process is also carried out when the respective cavities 141 are initially filled with ink after the ink cartridges 31 are attached to the printing means 3.
A wiping process (i.e., processing by which fouling (such as paper dust or dust) adhering onto the head surface of the printing means 3 are wiped out by a wiper not shown in FIG. 1) may be carried out to clean the nozzle plate (nozzle surface) 150. In this case, however, a negative pressure may be produced inside the nozzles 110 and ink of other colors (other kinds of droplets) may be sucked therein. Hence, the flushing operation is carried out after the wiping process in order to force a predetermined quantity of ink droplets to be ejected through all the nozzles 110 of the head unit 35. Further, the flushing process may be carried out from time to time in order to ensure satisfactory printing by maintaining the meniscus of the nozzles 110 in a normal state.
First, the ejection failure detection and judgment processing during the flushing process will be described with reference to flowcharts shown in FIG. 40 through FIG. 42. In this regard, these flowcharts will be explained with reference to the block diagrams of FIG. 36 through FIG. 39 (the same can be said in the processing during the printing operations below). FIG. 40 is a flowchart showing the detection timing of an ejection failure during the flushing operation by the ink jet printer 1 shown in FIG. 36.
When the flushing process of the ink jet printer 1 is carried out at the predetermined timing, the ejection failure detection and judgment processing shown in FIG. 40 is carried out. The control section 6 inputs ejection data for one nozzle 110 into the shift register 182a of the ejection selecting means 182 (Step S701), the latch signal is inputted into the latch circuit 182b (Step S702), whereby the ejection data is latched therein. At this time, the switching means 23 connects the electrostatic actuator 120 of the ink jet head 100, the target of the ejection data, to the driving waveform generating means 181 (Step S703).
Subsequently, the ejection failure detection and judgment processing shown in the flowchart of FIG. 27 is carried out for the ink jet head 100, which has carried out the ink ejection operation, by the ejection failure detecting means 10 (Step S704). At Step S705, the control section 6 judges whether or not the ejection failure detection and judgment processing has been completed for all the nozzles 110 of the ink jet heads 100a through 100e in the ink jet-printer 1 shown in FIG. 36, on the basis of the ejection data outputted to the ejection selecting means 182. In the case where it is judged that the processing is not completed for all the nozzles 110, the control section 6 inputs the ejection data corresponding to the nozzle 110 of the following ink jet head 100 into the shift register 182a (Step S706). The control section 6 then returns to Step S702 and repeats the processing in the same manner.
On the other hand, in the case where it is judged at Step S705 that the ejection failure detection and judgment processing described above is completed for all the nozzles 110, the control section 6 releases the latch circuit 182b from the latch state by inputting a CLEAR signal into the latch circuit 182b (Step S707), and ends (terminates) the ejection failure detection and judgment processing in the ink jet printer 1 shown in FIG. 36.
As described above, because the detection circuit is constructed from one ejection failure detecting means 10 and one switching means 23 for the ejection failure detection and judgment processing in the printer 1 shown in FIG. 36, the ejection failure detection and judgment processing is repeated as many times as the number of the ink jet heads 100; however, there is an advantage that the circuit forming the ejection failure detecting means 10 is increased little in size.
FIG. 41 is a flowchart showing the detection timing of an ejection failure during the flushing operation by the ink jet printers 1 shown in FIGS. 37 and 38. The ink jet printer 1 shown in FIG. 37 and the ink jet printer 1 shown in FIG. 38 are slightly different in terms of the circuitry, but the same in the point that the number of ejection failure detecting means 10 and the number of switching means 23 correspond with (are equal to) the number of ink jet heads 100. For this reason, the ejection failure detection and judgment processing during the flushing operation comprises the same steps.
When the flushing process of the ink jet printer 1 is carried out at the predetermined timing, the control section 6 inputs ejection data for all the nozzles 110 into the shift register 182a of the ejection selecting means 182 (Step S801), then the latch signal is inputted into the latch circuit 182b (Step S802), whereby the ejection data is latched therein. At this time, the switching means 23a through 23e connect all the ink jet heads 100a through 100e to the driving waveform generating means 181, respectively (Step S803).
Subsequently, the ejection failure detection and judgment processing shown in the flowchart of FIG. 27 is carried out in parallel for all the ink jet heads 100, which have carried out the ink ejection operation, by the ejection failure detecting means 10a through 10e corresponding to the respective ink jet heads 100a through 100e (Step S804). In this case, the judgment results corresponding to all the ink jet heads 100a through 100e are correlated with the ink jet heads 100 as the targets of the processing, and stored into the predetermined storage region of the storage means 62 (Step S207 of FIG. 27).
In order to clear the ejection data latched in the latch circuit 182b of the ejection selecting means 182, the control section 6 releases the latch circuit 182b from the latch state by inputting a CLEAR signal into the latch circuit 182b (Step S805), and ends (terminates) the ejection failure detection and judgment processing in the ink jet printers 1 shown in FIGS. 37 and 38.
As described above, because the detection and judgment circuit is constructed from a plurality of (five, in this embodiment) ejection failure detecting means 10 and a plurality of switching means 23 corresponding to the ink jet heads 100a through 100e in the processing in the printers 1 shown in FIGS. 37 and 38, there is an advantage that the ejection failure detection and judgment processing can be carried out in a short time for all the nozzles 110 at a time.
FIG. 42 is a flowchart showing the detection timing of an ejection failure during the flushing operation by the ink jet printer 1 shown in FIG. 39. The ejection failure detection processing and the cause judgment processing during the flushing operation will now be described with the use of the circuitry of the ink jet printer 1 shown in FIG. 39.
When the flushing process in the ink jet printer 1 is carried out at the predetermined timing, the control section 6 first outputs a scanning signal to the switching selecting means (selector) 19a, and sets (identifies) first switching means 23a and ink jet head 100a by the switching selecting means 19a and the switching control means 19 (Step S901). The control section 6 then inputs ejection data for all the nozzles 110 into the shift register 182a of the ejection selecting means 182 (Step S902), and the latch signal is inputted into the latch circuit 182b (Step S903), whereby the ejection data is latched. At this time, the switching means 23a connects the electrostatic actuator 120 of the ink jet head 100a to the driving waveform generating means 181 (Step S904).
Subsequently, the ejection failure detection and judgment processing shown in the flowchart of FIG. 27 is carried out for the ink jet head 100a that has carried out the ink ejection operation (Step S705). In this case, the driving/detection switching signal as the output signal from the switching selecting means 19a and the ejection data outputted from the latch circuit 182b are inputted into the AND circuit ANDa, and the output signal from the AND circuit ANDa shifts to the high level at Step S203 of FIG. 27, whereby the switching means 23a connects the electrostatic actuator 120 of the ink jet head 100a to the ejection failure detecting means 10. The judgment result in the ejection failure judgment processing carried out at Step S206 of FIG. 27 is correlated with the ink jet head 100 as the target of processing (herein, the ink jet head 100a), and is stored in the predetermined storage region of the storage means 62 (Step S207 of FIG. 27).
At Step S906, the control section 6 judges whether or not the ejection failure detection and judgment processing has been completed for all the nozzles 110. In the case where it is judged that the ejection failure detection and judgment processing is not completed for all the nozzles 110, the control section 6 outputs a scanning signal to the switching selecting means (selector) 19a, and sets (identifies) the following switching means 23b and ink jet head 100b by the switching selecting means 19a and the switching control means 19 (Step S907). The control sections 6 then returns to Step S903 and repeats the processing in the same manner. Thereafter, this loop is repeated until the ejection failure detection and judgment processing is completed for all the ink jet heads 100.
On the other hand, in the case where it is judged at Step S906 that the ejection failure detection and judgment processing is completed for all the nozzles 110, the control section 6 releases the latch circuit 182b from the latch state by inputting a CLEAR signal into the latch circuit 182b in order to clear the ejection data latched in the latch circuit 182b of the ejection selecting means 182 (Step S908), and ends (terminates) the ejection failure detection and judgment processing in the ink jet printer 1 shown in FIG. 39.
As described above, according to the processing in the ink jet printer 1 shown in FIG. 39, the detection circuit is constructed from a plurality of switching means 23 and one ejection failure detecting means 10, and the ejection failure of the corresponding ink jet head 100 is detected and the cause thereof is judged by allowing only the switching means 23, identified by the scanning signal from the switching selecting means (selector) 19a and corresponding to the ink jet head 100 to carry out ejection driving operation in response to the ejection data, to carry out the switching operation. Therefore, it is possible to detect an ejection failure of the ink jet head 100 and to judge the cause thereof more efficiently.
In this regard, at Step S902 of this flowchart, the ejection data corresponding to all the nozzles 110 is inputted into the shift register 182b. However, as in the flowchart shown in FIG. 40, the ejection failure detection and judgment processing may be carried out for the nozzles 110 one by one by inputting the ejection data to be inputted into the shift register 182a into one corresponding ink jet head 100 in the scanning order of the ink jet heads 100 by the switching selecting means 19a. 
Next, the ejection failure detection and judgment processing in the ink jet printer 1 during the printing operation will now be described with reference to the flowcharts shown in FIGS. 43 and 44. Because the ink jet printer 1 shown in FIG. 36 is chiefly suitable for the ejection failure detection and judgment processing during the flushing operation, the description of the flowchart and the operation thereof during the printing operation is omitted. However, the ejection failure detection and judgment processing may be carried out during the printing operation as well in the ink jet printer 1 shown in FIG. 36.
FIG. 43 is a flowchart showing the detection timing of an ejection failure during the printing operation by the ink jet printers 1 shown in FIGS. 37 and 38. The processing according to this flowchart is carried out (started) in response to a printing (print) command from the host computer 8. When the printing data is inputted to the shift register 182a of the ejection selecting means 182 from the host computer 8 via the control section 6 (Step S1001), the latch signal is inputted into the latch circuit 182b (Step S1002), whereby the printing data is latched therein. At this time, the switching means 23a through 23e connect all the ink jet heads 100a through 100e to the driving waveform generating means 181 (Step S1003).
The ejection failure detecting means 10 corresponding to the ink jet heads 100 that have carried out the ink ejection operation then carry out the ejection failure detection and judgment processing shown in the flowchart of FIG. 27 (Step S1004). In this case, the judgment results corresponding to the ink jet heads 100 are respectively correlated with the ink jet heads 100 as the targets of processing, and stored in the predetermined storage region of the storage means 62.
Here, in the case of the ink jet printer 1 shown in FIG. 37, the switching means 23a through 23e respectively connect the ink jet heads 100a through 100e to the ejection failure detecting means 10a through 10e according to the driving/detection switching signal outputted from the control section 6 (Step S203 of FIG. 27). Hence, because the electrostatic actuator 120 is not driven in the ink jet head 100 in which the printing data is absent, the residual vibration detecting means 16 of the ejection failure detecting means 10 does not detect the residual vibration waveform of the diaphragm 121. On the other hand, in the case of the ink jet printer 1 shown in FIG. 38, the switching means 23a through 23e connect the ink jet head 100 in which the printing data is present to the corresponding ejection failure detecting means 10 according to the output signal from the AND circuit into which the driving/detection switching signal outputted from the control section 6 and the printing data outputted from the latch circuit 182b are inputted (Step S203 of FIG. 27).
At Step S1005, the control section 6 judges whether or not the printing operation by the ink jet printer 1 has been completed. In the case where it is judged that the printing operation is not completed, the control section 6 returns to Step S1001, and inputs the following printing data into the shift register 182a to repeat the processing in the same manner. On the other hand, in the case where it is judged that the printing operation is completed, the control section 6 releases the latch circuit 182b from the latch state by inputting a CLEAR signal into the latch circuit 182b in order to clear the ejection data latched in the latch circuit 182b of the ejection selecting means 182 (Step S1006), and ends (terminates) the ejection failure detection and judgment processing in the ink jet printers 1 shown in FIGS. 37 and 38.
As described above, the ink jet printers 1 shown in FIGS. 37 and 38 are provided with a plurality of switching means 23a through 23e and a plurality of ejection failure detecting means 10a through 10e so that the ejection failure detection and judgment processing is carried out for all the ink jet heads 100 at a time. Hence, it is possible to carry out the processing in a short time. Also, the ink jet printer 1 shown in FIG. 38 is further provided with the switching control means 19, that is, the AND circuits ANDa through ANDe executing the logical operation AND of the driving/detection switching signal and the printing data so that the switching operation is carried out by the switching means 23 for only the ink jet head 100 that will carry out the printing operation. Hence, it is possible to carry out the ejection failure detection and judgment processing without carrying out useless detection.
FIG. 44 is a flowchart showing the detection timing of an ejection failure during the printing operation by the ink jet printer 1 shown in FIG. 39. The processing according to this flowchart is carried out by the ink jet printer 1 shown in FIG. 39 in response to a printing command from the host computer 8. The switching selecting means 19a sets (identifies) in advance first switching means 23a and ink jet head 100a (Step S1101).
When the printing data is inputted into the shift register 182a of the ejection selecting means 182 from the host computer 8 via the control section 6 (Step S1102), the latch signal is inputted into the latch circuit 182b (Step S1103), whereby the printing data is latched. At this stage, the switching means 23a through 23e connect all the ink jet heads 100a through 100e to the driving waveform generating means 181 (the driver 182c of the ejection selecting means 182) (Step S1104).
In the case where the printing data is present in the ink jet head 100a, the control section 6 controls the switching selecting means 19a to connect the electrostatic actuator 120 to the ejection failure detecting means 10 after the ejection operation (Step S203 of FIG. 27), and carries out the ejection failure detection and judgment processing shown in the flowchart of FIG. 27 (and FIG. 32 through FIG. 34) (Step S1105). The judgment result in the ejection failure judgment processing carried out at Step S206 of FIG. 27 is correlated with the ink jet head 100 as the target of processing (herein, the ink jet head 100a), and is stored in the predetermined storage region of the storage means 62 (Step S207 of FIG. 27).
At Step S1106, the control section 6 judges whether or not the ejection failure detection and judgment processing described above has been completed for all the nozzles 110 (all the ink jet heads 100). In the case where it is judged that the above processing is completed for all the nozzles 110, the control section 6 sets the switching means 23a corresponding to the first nozzle 110 in response to the scanning signal (Step S1108). On the other hand, in the case where it is judged that the above processing is not completed for all the nozzles 110, the control section 6 sets the switching means 23b corresponding to the following nozzle 110 (Step S1107).
At Step S1109, the control section 6 judges whether or not the predetermined printing operation specified by the host computer 8 has been completed. In the case where it is judged that the printing operation is not completed, the control section 6 inputs the following printing data into the shift register 182a (Step S1102), and repeats the processing in the same manner. On the other hand, in the case where it is judged that the printing operation is completed, the control section 6 releases the latch circuit 182b from the latch state by inputting a CLEAR signal into the latch circuit 182b in order to clear the ejection data latched in the latch circuit 182b of the ejection selecting means 182 (Step S1110), and ends (terminates) the ejection failure detection and judgment processing in the ink jet printer 1 shown in FIG. 39.
As described above, the droplet ejection apparatus (ink jet printer 1) of the invention is provided with a plurality of ink jet heads (droplet ejection heads) 100 each having the diaphragm 121, the electrostatic actuator 120 for displacing the diaphragm 121, the cavity 141 filled with liquid and whose internal pressure varies (increases or decreases) with the displacement of the diaphragm 121, and the nozzle 110 communicating with the cavity 141 and through which the liquid within the cavity 141 is ejected in the form of droplets due to a change (increase and decrease) in internal pressure of the cavity 141. The apparatus is further provided with the driving waveform generating means 181 for driving the electrostatic actuators 120, the ejection selecting means 182 for selecting one or more nozzle 110 out of a plurality of nozzles 110 from which the droplets are to be ejected, one or more ejection failure detecting means 10 for detecting the residual vibration of the diaphragm 121 and detecting an ejection failure of the droplets on the basis of the residual vibration of the diaphragm 121 thus detected, and one or more switching means 23 for switching the connection of the electrostatic actuator 120 to the ejection failure detecting means 10 from the driving waveform generating means 181 in response to the driving/detection switching signal or on the basis of the driving/detection switching signal and the printing data, or the scanning signal in addition to these after the ejection operation of the droplets by driving the electrostatic actuator 120. Hence, an ejection failure of a plurality of nozzles 110 can be detected either at a time (in parallel) or sequentially.
Therefore, according to the droplet ejection apparatus and the method of detecting and judging a head failure of the invention, an ejection failure can be detected and the cause thereof can be judged in a short time. Further, it is possible to scale down the circuitry of the detection circuit including the ejection failure detecting means 10, and to prevent an increase of the manufacturing costs of the droplet ejection apparatus. Furthermore, because the detection of an ejection failure and the judgment of the cause thereof is carried out by switching to the ejection failure detecting means 10 after the electrostatic actuators 120 are driven, the driving of the actuators is not influenced at all, and therefore the throughput of the droplet ejection apparatus of the invention will be neither reduced nor deteriorated. Moreover, it is possible to provide the ejection failure detecting means 10 of the invention to an existing droplet ejection apparatus (such as ink jet printer) provided with predetermined components.
In contrast to the configuration described above, another droplet ejection apparatus of the invention is provided with a plurality of switching means 23, the switching control means 19, and one or a plurality of (i.e., as many as the number of nozzles 110) ejection failure detecting means 10. The detection of an ejection failure and the judgment of the cause thereof is carried out by switching the corresponding electrostatic actuator 120 from the driving waveform generating means 181 or the ejection selecting means 182 to the ejection failure detecting means 10 in response to the driving/detection switching signal and the ejection data (printing data) or to the scanning signal, the driving/detection switching signal and the ejection data (printing data).
Therefore, the switching means 23 corresponding to the electrostatic actuator 120 into which the ejection data (printing data) has not been inputted, that is, the one that has not carried out the ejection driving operation, do not carry out the switching operation. The droplet ejection apparatus of the invention is thus able to avoid useless detection and judgment processing. Further, in the case of using the switching selecting means 19a, because the droplet ejection apparatus has to be provided with only one ejection failure detecting means 10, it is possible to scale down the circuitry of the droplet ejection apparatus, and to prevent an increase of the manufacturing costs of the droplet ejection apparatus.
In this regard, in the first embodiment of the invention, the structure in which the ink jet printers 1 shown in FIG. 36 through 39 to explain the timing of the detection of the ejection failure includes five ink jet heads 100 (i.e., five nozzles 110) on the head unit 35 is shown and described for ease of explanation. However, in the droplet ejection apparatus of the invention, the number of ink jet heads (droplet ejection heads) 100 is not limited to five. It is possible to detect and judge an ejection failure for all nozzles 110 actually mounted (provided) on the head unit 35.
Next, the configuration (recovery means 24) to carry out recovery processing by which a cause of an ejection failure (head failure) is eliminated for the ink jet head 100 in the droplet ejection apparatus (ink jet printer 1) of the invention will now be described. FIG. 45 is a drawing schematically showing the structure (part of which is omitted) when viewed from the top of the ink jet printer 1 shown in FIG. 1. The ink jet printer 1 shown in FIG. 45 is provided with a wiper 300 and a cap 310 used to carry out the recovery processing for ink droplet non-ejection (head failure) of the invention in addition to the configuration shown in the perspective view of FIG. 1.
The recovery processing carried out by the recovery means 24 of the invention includes the flushing process by which droplets are preliminarily ejected through the nozzles 110 of the respective ink jet heads 100, the wiping process by the wiper 300 described below (see FIG. 46), and a pumping process (pump-suction process) by a tube pump 320 described below. In other words, the recovery means 24 is provided with the tube pump 320, a pulse motor for driving the same, the wiper 300 and a vertical driving mechanism of the wiper 300, and a vertical driving mechanism (not shown) of the cap 310. The head driver 33, the head unit 35 and the like in the flushing process, and the carriage motor 41 and the like in the wiping process function as part of the recovery means 24. Because the flushing process is already described above, the wiping process and the pumping process will be described below.
The wiping process referred to herein is defined as the process by which foreign substances such as paper dust adhering to the nozzle plate 150 (nozzle surface) of the ink jet heads 100 is wiped out with the wiper 300. The pumping process (pump-suction process) referred to herein is defined as process by which ink inside the cavities 141 is sucked (removed by a vacuum) and discharged through the respective nozzles 110 of the ink jet heads 100 by driving the tube pump 320 described below. Thus, the wiping process is appropriate process as the recovery processing for a state of adhesion of paper dust, which is one of the causes of an ejection failure of droplets of the ink jet head 100 as described above. Further, the pump-suction process is appropriate process as the recovery processing for eliminating air bubbles inside the cavities 141 which cannot be eliminated by the flushing process described above, or for eliminating thickened ink when ink has thickened due to drying in the vicinity of the nozzles 110 or when ink inside the cavities 141 has thickened by aged deterioration. In this regard, the recovery processing may be carried out by the flushing process described above in the case where ink has thickened slightly and the viscosity thereof is not noticeably high. In this case, because a quantity of ink to be discharged is small, appropriate recovery processing can be carried out without deteriorating the throughput or the running costs.
A plurality of head units 35 each of which includes a plurality of ink jet heads (droplet ejection heads) 100 are mounted on the carriage 32, guided by the two carriage guide shafts 422, and moved by the carriage motor 41 as it is coupled to the timing belt 421 via a coupling portion 34 provided at the top edge of the printing means 3 in the drawing. The head units 35 mounted on the carriage 32 can be moved in the main scanning direction via the timing belt 421 (i.e., in conjunction with the timing belt 421) that moves when driven by the carriage motor 41. The carriage motor 41 serves as a pulley for continuously turning the timing belt 421, and a pulley 44 is provided at the other end as well.
The cap 310 is used to carry out capping the nozzle plate 150 of the ink jet heads 100 (see FIG. 5). The cap 310 is provided with a hole on the side surface of the bottom portion, and as will be described below, a flexible tube 321, one component of the tube pump 320, is connected to the bottom portion of the cap 310. In this regard, the tube pump 320 will be described below with reference to FIG. 48.
During the recording (printing) operation, a recording sheet P moves in the sub scanning direction, that is, downward in FIG. 45, and the printing means 3 moves in the main scanning direction, that is, the horizontal direction in FIG. 45 while the electrostatic actuators 120 of the predetermined ink jet heads (droplet ejection heads) 100 are being driven, so that the ink jet printer (droplet ejection apparatus) 1 prints (records) a predetermined image or the like on the recording sheet P on the basis of the printing data (print data) inputted from the host computer 8.
FIG. 46 is a drawing showing the positional relationship between the wiper 300 and the printing means 3 (head unit 35) shown in FIG. 45. Referring to FIG. 46, the printing means 3 (head unit 35) and the wiper 300 are shown as part of the side view of the ink jet printer 1 shown in FIG. 45 when viewed from bottom to top in the drawing. As shown in FIG. 46(a), the wiper 300 is vertically-movably provided so as to be able to abut on the nozzle surface of the head unit 35, that is, the nozzle plate 150 of the ink jet heads 100.
Here, the wiping process as the recovery processing using the wiper 300 will now be described. When the wiping process is carried out, as shown in FIG. 46(a), the wiper 300 is moved upward by a driving device (not shown) so that the tip end of the wiper 300 is positioned above the nozzle surface (nozzle plate 150). In this case, when the printing means 3 (head unit 35) is moved to the left of the drawing (in a direction indicated by an arrow) by driving the carriage motor 41, a wiping member 301 abuts on the nozzle plate 150 (nozzle surface).
Because the wiping member 301 is formed from a flexible rubber member or the like, as shown in FIG. 46(b), the tip end portion of the wiping member 301 abutting on the nozzle plate 150 is bent, and the wiping member 301 thereby cleans (wipes out) the surface of the nozzle plate 150 (nozzle surface) by the tip end portion thereof. This makes it possible to remove foreign substances, such as paper dust (for example, paper dust, dust afloat in air, pieces of rubber), adhering to the nozzle plate 150 (nozzle surface). Further, the wiping process may be carried out more than once depending on the adhesion state of such foreign substances (i.e., in the case where a large quantity of foreign substances are adhering thereto) by allowing the printing means 3 to reciprocate above the wiper 300.
FIG. 47 is a drawing showing the relationship between the head unit 35 (ink jet heads 100), the cap 310 and the pump 320 during the pump-suction process. The tube 321 forms an ink discharge path used in the pumping process (pump-suction process), and one end thereof is connected to the bottom portion of the cap 310 as described above, and the other end thereof is connected to a discharged ink cartridge 340 via the tube pump 320.
An ink absorber 330 is placed on the inner bottom surface of the cap 310. The ink absorber 330 absorbs and temporarily preserves ink ejected through the nozzles 110 of the ink jet heads 100 during the pump-suction process or the flushing process. The ink absorber 330 prevents ejected droplets from splashing back and thereby smearing the nozzle plate 150 during the flushing operation into the cap 310.
FIG. 48 is a schematic view showing the configuration of the tube pump 320 shown in FIG. 47. As shown in FIG. 48(b), the tube pump 320 is a rotary pump, and is provided with a rotor 322, four rollers 323 placed to the circumferential portion of the rotor 322, and a guiding member 350. The rollers 323 are supported by the rotor 322, and apply a pressure to the flexible tube 321 placed arc-wise along a guide 351 of the guiding member 350.
In this tube pump 320, the rotor 322 is rotated with the shaft 322a as the center thereof in a direction indicated by an arrow X of FIG. 48, which allows one or two rollers 323 abutting on the tube 321 to sequentially apply pressure to the tube 321 placed on the arc-shaped guide 351 of the guiding member 350 while rotating in the Y direction. The tube 321 thereby undergoes deformation, and ink (liquid material) within the cavities 141 of the respective ink jet heads 100 is sucked via the cap 310 due to a negative pressure generated in the tube 321. Then, unwanted ink intruded with air bubbles or having thickened due to drying is discharged into the ink absorber 330 through the nozzles 110, and the discharged ink absorbed in the ink absorber 330 is then discharged to the discharged ink cartridge 340 (see FIG. 47) via the tube pump 320.
In this regard, the tube pump 320 is driven by a motor (not shown) such as a pulse motor. The pulse motor is controlled by the control section 6. A look-up table in which driving information as to the rotational control of the tube pump 320 (for example, the rotational speed, the number of rotations and the like), a control program written with sequence control, and the like are stored in the PROM 64 of the control section 6. The tube pump 320 is controlled by the CPU 61 of the control section 6 according to the driving information specified above.
Next, the operation of the recovery means 24 (ejection failure recovery processing) of the invention will now be described. FIG. 40 is a flowchart showing the ejection failure recovery processing in the ink jet printer 1 (droplet ejection apparatus) of the invention. When an ejection failure of the nozzle 110 in the ink jet head 100 is detected and the cause thereof is judged in the ejection failure detection and judgment processing described above (see the flowcharts of FIGS. 26 and 27), the printing means 3 (head unit 35) is moved to the predetermined stand-by region (for example, in FIG. 45, a position at which the nozzle plate 150 of the printing means 3 (the head units 35) is covered with the cap 310 or a position at which the wiping process by the wiper 300 can be carried out) at the predetermined time while the printing operation (print operation) or the like is not carried out, and the ejection failure recovery processing of the invention is carried out.
The control section 6 first controls the informing means (the operation panel 7 or the host computer 8) to display the content that the ink jet head 100 in which an ejection failure occurs has been detected (Step S1201), and reads out the judgment results stored at Step S207 of the flowchart shown in FIG. 27 from the storage means 62 to obtain the cause of the ejection failure (head failure) (Step S1202).
At Step S1203, the control section 6 judges whether or not the recovery processing by the recovery means 24 is terminated and therefore the cause of the ejection failure is eliminated. In the case where it is judged that the recovery processing has been terminated, the control section 6 cancels the display of the occurrence of the ejection failure by the informing means (Step S1204), and this ejection failure recovery processing is terminated. On the other hand, in the case where it is judged that the recovery processing has never been terminated, the control section 6 judges whether or not the cause of the ejection failure is adhesion of paper dust (Step S1205). In the case where it is judged that the cause of the ejection failure is adhesion of paper dust, the recovery means 24 carries out a wiping process by the wiping means (Step S1206), and then the control section 6 proceeds to Step S1202 to repeat the processing in the same manner.
On the other hand, in the case where it is judged that the cause of the ejection failure is not adhesion of paper dust, the control section 6 further judges whether or not the cause of the ejection failure is intrusion of an air bubble or thickening of ink due to drying (L) (Step S1207). In the case where it is judged that the cause of the ejection failure is intrusion of an air bubble or thickening of ink due to drying (L), the recovery means 24 carries out a pump-suction process by the tube pump 320 (Step S1208), and then the control section 6 proceeds to Step S1202 to repeat the processing in the same manner. On the other hand, in the case where it is judged that the cause of the ejection failure is neither intrusion of an air bubble nor thickening of ink due to drying (L), thickening of ink due to drying (S) is identified as the cause of the ejection failure, and the recovery means 24 carries out a flushing process (Step S1209), and then the control section 6 proceeds to Step S1202 to repeat the processing in the same manner. In this regard, in order to improve the effectiveness of judgment of Step S1203, it is better to carry out the ejection failure detection and judgment processing shown in FIG. 27 again prior to proceeding Step S1202.
Next, the ejection failure recovery processing in the case of considering the judgment result of the ejection failure judgment processing described above (see FIG. 32 through FIG. 34) and the held count value (subtraction result Nd) and lapsed time (T) will now be described. FIG. 50 is a flowchart showing the ejection failure recovery processing in the ink jet printer 1 (droplet ejection apparatus) of the invention in consideration of the count value and the lapsed time.
The control section 6 first controls the informing means (the operation panel 7 or the host computer 8) to display the content that the ink jet head 100 in which an ejection failure occurs has been detected (Step S1301), and reads out the judgment results stored at Step S207 of the flowchart shown in FIG. 27 from the storage means 62 to obtain the cause of the ejection failure (head failure) (Step S1302).
At Step S1303, the control section 6 judges whether or not the recovery processing by the recovery means 24 is terminated and therefore the cause of the ejection failure is eliminated. In the case where it is judged that the recovery processing has been terminated, the control section 6 cancels the display of the occurrence of the ejection failure by the informing means (Step S1304), and this ejection failure recovery processing is terminated. On the other hand, in the case where it is judged that the recovery processing has never been terminated, the control section 6 judges whether or not the cause of the ejection failure is adhesion of paper dust (Step S1305). In the case where it is judged that the cause of the ejection failure is adhesion of paper dust, the control section 6 sets the number of wiping operations to be carried out by the wiping means on the basis of the degree of the adhesion of paper dust (Step S1306), and the recovery means 24 carries out a wiping process by the wiping means (Step S1307), and then the control section 6 proceeds to Step S1302 to repeat the processing in the same manner.
On the other hand, in the case where it is judged that the cause of the ejection failure is not adhesion of paper dust, the control section 6 further judges whether or not the cause of the ejection failure is intrusion of an air bubble (Step S1308). In the case where it is judged that the cause of the ejection failure is intrusion of an air bubble, the control section 6 sets a suction time Tb1 of the tube pump 320 on the basis of the subtraction result Nd stored in the storage means 62 (Step S1309). Then, the control section 6 judges whether or not the cause of the ejection failure is thickening of ink due to drying (L) at Step S1310. In the case where it is judged at Step S1310 that the cause of the ejection failure is thickening of ink due to drying (L), the control section 6 sets a suction time Tb2 of the tube pump 320 on the basis of the waiting time (lapsed time) T (Step S1311), and selects the longer suction time between Tb1 and Tb2 (Step S1312). Then, the recovery means 24 carries out the pump-suction process by the tube pump 320 for the selected suction time (Step S1313), and then the control section 6 proceeds to Step S1302 and repeats the processing in the same manner.
On the other hand, in the case where it is judged at Step S1310 that the cause of the ejection failure is not thickening of ink due to drying (L), the recovery means 24 carries out a pump-suction process by the tube pump 320 for the suction time Tb1 (Step S1313), and then the control section 6 proceeds to Step S1302 to repeat the processing in the same manner.
Further, in the case where it is judged at Step S1308 that the cause of the ejection failure is not intrusion of an air bubble, the control section 6 further judges whether or not the cause of the ejection failure is thickening of ink due to drying (L) (Step S1314). In the case where it is judged that the cause of the ejection failure is thickening of ink due to drying (L), the control section 6 sets a suction time Tb2 of the tube pump 320 on the basis of the waiting time (lapsed time) T (Step S1311), and selects the longer suction time between Tb1 (in this case, Tb1=0) and Tb2 (Step S1312). Then, the recovery means 24 carries out the pump-suction process by the tube pump 320 for the selected suction time (Step S1313), and then the control section 6 proceeds to Step S1302 and repeats the processing in the same manner.
In the case where it is judged at Step S1314 that the cause of the ejection failure is not thickening of ink due to drying (L), thickening of ink due to drying (S) is identified as the cause of the ejection failure, and the control section 6 sets the number of ejection operations by a flushing process on the basis of the subtraction result Nd (Step S1315), and the recovery means 24 carries out the flushing process (Step S1316), and then the control section 6 proceeds to Step S1302 to repeat the processing in the same manner. In this regard, similar to the flowchart shown in FIG. 49, in order to improve the effectiveness of judgment of Step S1303, it is better to carry out the ejection failure detection and judgment processing shown in FIG. 27 again prior to proceeding Step S1302.
As described above, the droplet ejection apparatus of the invention (ink jet printer 1) is provided with the plurality of droplet ejection heads (ink jet heads 100), each of the droplet ejection heads including: the diaphragm 121; the electrostatic actuator 120 which displaces the diaphragm 121; the cavity 141 filled with a liquid (ink), an internal pressure of the cavity 141 being increased and decreased in response to displacement of the diaphragm 121; and a nozzle 110 communicated with the cavity 141, through which the liquid is ejected in the form of droplets in response to the increase and decrease of the internal pressure of the cavity 141; the driving circuit 18 which drives the electrostatic actuator 120 of each droplet ejection head; residual vibration detecting means 16 for detecting a residual vibration of the diaphragm 121 displaced by the electrostatic actuator 120 after the electrostatic actuator 120 has been driven by the driving circuit 18; pulse generating means for generating reference pulses; computation means 17 for carrying out a computation (the subtraction processing by the subtraction counter 45) for the number of reference pulses generated by the pulse generating means on the basis of the residual vibration of the diaphragm 121 detected by the residual vibration detecting means 16; time measuring means 25 for measuring a lapsed time A since the electrostatic actuator 120 has been driven by the driving circuit 18; and head failure judging means (judging means 20) for judging a head failure in the droplet ejection heads (ink jet heads 100) on the basis of the computation result (subtraction result Nd) of the computation means 17 and the lapsed time T measured by the time measuring means 25.
Therefore, according to the droplet ejection apparatus and the method of detecting and judging a head failure in the droplet ejection heads of the invention, compared with the conventional droplet ejection apparatus and the droplet ejection head capable of detecting an ejection failure (missing dot) (for example, an optical detecting method), the droplet ejection apparatus of this embodiment as described above does not need other parts (for example, optical missing dot detecting device or the like) in order to detect the ejection failure. As a result, not only an ejection failure of the droplets can be detected accurately without increasing the size of the droplet ejection head, but also the manufacturing costs of the droplet ejection apparatus capable of carrying out an ejection failure (missing dot) detecting processing can be reduced. Further, in the droplet ejection apparatus of the invention, because the droplet ejection apparatus detects an ejection failure of the droplets through the use of the residual vibration of the diaphragm after the droplet ejection operation, an ejection failure of the droplets can be detected even during the printing operation. Hence, even though the method of detecting and judging the head failure in the droplet ejection heads (the ejection failure detecting processing) of the invention is carried out during the printing operation, the throughput of the droplet ejection apparatus of the invention will be neither reduced nor deteriorated.
Moreover, according to the droplet ejection apparatus of the invention, it is possible to judge a cause of an ejection failure of droplets, which the apparatus such as an optical detecting apparatus capable of carrying out a conventional missing dot detection operation cannot judge. Therefore, it is possible to select and carry out appropriate recovery processing in accordance with the cause if needed. Therefore, it is possible to reduce useless discharged ink.
Furthermore, in the droplet ejection apparatus of the invention, the cause of the ejection failure is detected and identified on the basis of the lapsed time since the electrostatic actuator 120 has been driven or the droplet ejection apparatus (ink jet printer 1) has been powered on and a cycle of the residual vibration of the diaphragm 121 after the ejection driving operation (count value (subtraction result) of the subtraction counter 45). Hence, it is possible to carry out the identification (judgment) of the cause of the ejection failure more accurately.
In this regard, as an example of comparison reference values (count thresholds) stored in the comparison reference value memory 47, the first count threshold is a count value corresponding to the range between +3% and +7% (preferably, about +5%) of the cycle of the residual vibration of diaphragm 121 at a normal ejection operation at which the ambient temperature is 20° C., and the second count threshold is a count value corresponding to the range between −3% and −7% (preferably, about −5%) of the cycle of the residual vibration of diaphragm 121 at a normal ejection operation at which the ambient temperature is 20° C. Further, the third count threshold is a count value corresponding to the range of −8% to −12% or more (preferably, about −10% or more) of the cycle of the residual vibration of diaphragm 121 at a normal ejection operation at which the ambient temperature is 20° C.
Further, as an example of the pump suction time, it is preferable that the suction time (for example, in the range of 1 to 3 seconds) in the case where the time-up time (waiting time) T is long becomes several times as long as the suction time (for example, in the range of 0.3 to 0.5 seconds) in the case where the time-up time (waiting time) T is short. It is preferable that the number of ejection operations in the flushing process is changeable in the range of 50 to 500 shots (times) in response to the subtraction result Nd. Moreover, it is preferable that the number of wiping operations is one or more in the case where the subtraction result Nd is in the range between the second count threshold and the third count threshold, and it is two or more in the case where the subtraction result Nd is smaller than the third count threshold.
SECOND EMBODIMENT
Examples of other configurations of the ink jet head of the invention will now be described. FIGS. 51-54 are cross sectional views each schematically showing an example of other configuration of the ink jet head (head unit). Hereinafter, an explanation will be given with reference to these drawings; however, differences from the first embodiment described above are chiefly described, and the description of the similar portions is omitted.
An ink jet head 100A shown in FIG. 51 is one that ejects ink (liquid material) within a cavity 208 through a nozzle 203 as a diaphragm 212 vibrates when a piezoelectric element 200 is driven. A metal plate 204 made of stainless steel is bonded to a nozzle plate 202 made of stainless steel in which the nozzle (hole) 203 is formed, via an adhesive film 205, and another metal plate 204 made of stainless steel is further bonded to the first-mentioned metal plate 204 via an adhesive film 205. Furthermore, a communication port forming plate 206 and a cavity plate 207 are sequentially bonded to the second mentioned metal plate 204.
The nozzle plate 202, the metal plates 204, the adhesive films 205, the communication port forming plate 206, and the cavity plate 207 are molded into their respective predetermined shapes (a shape in which a concave portion is formed), and the cavity 208 and a reservoir 209 are defined by laminating these components. The cavity 208 and the reservoir 209 communicate with each other via an ink supply port 210. Further, the reservoir 209 communicates with an ink intake port 211.
The diaphragm 212 is placed at the upper surface opening portion of the cavity plate 207, and the piezoelectric element 200 is bonded to the diaphragm 212 via a lower electrode 213. Further, an upper electrode 214 is bonded to the piezoelectric element 200 on the opposite side of the lower electrode 213. A head driver 215 is provided with a driving circuit that generates a driving voltage waveform. The piezoelectric element 200 starts to vibrate when a driving voltage waveform is applied (supplied) between the upper electrode 214 and the lower electrode 213, whereby the diaphragm 212 bonded to the piezoelectric element 200 starts to vibrate. The volume (and the internal pressure) of the cavity 208 varies with the vibration of the diaphragm 212, and ink (liquid) filled in the cavity 208 is thereby ejected through the nozzle 203 in the form of droplets.
A reduced quantity of liquid (ink) in the cavity 208 due to the ejection of droplets is replenished with ink supplied from the reservoir 209. Further, ink is supplied to the reservoir 209 through the ink intake port 211.
Likewise, an ink jet head 100B shown in FIG. 52 is one that ejects ink (liquid material) within a cavity 221 through a nozzle 223 when the piezoelectric element 200 is driven. The ink jet head 100B includes a pair of opposing substrates 220, and a plurality of piezoelectric elements 200 are placed intermittently at predetermined intervals between both substrates 220.
Cavities 221 are formed between adjacent piezoelectric elements 200. A plate (not shown) and a nozzle plate 222 are placed in front and behind the cavities 221 of FIG. 52, respectively, and nozzles (holes) 223 are formed in the nozzle plate 222 at positions corresponding to the respective cavities 221.
Pairs of electrodes 224 are placed on one and the other surfaces of each piezoelectric element 200. That is to say, four electrodes 224 are bonded to one piezoelectric element 200. When a predetermined driving voltage waveform is applied between predetermined electrodes of these electrodes 224, the piezoelectric element 200 undergoes share-mode deformation and starts to vibrate (indicated by arrows in FIG. 52). The volume of the cavities 221 (internal pressure of cavity) varies with the vibration, and ink (liquid material) filled in the cavities 221 is thereby ejected through nozzles 223 in the form of droplets. In other words, the piezoelectric elements 200 per se function as the diaphragms in the ink jet head 100B.
Likewise, an ink jet head 100C shown in FIG. 53 is one that ejects ink (liquid material) within a cavity 233 through a nozzle 231 when the piezoelectric element 200 is driven. The ink jet head 100C is provided with a nozzle plate 230 in which the nozzle 231 is formed, spacers 232, and the piezoelectric element 200. The piezoelectric element 200 is placed to be spaced apart from the nozzle plate 230 by a predetermined distance with the spacers 232 in between, and the cavity 233 is defined by a space surrounded by the nozzle plate 230, the piezoelectric element 200, and the spacers 232.
A plurality of electrodes are bonded to the top surface of the piezoelectric element 200 in FIG. 53. To be more specific, a first electrode 234 is bonded to a substantially central portion of the piezoelectric element 200, and second electrodes 235 are bonded on both sides thereof. When a predetermined driving voltage waveform is applied between the first electrode 234 and the second electrodes 235, the piezoelectric element 200 undergoes share-mode deformation and starts to vibrate (indicated by arrows of FIG. 53). The volume of the cavity 233 (internal pressure of cavity 233) varies with the vibration, and ink (liquid material) filled in the cavity 233 is thereby ejected through the nozzle 231 in the form of droplets. In other words, the piezoelectric element 200 per se functions as the diaphragm in the ink jet head 100C.
Likewise, an ink jet head 100D shown in FIG. 54 is one that ejects ink (liquid material) within a cavity 245 through a nozzle 241 when the piezoelectric element 200 is driven. The ink jet head 100D is provided with a nozzle plate 240 in which the nozzle 241 is formed, a cavity plate 242, a diaphragm 243, and a layered piezoelectric element 201 comprising a plurality of piezoelectric elements 200 to be layered.
The cavity plate 242 is molded into a predetermined shape (a shape in which a concave portion is formed), by which the cavity 245 and a reservoir 246 are defined. The cavity 245 and the reservoir 246 communicate with each other via an ink supply port 247. Further, the reservoir 246 communicates with an ink cartridge 31 via an ink supply tube 311.
The lower end of the layered piezoelectric element 201 in FIG. 54 is bonded to the diaphragm 243 via an intermediate layer 244. A plurality of external electrodes 248 and internal electrodes 249 are bonded to the layered piezoelectric element 201. To be more specific, the external electrodes 248 are bonded to the outer surface of the layered piezoelectric element 201 and the internal electrodes 249 are provided in spaces between piezoelectric elements 200, which together form the layered piezoelectric element 201 (or inside each piezoelectric element). In this case, the external electrodes 248 and the internal electrodes 249 are placed so that parts of them are alternately layered in the thickness direction of the piezoelectric element 200.
By applying a driving voltage waveform between the external electrodes 248 and the internal electrodes 249 by the head driver 33, the layered piezoelectric element 201 undergoes deformation (contracts in the vertical direction of FIG. 54) and starts to vibrate as indicated by arrows in FIG. 54, whereby the diaphragms 243 undergoes vibration due to this vibration. The volume of the cavity 245 (internal pressure of cavity 245) varies with the vibration of the diaphragm 243, and ink (liquid material) filled in the cavity 245 is thereby ejected through the nozzle 241 in the form of droplets.
A reduced quantity of liquid (ink) in the cavity 245 due to the ejection of droplets is replenished with ink supplied from the reservoir 246. Further, ink is supplied to the reservoir 246 from the ink cartridge 31 through the ink supply tube 311.
As with the electric capacitance type of ink jet head 100 as described above, the ink jet heads 100A through 100D provided with piezoelectric elements 200 are also able to detect an ejection failure of droplets and identify the cause of the ejection failure on the basis of the residual vibration of the diaphragm or the piezoelectric element functioning as the diaphragm. Alternatively, the ink jet heads 100B and 100C may be provided with a diaphragm (diaphragm used to detect the residual vibration) serving as a sensor at a position facing the cavity, so that the residual vibration of this diaphragm is detected.
FIG. 55 is a block diagram schematically showing switching means 23 between the driving circuit 18 and detecting circuit (herein, residual vibration detecting means) 16 in the case of using a piezoelectric actuator (piezoelectric element 200). By having such a structure, the electromotive voltage of the piezoelectric element 200 in the piezoelectric actuator after the ejection driving operation can be inputted into a waveform shaping circuit 15 via a buffer 54, and a rectangular waveform can be shaped by the waveform shaping circuit 15. Therefore, by using the electromotive voltage of the piezoelectric element 200, it is possible to carry out the same ejection failure detection processing as that in the first embodiment described above.
In this regard, in the case where the ejection failure detection and judgment processing as described above is carried out by detecting the residual vibration of the electromotive voltage of the piezoelectric actuator (piezoelectric element 200), the processing as the flowchart shown in FIG. 56 is carried out in stead of the processing in the flowchart shown in FIG. 28 (residual vibration detection processing). FIG. 56 is a flowchart showing the residual vibration detection processing in another embodiment according to the invention.
At Step S203 of the flowchart shown in FIG. 27, when the switching means 23 switches the connection of the piezoelectric actuator (piezoelectric element 200) from the driving circuit 18 to the detection circuit (ejection failure detecting means 10), an electromotive voltage is generated from the electrostatic element 200 after the ejection driving operation (Step S1401). The capacitor C3 of the waveform shaping circuit 15 eliminates the DC components (direct current components) from the electromotive voltage (voltage signal) (Step S1402), and the operational amplifier 151 amplifies AC components of the electromotive voltage from which the DC components have been eliminated, that is, output of the residual vibration waveform of the electromotive voltage (Step S1403). Then, the comparator 152 converts (waveform-shapes) the residual vibration waveform into pulses of the residual vibration (Step S1404).
The processing after Step S205 of FIG. 27 is also carried out in a same manner in the case of using the residual vibration of the electromotive voltage of such a piezoelectric element 200 (piezoelectric actuator). Further, the ejection failure detection and judgment processing during the printing operation shown in FIG. 26 can be carried out in the same manner.
As described above, in the droplet ejection apparatus and the method of detecting and judging an ejection failure in the droplet ejection heads of the invention, when the operation in which liquid is ejected from a droplet ejection head in the form of droplets was carried out by driving an electrostatic actuator or a piezoelectric actuator, the residual vibration of a diaphragm displaced by the actuator or the electromotive voltage of the piezoelectric element is detected, and it is detected whether or not the droplet has been normally ejected (normal ejection or ejection failure) on the basis of the residual vibration of the diaphragm or the electromotive voltage of the piezoelectric element and the lapsed time from the previous ejection driving operation or power on of the droplet ejection apparatus.
Further, in the invention, a cause of the ejection failure of the droplets is judged on the basis of a vibration pattern of the residual vibration of the diaphragm (for example, a cycle of a residual vibration waveform, a subtraction result of the subtraction counter, lapsed time and the like) or a voltage pattern of the electromotive voltage of the piezoelectric element.
Therefore, according to the invention, compared with the conventional droplet ejection apparatus capable of detecting an ejection failure (missing dot), the droplet ejection apparatus of this embodiment as described above does not need other parts (for example, optical missing dot detecting device or the like). As a result, not only an ejection failure of the droplets can be detected without increasing the size of the droplet ejection head, but also the manufacturing costs thereof can be reduced. In addition, in the droplet ejection apparatus of the invention, because the droplet ejection apparatus of the invention detects an ejection failure of the droplets through the use of the residual vibration of the diaphragm or the electromotive voltage after the droplet ejection operation, an ejection failure of the droplets can be detected even during the printing operation.
Further, according to the invention, it is possible to judge a cause of an ejection failure of droplets, which the apparatus such as an optical detecting apparatus capable of carrying out a conventional missing dot detection operation cannot judge. Therefore, it is possible to select and carry out appropriate recovery processing in accordance with the cause if needed. Therefore, it is possible to reduce useless discharged ink.
The droplet ejection apparatus and the method of detecting and judging a head failure of the invention have been described based on embodiments shown in the drawings, but it is to be understood that the invention is not limited to these embodiments, and respective portions forming the droplet ejection head or the droplet ejection apparatus can be replaced with an arbitrary arrangement capable of functioning in the same manner. Further, any other arbitrary component may be added to the droplet ejection head or the droplet ejection apparatus of the invention.
Liquid to be ejected (droplets) that is ejected from a droplet ejection head (ink jet head 100 in the embodiments described above) in the droplet ejection apparatus of the invention is not particularly limited, and for example, it may be liquid (including dispersion liquid such as suspension and emulsion) containing various kinds of materials as follows. Namely, a filter material (ink) for a color filter, a light-emitting material for forming an EL (Electroluminescence) light-emitting layer in an organic EL apparatus, a fluorescent material for forming a fluorescent body on an electrode in an electron emitting device, a fluorescent material for forming a fluorescent body in a PDP (Plasma Display Panel) apparatus, a migration material forming a migration body in an electrophoresis display device, a bank material for forming a bank on the surface of a substrate W, various kinds of coating materials, a liquid electrode material for forming an electrode, a particle material for forming a spacer to provide a minute cell gap between two substrates, a liquid metal material for forming metal wiring, a lens material for forming a microlens, a resist material, a light-scattering material for forming a light-scattering body, liquid materials for various tests used in a bio-sensor such as a DNA chip and a protein chip, and the like may be mentioned.
Further, in the invention, a droplet receptor to which droplets are ejected is not limited to paper such as a recording sheet, and it may be other media such as a film, a woven cloth, a non-woven cloth or the like, or a workpiece such as various types of substrates including a glass substrate, a silicon substrate and the like.

## Claims

1. A droplet ejection apparatus comprising:
a plurality of droplet ejection heads, each of the droplet ejection heads including:
a cavity filled with a liquid;
a nozzle communicating with the cavity; and
an actuator which changes an internal pressure of the cavity to eject the liquid in the form of droplets through the nozzle in response to the pressure changes;

a driving circuit which drives the actuator of each droplet ejection head;
a residual vibration detector detecting a residual vibration of an electromotive voltage generated from the actuator after the actuator has been driven by the driving circuit;
a pulse generator generating reference pulses;
an information processor carrying out a computation for the number of reference pulses generated by the pulse generator based on the residual vibration of the electromotive voltage detected by the residual vibration detector;
a time measurer measuring a lapsed time since the actuator has been driven by the driving circuit;
a head failure judge judging a head failure in the droplet ejection heads based on the computation result of the information processor and the lapsed time measured by the time measurer; and
a switch switching a connection of the actuator from the driving circuit to the residual vibration detector after carrying out the droplet ejection operation by driving the actuator.

2. A method of detecting and judging a head failure in a droplet ejection apparatus, the method comprising the steps of:
detecting a residual vibration of an electromotive voltage generated from an actuator in a droplet ejection head after carrying out a droplet ejection operation by driving the actuator with a driving circuit by switching a connection of the actuator from the driving circuit to a residual vibration detector;
generating reference pulses at the same time when detecting the residual vibration of the electromotive voltage;
carrying out an operation for the number of reference pulses generated based on the residual vibration of the electromotive voltage;
measuring a lapsed time since the actuator has been driven by the driving circuit; and
judging a head failure in the droplet ejection head based on the computation result and the measured lapsed time.

3. The droplet ejection apparatus as claimed in claim 1, wherein the information processor includes a timing generator generating predetermined timing based on the residual vibration detected by the residual vibration detector, a counter which counts the number of reference pulses generated by the pulse generator for a predetermined time period, and a holder holding the count value of the counter at the timing generated by the timing generator.

4. The droplet ejection apparatus as claimed in claim 1, wherein the head failure judge judges presence or absence of the head failure in the droplet ejection heads and a cause thereof based on the computation result by the information processor and the lapsed time.

5. The droplet ejection apparatus as claimed in claim 1, further comprising storage storing the judgment result judged by the head failure judge in association with the nozzle for which the judgment was carried out.

6. The droplet ejection apparatus as claimed in claim 1, further comprising:
a plurality of switches which respectively correspond to the plurality of droplet ejection heads; and
a detection determiner determining for which droplet ejection head the residual vibration detector detects the residual vibration;
wherein the corresponding switch switches a connection of the actuator from the driving circuit to the residual vibration detector after carrying out the driving operation of the actuator of the droplet ejection head determined by the detection detector.

7. The droplet ejection apparatus as claimed in claim 1, wherein the residual vibration detector includes an oscillation circuit and the oscillation circuit oscillates in response to an electric capacitance component of the actuator that varies with the residual vibration of the diaphragm or in response to an electromotive voltage component of the actuator.

8. The droplet ejection apparatus as claimed in claim 1, wherein the actuator includes a piezoelectric actuator having a piezoelectric element and using a piezoelectric effect of the piezoelectric element.

9. The droplet ejection apparatus as claimed in claim 1, wherein the droplet ejection apparatus includes an ink jet printer.

10. The method as claimed in claim 2, further comprising the step of:
carrying out recovery processing to eliminate a cause of the head failure in response to the judged cause of the head failure.