Abstract:
A self-configuring printer includes a print head configured to print on a print media, and a sensor configured to sense indicia on the print media. The indicia includes a top-of-form mark and at least one data segment. The printer includes a processor in operative communication with the sensor and a memory in operative communication with the processor. The memory stores a set of instructions, which, when executed by the processor, cause the processor to execute a method of operating the printer. The method includes receiving, from the sensor, signals corresponding to the a top-of-form mark and the at least one data segment; determining, from the signals, a top-of-form location of the print media and at least one printer operational property; moving the top-of-form location of the print media to a predetermined position with respect to the print head; and configuring the printer utilizing the at least one printer operational property.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 61/971,189 entitled “SYSTEMS AND METHODS FOR AUTOMATIC PRINTER CONFIGURATION”, filed Mar. 27, 2014, the contents of which are hereby incorporated by reference. 
     
    
     BACKGROUND 
       [0002]    1. Technical Field 
         [0003]    The present disclosure relates to continuous feed printers, and more particularly, to a portable label or thermal printer configured to perform self-calibration in response to indicia encoded on media. 
         [0004]    2. Background of Related Art 
         [0005]    Portable or desktop printers used in many settings, e.g., in warehouses, in industrial and manufacturing environments, by shipping services, in the vending and gaming industries, and in retail establishments for ticket printing and inventory control. Ideally, portable printers weigh only a few pounds, and some are small enough to be easily carried during use and/or easily attached to a buckle or a harness-type device. This enables the user to print labels or receipts on demand without having to retrieve a printed label from a printing station. Because the printer is portable, the printer may include a power source, such as a disposable or rechargeable battery, and may additionally communicate with a host terminal or network connection via a wireless interface, such as a radio or optical interface. A portable printer may utilize sheet-fed media, or, more popularly, continuous-feed media, e.g., rolls of paper, labels, tags, and the like. Portable printers commonly employ direct thermal transfer techniques, whereby thermochromic media passes over a thermal print head which selectively heats areas of the media to create a visible image. Also popular are thermal transfer printers which employ a heat-sensitive ribbon to transfer images to media. 
         [0006]    A continuous feed printer is particularly suitable for printing onto stock material which may include, but is not necessarily limited to, labels, receipts, item labels, shelf labels/tags, ticket stubs, stickers, hang tags, price stickers, and the like. Label printers may incorporate a media supply of “peel away” labels adhered to a coated substrate wound in a rolled configuration. Alternatively, a media supply may include a plain paper roll suitable for ink-based or toner-based printing. Continuous media is typically supplied in rolls, and is available in various widths. The roll media may be wound around a generally tubular core which supports the roll media. The core may have a standard size, or arbitrarily-sized inner diameter. In use, the media is drawn against a printing head, which, in turn, causes images to be created on the media stock by, e.g., impact printing (dot matrix, belt printing), by localized heating (direct thermal or thermal transfer printing), inkjet printing, toner-based printing, or other suitable printing methods. 
         [0007]    Portable or thermal printers may be designed for use with many different types of print media. Each different type of print media may have particular properties which affect the printing process, for example, media type (direct thermal, thermal transfer, impact, etc.), label length, label width, thermal transfer characteristics, surface texture, color, manufacturing date and lot number, and so forth. When a user loads media into a printer, he or she may need to provide, typically using a control panel or other user interface device, one or more media parameters to the printer to ensure that images printed on the media are properly rendered. For example, if a thermal printhead provides insufficient heat to a particular type of thermal media, the resulting label may appear washed out or unreadable. The manual entry of media parameters may be error-prone. In addition, if a user fails to enter the necessary media parameters, labels may be wasted and/or other inefficiencies or unforeseen consequences may ensue. 
       SUMMARY 
       [0008]    The present disclosure is directed to self-configuring printer. In one embodiment in accordance with the present disclosure, the self-configuring printer includes a print head configured to print on a print media, and a sensor configured to sense indicia on the print media. The indicia includes a top-of-form mark and at least one data segment. The printer includes a processor in operative communication with the sensor and a memory in operative communication with the processor. The memory stores a set of instructions, which, when executed by the processor, cause the processor to execute a method of operating the printer. The method includes receiving, from the sensor, signals corresponding to the a top-of-form mark and the at least one data segment; determining, from the signals, a top-of-form location of the print media and at least one printer operational property; moving the top-of-form location of the print media to a predetermined position with respect to the print head; and configuring the printer utilizing the at least one printer operational property. 
         [0009]    In some aspects the at least one data segment includes at least one mark and at least one space. The at least one mark and the at least one space are decoded to form a bit mapped representation. 
         [0010]    In some aspects the at least one printer operational property includes one or more digital codes that includes thermal print heat settings. The thermal print heat settings include a temperature, a print speed, a minimum temperature, a maximum temperature, a ramp-up time, a ramp-down time, a security indicator, and/or an authentication indicator. The at least one printer operational property may also include a number of sheets or a number of remaining sheets. 
         [0011]    In another embodiment of the present disclosure, media for use in a printer is provided. The media includes a top-of-form mark and the at least one data segment. The at least one data segment includes at least one mark and at least one space. The at least one mark and the at least one space are decoded to form a bit mapped representation. 
         [0012]    In some aspects the at least one printer operational property includes one or more digital codes that includes thermal print heat settings. The thermal print heat settings include a temperature, a print speed, a minimum temperature, a maximum temperature, a ramp-up time, a ramp-down time, a security indicator, and/or an authentication indicator. The at least one printer operational property may also include a number of sheets or a number of remaining sheets. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    Various embodiments of the subject instrument are described herein with reference to the drawings wherein: 
           [0014]      FIG. 1  is a view of an embodiment of self-configuring printer in accordance with the present disclosure showing a cover in a closed configuration; 
           [0015]      FIG. 1A  is a view of another embodiment of self-configuring printer in accordance with the present disclosure having a modular construction; 
           [0016]      FIG. 2  is a view of an embodiment of the self-configuring printer of  FIG. 1  showing a cover in an open configuration; 
           [0017]      FIG. 3  is a block diagram of an embodiment of a self-configuring printer in accordance with the present disclosure; 
           [0018]      FIG. 4  is a view of an embodiment of encoded media in accordance with the present disclosure; 
           [0019]      FIG. 5  is a view of another embodiment of encoded media in accordance with the present disclosure; and 
           [0020]      FIG. 6  is a view of yet another embodiment of encoded media in accordance with the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    Particular embodiments of the present disclosure are described hereinbelow with reference to the accompanying drawings; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure, which may be embodied in various forms. Well-known and/or repetitive functions and constructions are not described in detail to avoid obscuring the present disclosure in unnecessary or redundant detail. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure in virtually any appropriately detailed structure. In addition, as used herein, terms referencing orientation, e.g., “top,” “bottom,” “up,” “down,” “left,” “right,” “clockwise,” “counterclockwise,” and the like, are used for illustrative purposes with reference to the figures and features shown therein. It is to be understood that embodiments in accordance with the present disclosure may be practiced in any orientation without limitation. In this description, as well as in the drawings, like-referenced numbers represent elements which may perform the same, similar, or equivalent functions. In the drawings and description, any dimensions should be understood to represent example embodiments and are not to be construed as limiting. The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. The word “example” may be used interchangeably with the term “exemplary.” 
         [0022]      FIGS. 1 and 2  illustrate an example embodiment of a printer  10  in accordance with the present disclosure. The printer  10  includes a bottom housing  18  and a selectively positionable top cover  11  that may be positioned in a closed position as shown in  FIG. 1  and an open position as shown in  FIG. 2 . Top cover  11  and bottom housing  18  are pivotably joined by a hinge  19 . Top cover  11  includes a user interface panel  12 , one or more user input devices  14 , and one or more indicators  13 . User interface panel  12  many include any suitable form of display panel, including without limitation an LCD screen. User input device may include any suitable form of input device, e.g., a snap dome or membrane pushbutton switch. Indicator  13  may be any suitable indication, such as without limitation a light-emitting diode (LED). Indicator  13  may illuminate to indicate the status an operational parameter, e.g., power, ready, media empty, media jam, self-test, and the like. Printer  10  includes a power switch  15 . A pair of latches  16  are disposed on either side of top cover  11  to retain top cover  11  in a closed position, and may be disengaged using finger pressure to facilitate opening of top cover  11 . A media door  17  provides an alternative point of egress for media, which may be advantageous with self-adhesive labels whereby the labels peel away from the substrate upon exiting the printer. 
         [0023]    Turning to  FIG. 2 , top cover  11  includes a print frame assembly  20  pivotably mounted therein. Print frame assembly  20  includes a ribbon supply roll  22  and a ribbon take up roll  21  that are arranged to supply transfer ribbon  51  across a print head  68 . Print frame assembly  20  is selectively positionable between an open position as shown in  FIG. 2  and a closed position as shown in  FIG. 2A . Print frame assembly  20  includes a latch  71  that engages a retaining pin (not explicitly shown) provided within top housing  11  to retain print frame assembly  20  in a closed position. A release  70  is operatively associated with latch  71  that, when depressed, releases latch  71  from the retaining pin to enable print frame assembly  20  to swing outward to an open position. 
         [0024]    Printer  10  includes a first and a second media support members  24 ,  25 , respectively, that are configured to support roll media  100  held therebetween. Media support members  24  and  25  are moveable along a transverse axis and are operatively associated with a reciprocal movement mechanism (not explicitly shown) that is configured to translate a transverse movement of first media support member  24  into a corresponding opposite transverse movement of second media support member  25 , and vice versa. By this arrangement, roll media  100  of arbitrary width may be accommodated while concurrently centering roll media  100  with respect to the longitudinal axis “A-A” of the print head  68  and thus to the centerline of a feed path  76  corresponding thereto. First and a second media support members  24 ,  25  may be biased inwardly, e.g., toward the centerline, by a biasing member, e.g., a spring (not explicitly shown), to aid in gripping media roll  100  between the support members  24 ,  25 . A selectively adjustable stop  26  enables the position of media support members  24 ,  25  to be preset. Stop  26  is slidably disposed within an elongate slot  83  transversely defined in feed path  76  of lower chassis  34 . Stop  26  and elongate slot  83  are configured to provide sufficient friction therebetween to enable stop  26 , when positioned, to overcome the inward biasing force of media support members  24 ,  25  and maintain media support members  24 ,  25  in the desired position. 
         [0025]    A first media guide member  27  and a second media guide member  28  are moveable along a transverse axis and are operatively associated with a second reciprocal movement mechanism (not explicitly shown) that is configured to translate a transverse movement of first media guide member  27  into a corresponding opposite transverse movement of second media support member  28 , and vice versa. A platen roller  29  opposes print head  68  when top cover  11  is in the closed position to ensure intimate contact between print head  68 , transfer ribbon  51 , and media  100  during use, which, in turn, promotes consistent high print quality. Print head  68  includes pair of saddles  44  that engage a portion of platen roller  29  to ensure precise alignment between print head  68  and platen roller  29  when top cover  11  is in a closed position. 
         [0026]    In another aspect, as shown in  FIG. 1A , embodiments of the present disclosure include a modular printer having a media take-up assembly, a support block assembly, a printhead assembly, a stepper motor assembly and a display assembly is provided. A support housing having a plurality of recesses formed on an internal wall of the modular printer is also provided. Each of the recesses is configured to receive and align one of the modular printer assemblies with the other modular printer assemblies. Each of the assemblies is configured as a module which can be easily accessed and quickly secured to or detached from the support housing. The support housing is adapted to receive assembly modules for both thermal ink printers and ribbon ink printers such that the modular printer can be easily converted from one to the other. 
         [0027]    For a detailed description of the construction and operation of exemplary printers which may be utilized in accordance with embodiments of the present disclosure, reference may be made to U.S. Pat. No. 5,326,182, filed Sep. 14, 1992, U.S. Pat. No. 7,042,478, filed Sep. 22, 2003, and U.S. Pat. No. 8,500,351, filed Dec. 21, 2010, the entire contents of each of which are hereby incorporated herein by reference. 
         [0028]    Media  100  includes indicia  110  printed on the back side  101  of the media which is encoded with media properties, printer settings, and/or any other desired information. Printer  10  includes a sensor  120  that is configured to read indicia  110  as media  100  advances through the printer  10 . In embodiments, sensor  120  may include a light source and a light sensor, such as an LED and a phototransistor, to facilitate the reading of indicia  110 . Sensor  120  is in operative communication with a controller  130 . Controller  130  is in operative communication with print head  68 , a drive motor  140 , and a communications interface  150 . In use, communications interface communicates with a host computer  160  to communicate print commands to controller  130 . Controller  130  includes a processor and a set of instructions which, when executed on the processor, cause the processor to receive a signal indicative of the indicia  110 , to adjust a printing parameter in accordance with the signal, and to cause drive motor  140  and/or print head  68  to print a desired pattern (e.g., text, graphics, etc.) onto a media  100 . 
         [0029]    Embodiments in accordance with the present disclosure have several novel characteristics. A single sensor  120  may be used to detect both top-of-form and media settings, which reduces manufacturing costs. The media  100  includes indicia  110 , which may include a barcode, in which is encoded at least one of media parameters, printer parameters, a label parameter, and a label count (total labels, number of labels remaining, etc.) In one advantageous aspect, a printer  10  in accordance with the present disclosure may be configured to issue an alert (e.g., to a user and/or to a host computer) when a predetermined number of labels is remaining on the media roll  100 . As the media  100  advances through printer  10 , sensor  120  detects the indicia  110 , and conveys the indicia information to controller  130 . The indicia is decoded, and the decoded data is utilized to set the various printing parameters of the printer  10 . In embodiments, an arbitrary number of parameters may be encoded in the indicia and extracted therefrom. In embodiments the indicia comprises one or more digital codes that contains thermal print heat settings, including without limitation a temperature, a print speed, a minimum temperature, a maximum temperature, a ramp-up time, a ramp-down time, a security indicator, and/or an authentication indicator. The indicia may additionally or alternatively include the number of sheets or pages total and/or remaining on media  100 . In these embodiments, when the printer cover is opened, and new media is loaded therein, the indicia provides the number of expected pages. The printer can initiate a page count which then can be used to signal a media low condition and/or a media empty condition. The status can be communicated to the host for workflow and/or logistics management. 
         [0030]    With additional reference to  FIGS. 4-6 , in an embodiment, a printer in accordance with the present disclosure is configured advance media  100  through printer  10  to identify a top of form block  111  and marks  110   a /spaces  110   b  of indicia  110 . Initially, a leading edge of top-of form (TOF) block  111  is detected and its position recorded. In embodiments, TOF detection is performed by identifying a filtered (de-noised) transition between light and dark areas based on a calibrated threshold level. In embodiments, an automated gain control (AGC) arrangement may be utilized to improve detection accuracy. TOF detection is temporarily disabled for 1.5″ and TOF readings are recorded at each full step for next 1.5″. After these readings are performed, the data is decoded. 
         [0031]    In one embodiment, the indicia encoded on the media is decoded by populating a bit mapped representation of the dark and light (e.g., mark  110   a  and space  110   b ) segments which make up the indicia (e.g., barcode). In embodiments, the bit mapped representation may be stored in a processor register, in memory, and/or may be encoded using any suitable data type (integer, string, Boolean, and so forth). Each bit represents one position of the encoded indicia at which a segment may be present. Initially, each bit position is set to zero, which represents the binary (bit) value indicative of a space. In the present embodiment, the individual bits are assembled into a bit string of any desired length (e.g., 8 bits, 16, bits, 32, bits, 11 bits, etc.) sufficient in length to represent the number of expected segments. For each ⅛″ segment of media, up to a predetermined maximum number of segments, the number of high readings in a segment that are above a threshold level (e.g., appearing as dark areas) is counted. If the number of high readings in a segment is larger than 85%, the segment bit is determined to be a 1 (e.g., a mark). If the number of low readings in a segment is larger than 85%, the segment bit is determined to be 0. If neither number of high or low readings exceeds 85%, the segment is deemed invalid. In this event, in some embodiments, the printer may advance to the next TOF block and re-attempt the decoding and/or indicate an error condition. 
         [0032]    Once a segment bit is identified, the resultant bit string is shifted once to the left and the segment bit is written into its respective position into the resultant bit string. In some embodiments, a Boolean OR function is performed to a write the segment bit into the bit string. The consequent marks and space segments of the indicia are iteratively identified in the manner just described, until all segments counted. The results are validated by assuring that a leading sync code is “1-0” and a termination code “0-1” have been identified. The sync code and the termination code are stripped from the resultant bit string, and the middle binary code is extracted as the final indicia content, which, in turn, may be used directly to set printer characteristics, and/or used as an index into a printer setup table. The printer setup table is configured to provide one or more printer configuration properties as a function of the index. The printer characteristics may be configured based upon one or more the printer configuration properties provided by the printer setup table. 
         [0033]    In one embodiment, a 0.12″ high black bar is used to represent one segment. In other embodiments, this can be increased or decreased based on the sensor detection accuracy and the print speed. In some embodiments, the TOF mark may be greater than, or less than, the width that is used to represent one segment. In this manner, a TOF mark is discernable from a segment mark, which facilitates the use of a single sensor to detect both top-of-form properties and media parameter properties of a supply of media. 
         [0034]    The described embodiments of the present disclosure are intended to be illustrative rather than restrictive, and are not intended to represent every embodiment of the present disclosure. Further variations of the above-disclosed embodiments and other features and functions, or alternatives thereof, may be made or desirably combined into many other different systems or applications without departing from the spirit or scope of the disclosure as set forth in the following claims both literally and in equivalents recognized in law.