Patent Abstract:
A printhead having multiple print lines of conventional design and a printhead control system for using the multiple print lines in a variety of operations. In one embodiment, the printhead control system prints an image by superimposing the printing from multiple print lines. In another embodiment, the image is printed by alternating the energization of one print line so that each print line is used to print only ⅓ of the image lines. As a result, the print lines are allowed a relatively long time to cool, thus allowing the printhead to be operated at a faster speed. In another embodiment, the printing elements of each print line print with a different image density, and images printed by superimposing the printing elements in the print lines with a variety of combinations depending upon the desired magnitude of the image density. In still another embodiment of the printhead control system, the resistance of each printing element is checked and, if found to be unacceptably high, corresponding printing elements of other print lines are used for printing.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 08/869,804, filed Jun. 4, 1997, now U.S. Pat. No. 6,025,861; which is a divisional of U.S. patent application Ser. No. 08/156,266, filed Nov. 22, 1993, issued as U.S. Pat. No. 5,675,370. 
    
    
     TECHNICAL FIELD 
     This invention relates to thermal printers, and more particularly, to a method and apparatus for improving the printing quality, speed, and capabilities of such printers. 
     BACKGROUND OF THE INVENTION 
     Thermal printers are commonly used to print alphanumeric characters and bar codes on a variety of printing media such as paper, label stock, tubing, etc. Thermal printers utilize a thermal printhead having a line of thermal printing elements, each of which may be selectively heated. As each printing element is heated, appropriate markings are applied to the printing media, either directly or through a meltable transfer medium. 
     The thermal printheads used in thermal printers generally include both mechanical components containing the printing elements and associated electrical circuitry applying heating signals to the printing elements. The mechanical printhead is generally formed by a fairly thick substrate of aluminum or some other material that conducts heat readily. A ceramic insulating layer having a high thermal conductivity is then formed on the upper surface of the aluminum. The insulating layer preferably not only conducts heat well, but it also has a relatively low heat capacity so that it does not itself retain heat transferred to the substrate. A relatively thin underglaze layer coats the insulating layer, and a metallic pattern is then placed on top of the underglaze layer to form the conductors for the printing elements. The conductive pattern may include an elongated anode conductor extending along the length of the printhead, and a plurality of spaced-apart finger conductors projecting perpendicularly from the elongated anode. Individual conductive leads are interleaved with the finger conductors. A bar of resistive material overlies the finger conductors and individual leads so that current will flow through the resistive material from a finger conductor to any individual lead that is connected to ground. Thus, a “dot” of resistive material can be heated by simply grounding an individual lead positioned between two finger conductors. The length of the dot corresponds to the distance between adjacent finger conductors. An electrically insulative but thermally conductive overglaze is then placed over the resistive material and conductors. 
     The above-described structure is used for a thick film printhead. A thin film printhead has substantially the same structure except that the individual leads are generally positioned adjacent a projecting finger conductor rather than between two finger conductors. A resistive sheet overlies the finger conductors and individual leads so that localized “dots” of the resistive sheet may be heated by selectively grounding the individual leads. 
     The electrical components of the printhead generally include a set of registers which receive a serial data stream of data bits corresponding in number to the number of printing elements. The registers retain the data bits and ground the individual leads corresponding to the registers that store a logical “1”. However, the data output by each register is generally ANDed with a strobe signal to precisely control the timing and duration of the grounding of the individual leads. 
     One important limitation on the operating capability of thermal printers is their printing speed. The printing speed of a thermal printhead is limited by the time required to heat a printing element to an appropriate temperature in order to form a mark on a printing medium, as well as the time required for the printing element to cool so that a mark is not formed on the printing medium when no mark is desired. The time required to heat the printing element is a function of the current flowing through the resistive bar or sheet between conductors. The time required for a printing element to cool is a function of the thermal conductivity from the printing element to the substrate. While the print speed can be improved by using thin film printhead technology having a lower thermal mass, it would nevertheless be desirable to increase the speed of thermal printers. 
     Another problem with conventional thermal printers is that they lack the capability to perform various printing functions that are available with other types of printers. For example, thermal printers generally are incapable of performing high quality “gray scale” printing. For this reason, the use of thermal printers has generally been limited to printing alphanumeric letters, bar codes, and the like. Similarly, the resolution of conventional thermal printers is generally set at a fixed value, such as 150 dots per inch (“DPI”), and this fixed resolution cannot be varied without changing the printhead. However, different types of printing needs often require different printing resolutions. It would therefore be desirable to have a thermal printer that could provide the relatively high speed and low data requirement capabilities of a low resolution printhead yet also be able to provide the high quality printing capabilities of a high resolution printhead. 
     Another limitation of conventional thermal printers is their inability to alter the shape or aspect ratio of their printing elements. As explained above, the shape of the printing element is determined by the physical structure and geometry of the conductive pattern and overlying resistive layer. While different printing element shapes and aspect ratios can be achieved with different physical designs, the shape and aspect ratio of the printing element is nevertheless fixed for any particular design. 
     Another problem that sometimes occurs with conventional thermal printers results from changes in the resistivity of the resistive coating either with age or as a result of a malfunction. If the resistivity of some printing elements changes more than the resistivity of other printing elements, then the image formed on the printing medium will not have a uniform print density. If the resistance increases significantly, the printing element may even become unusable. 
     While thermal printers have found common acceptance, the above-described problems have nevertheless limited their usefulness for certain printing needs where optimum print quality, speed, and/or capabilities are required. 
     SUMMARY OF THE INVENTION 
     It is an object of the invention to provide a thermal printer that is capable of significantly higher speeds than conventional thermal printers. 
     It is another object of the invention to provide a thermal printer that has advanced capabilities, such as the capability of performing gray scale printing and variable resolution printing. 
     It is still another object of the invention to provide a thermal printer that can operate in an optimum manner despite degradations in the components of the thermal printhead with age and malfunction. 
     These and other objects of the invention are provided by a printhead having a plurality of spaced apart parallel print lines, each of which include a plurality of sequentially positioned printing elements that are selectively heated. The thermal printhead is preferably formed by a unitary printhead substrate having a plurality of discrete, separately energizable, parallel print lines spaced apart from each other by a predetermined distance. The printhead may further include means for selectively applying respective heating signals to each printing element in the print lines so that the print lines can print independently of each other on a common print media passing over the printhead from one print line to the next. 
     The printhead is connected to a printhead controller that receives data corresponding to an image to be printed on the print media. The printhead controller then selectively applies heating signals to the printing element in each of the print lines to thermally print a line of the image on the printing media. The printhead controller also preferably includes an image memory containing printhead data corresponding to the heating signals. The data is preferably stored in the memory in an order corresponding to the order that the heating signals are applied to the printhead. The printhead data may be stored in the memory in an N×M matrix where N is a number of scan line columns corresponding to the number of scan lines needed for the printhead to print the image on the print media, and M is a number of printing element rows corresponding to the number of printing elements in each print line of the printhead. In one embodiment of the invention, each line of the image is printed by superimposing the printing from all of the print lines. In another embodiment, each line of the image is printed by superimposing the printing from different combinations of print lines to produce an image having a variable image density. In this other embodiment, each of the print lines preferably prints with a different print density. In still another embodiment, each line of the image is printed by a single print line in a time-staggered sequence so that each print line has a relatively small duty cycle, thus increasing the printing speed of the printhead. The printhead controller may also include means for determining the resistance of the printing elements of each line of the printhead. The controller then applies a heating signal to one printing element in each set of correspondingly positioned printing elements as a function of the resistance of the printing elements in the set. As a result, when a heating element of a print line is found to be defective, correspondingly positioned printing elements in other print lines may be used. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic block diagram of a preferred embodiment of the inventive thermal printer. 
     FIG. 2 is a block diagram of one embodiment of the printhead control unit used in the preferred embodiment of FIG.  1 . 
     FIG. 3 is illustration of an image printed by the thermal printer of FIG.  1 . 
     FIG. 4 is a diagram showing the manner in which the printing elements used in the thermal printer of FIG. I are heated during each of several scan lines to print the image shown in FIG. 3 using all three printhead lines to print each line of the printed image. 
     FIG. 5 is a memory map showing the data stored in an image memory used in the printhead control unit of FIG. 2 to print the image shown in FIG.  3 . 
     FIG. 6 is a flow chart showing the software that is executed by a processor used in the printhead control unit of FIG. 2 to print the image shown in FIG. 3 using all print printhead lines for each pixel of the printed image. 
     FIG. 7 is a diagram showing the manner in which the printing elements used in the thermal printer of FIG. 1 are heated during each of several scan lines to print the image shown in FIG. 3 using one printhead line to print each line of the printed image. 
     FIG. 8 is a flow chart showing the software that is executed by a processor used in the printhead control unit of FIG. 2 to print the image shown in FIG. 3 using one printhead line to print each line of the printed image. 
     FIG. 9 is a diagram showing a single line of an image having a variable print density printed by the thermal printer of FIG. 1 shown along with the decimal and binary values of the print density of each pixel of the image. 
     FIG. 10 is a three-dimensional memory map showing the data stored in an image memory used in the printhead control unit of FIG. 2 to print the single line image shown in FIG.  9 . 
     FIG. 11 is a flow chart showing the software that is executed by a processor used in the printhead control unit of FIG. 2 to print the single line image shown in FIG.  9 . 
     FIG. 12 is a block diagram of another embodiment of the printhead control unit used in the preferred embodiment of FIG. 1 that checks the condition of each printing element in each printhead line, and alters its operation as a function of such check. 
     FIG. 13 is a flow chart showing the software that is executed by a processor used in the printhead control unit of FIG.  12 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A preferred embodiment of the inventive printer is illustrated in FIG.  1 . The printer  10  includes a printhead  12  connected to a printhead control unit  14 . The printhead  12  utilizes a conventional substrate, such as aluminum, and it is preferably covered with a single layer of insulative material, although separate, discrete areas of insulated material may be used. The insulative material is also preferably covered by an underglaze material (not shown) of conventional design. Where the inventive printhead  12  departs from conventional design is in the use of multiple lines  16 ,  18 ,  20  of printing elements rather than a single line of printing elements as in conventional designs. Each line  16 - 20  of printing elements is formed in a conventional manner with selectively grounded individual leads positioned adjacent or between common anode finger conductors, and each line of conductors is coated with a bar or layer of resistive material which is then covered with a protective overglaze. Although the printhead  12  is shown in FIG. 1 as having three printhead lines  16 - 20 , it will be understood that any number of multiple printhead lines (i.e., two or more) may be used. 
     The printhead control unit  14  provides a serial stream of data bits to the printhead  12  for each print line  16 - 20 , with the number of bits in the bit stream corresponding to the number of printing elements in each line  16 - 20 . The bits determine whether the corresponding printing element is energized or not energized during each scan line. 
     In operation, a sheet of print media  24 , such as paper, passes over the printhead  12  in the direction of the arrow with the surface of the print media  24  in contact with the printhead lines  16 - 20 . As explained in greater detail below, the printing elements in each of the lines  16 - 20  are selectively heated to create an image on the print media  24 , either directly or through a thermal transfer medium (not shown). 
     One embodiment of a printhead control unit  14  is illustrated in FIG.  2 . The printhead control unit  14  includes a microprocessor  30  of conventional design which receives alphanumeric or bar code data, for example, from an external unit (not shown) via an input bus  32 . The microprocessor determines which printing elements of each printhead line  16 - 20  should be energized during each scan line to produce an image corresponding to the data input via bus  32 . The bits indicative of the energization state of each printing element are then stored in an image memory  34 , which may be a conventional random access memory. The microprocessor  30  selectively reads the image data from image memory  34  and applies it to the printhead  12  via serial data lines  36 ,  38 ,  40  corresponding to printhead lines  16 ,  18 ,  20 . As is well known in the art, the printing elements in lines  16 - 20  are not immediately heated when the microprocessor  30  applies the data to the printhead  12 . Instead, the heating elements are energized only during a strobe signal. Strobe signals for each of the printhead lines  16 - 20  are generated by respective counter/timers  46 ,  48 ,  50  which are, in turn, programmed by the microprocessor  30  in a conventional manner. 
     In operation, data indicative of whether each printing element of each line  16 - 20  is to be heated during a scan line is transferred from the microprocessor  30  to the printhead  12 , as explained above. The counter/timers  46 - 50  are then programmed by the microprocessor  30  to produce a predetermined strobe signal. The microprocessor  30  then applies a trigger signal to the counter/timers  46 - 50 . The counter/timer  46  generates a strobe signal for the printhead line  16 , the counter/timer  48  generates a strobe signal for the printhead line  18 , and the counter/timer  50  generates a strobe signal for the printhead line  20 . The manner in which the printing elements for each printhead line  16 - 20  are heated in various operating modes is explained below. 
     As mentioned above, the inventive thermal printer can be used to print virtually any type of image, including alphanumeric characters and bar codes. One alphanumeric character that can be printed by the inventive thermal printer (the letter “E”) is illustrated in FIG.  3 . The image shown in FIG. 3 is composed of 60 pixels, shown generally at  56 , in a 6×10 pixel array. The pixels marked with an “X” are pixels that have been thermally marked, while pixels without an “X” are pixels that have not been thermally marked. Since the print media is moving from right to left, the leftmost column of pixels  58  reaches the printhead  12  first while the rightmost column of pixels  68  reaches the printhead  12  last. 
     In one operating mode of the inventive thermal printer, each printhead line  16 - 20  contributes to the printing of each line of image  58 - 68 . In other words, printhead line  16  first marks the pixels on image line  58  to a slight degree, the marking of the image line  58  is increased by heat from the second printhead line  18 , and the image line  58  is darkened to its final image density by heat from the third printhead line  20 . A diagram showing the heating condition of each of ten printing elements in each printhead line  16 - 20  for ten different scan lines is illustrated in FIG.  4 . As shown in FIG. 4A, the first image line  58  has not yet reached the first printhead line  16 . As a result, none of the printing elements in the printhead  12  are being heated. When the first image line  58  reaches the first printhead line  16 , all ten of the printing elements of line  16  are heated, as illustrated in FIG.  4 B. The print media is then incrementally stepped so that the first image line  58  is adjacent the second printhead line  18 , as illustrated in FIG.  4 C. In this position, the second printhead line  18  further increases the image density of the first image line  58 , while the first printhead line  16  initially marks the second image line  60  (FIG.  2 ). As shown in FIG. 4D, the first image line  58  has reached the third printhead line  20 . In this position, the first image line  58  is marked by printhead line  20  to its final image density, image line  60  is further marked by printhead line  18 , and the third image line  62  is initially marked by the first printhead line  16 . Note that four of the printhead elements of the first printhead line  16  are not heated during the scan line shown in FIG. 4D, thereby forming the initial portion of the openings between the arms of the “E”. 
     The printing media  24  is sequentially incremented past the printhead as shown in FIGS. 4E, F and G until it has stepped to the position shown in FIG.  4 H. In this position, the last image line  68  is being printed by the second printhead line  18  while the second to last image line  66  is being printed by the third printhead line  20 . As shown in FIG. 4I, the last image line  68  is being printed by the third printhead line  20 . Finally, the image shown in FIG. 3 has passed entirely beyond the printhead as shown in FIG.  4 J. 
     With reference to FIG. 5, the manner in which data are stored in the image memory  34  (FIG. 2) to allow the printhead control unit  14  to operate as shown in FIG. 4 is illustrated in FIG.  5 . The image memory  34  can be visualized as a 10×6 bit array of data corresponding to the 6×10 pixel array forming the image of FIG.  3 . In practice, the data can be stored in the image memory  34  in any order as long as it is transferred by the microprocessor  30  to the printhead  12  in the manner shown in FIG.  5 . Each column of data stored in the image memory has an address corresponding to an arbitrary starting column address and a column address increment which, as shown in FIG. 5, ranges between zero and seven. When N is equal to zero, the memory address is equal to the address of the starting column. The data bytes in column zero are transferred in serial to the printhead  12  to cause the first printhead line  16  to be heated as shown in FIG.  4 B. During the next scan line, the column increment N is incremented to 1 so that the data shown in column  1  are transferred to the first printhead line  16 . At the same time, the data in column  0  are transferred to the second printhead line  18 . During the next scan line, the data stored in column  0  are transferred to printhead line  30 , the data stored in column  1  are transferred to printhead line  18 , and the data stored in column  2  are transferred to printhead line  16 . In this same manner, the serial bytes of data stored in each column of the image memory  34  as shown in FIG. 5 are transferred to the printhead lines  16 - 20 . 
     One embodiment of software for controlling the operation of the microprocessor  30  to operate as explained above is illustrated in FIG.  6 . The program initializes the microprocessor  30  at step  80 . During this initialization step  80 , various registers and counters in the microprocessor  30 , including a scan line counter N are reset or cleared. At step  82 , the microprocessor  30  generates the printhead data (such as the data shown in FIG. 5) corresponding to the image data input via bus  32 , and stores the printhead data in the image memory  34 . The program then progresses to step  84  where the microprocessor  30  loads data from an address corresponding to the sum of the starting column and the scan line counter N into line  16  of the printhead. In the example illustrated in FIG. 5, the data byte “111111111” is loaded into the printhead line  16 . The program then progresses to step  86  where the microprocessor  30  loads data from the next lower column of image memory into printhead line  18 . In the above example, the data in this column are all zero. Finally, at step  88  the microprocessor  30  loads data from the second to next lowest column of image memory into printhead line  20 . In the example above, this data would be all zero&#39;s, although it is not shown in the image memory map. 
     After the printhead  12  has been loaded data for each printhead line  16 - 20 , the microprocessor  30  determines a value of strobe for each printhead line at step  90 . The microprocessor then outputs the strobe data to the counter/timers  46 - 50  at step  92 . The actual printing by the printhead line  16 - 20  occurs at step  94  when the microprocessor  30  applies the trigger signal to the counter/timers  46 - 50 . The microprocessor  30  then generates a paper advance pulse via line  33  to a conventional external paper control device at step  96  (not shown). The program then checks at step  98  to determine if the final image line has been printed. If not, the internal scan line counter N is incremented at  100 , and the program returns to step  84 . Since N is now equal to two, data from the second image memory column are loaded into printhead line  16  at step  84 , data from image memory column one are loaded into printhead line  18  at step  86 , and data from image memory column zero are loaded into printhead line  20  at step  88 . The program then causes strobe signals to be generated as explained below, advances the paper an additional image line and once again increments the scan line counter N at 100. This time, since N is equal to three, the third column of image memory is loaded into printhead line  16  at step  84 , the data in the second column of image memory are loaded into the second printhead line  18  at step  86 , and the data in the first image memory column are loaded into printhead line  20 . In the same manner, the program sequentially step through  84 - 100  until N has been incremented to eight. Data stored in the eighth image memory column are then loaded into printhead line  16 , data in image memory column line  7  are then loaded into printhead line  18 , and data stored in image memory column  6  are loaded into printhead line  20 . In this scan line, the final printing of the image shown in FIG. 3 is performed by the third printhead line, and the printing of the image is now complete. Thus, when the program checks at step  98  to determine if the image is complete, the program will now branch back to step  80  where the scan line counter N is reset to “1”. Printing then resumes with receipt of the next image data via line  32 . 
     As an alternative to using all three printhead lines  16 - 18  to print each image line, the inventive printer may also be used to print each image line using a single printhead line  16 - 20 , but energizing only one printhead line at a time in a predetermined sequence. The advantage of this operating mode is that the duty cycle of each printhead line  16 - 20  is 33% so that the printhead line  16 - 20  is allowed to cool for at least approximately two-thirds of the time. These relatively long cooling time allows the printhead  12  to operate at a relatively high speed, thus allowing the inventive printer to print significantly faster than conventional thermal printers. With reference to FIG. 7, the heating of each of ten printing elements of the printhead line  16 - 20  are illustrated in FIGS.  7 A-J in the same manner as in FIGS.  4 A-J. However, the diagram of FIGS.  7 A-J have been further marked with an asterisk (“*”) to designate the printhead line that is currently active. Thus, in FIG. 7A, printhead line  16  is active, although the first image line has not reached the printhead line  16  so that none of the printing elements of line  16  are energized. The next printhead line that is energized is line  20  as illustrated in FIG.  7 B. However, in this position the first image line has only reached the first printhead line  16 , so that none of the printing elements of line  20  are energized. Further, since printhead line  16  is not active, none of the printing elements of line  16  are energized, even though the first image line has reached the printhead line  16 . In FIG. 7C, printhead line  18  is active, and, in this position, the first image line  58  (FIG. 3) has reached printhead line  18  so that all of its printing elements are energized. The energization sequence of printhead lines  16 ,  20 ,  18  shown in FIGS.  7 A-C, respectively, then begins anew at FIG.  7 D. In this position, the third image line  62  has reached the active printhead line  16  so that the printing elements of line  16  are heated as illustrated in FIG.  7 D. In FIG. 7E, the second image line  60  is printed by the active third printhead line  20 . In the third scan line of the sequence illustrated in FIG. 7F, the fourth image memory line  64  is printed by the active second printhead line  18 . The above-described operation continues through FIG. 7G where the final image line  68  is printed by the first printhead line  16  and FIG. 7H where the image line  66  is printed by the third printhead line  20 . 
     A flow chart for causing the microprocessor  30  (FIG. 2) to operate as shown in FIG. 7 is illustrated in FIG.  8 . As with the flow chart of FIG. 6, the program is entered at an initialization step  110  during which a scan line counter N is reset to 1 and a printhead line counter X is also reset to 1. The program then causes the microprocessor to generate the printhead data from the image data input via bus  32  and store the printhead data in the image memory  34  at step  112  in the same manner as in step  82  of FIG.  6 . The program then progresses to  114  where data is loaded from a memory address designated by the sum of the starting column, N and X into printhead line X. Since N and X are both equal to 1 during the first pass through  114 , the data is loaded from the starting column into printhead line  1  corresponding to printhead line  16 . At  116 , the program determines a value of strobe for printhead line X (where X=1) and outputs that data to the counter/timers  46 - 50  at  118 . At  120 , the microprocessor  30  triggers the counter/timers  46 - 50 , thereby causing printhead line X (where X=1 for the first pass through  114 - 120 ) to print an image on the printing media. The microprocessor  30  then generates a paper advance pulse on line  33  at step  122  and checks to determine if the image is complete at line  124 . During the initial pass through the software, the image will not be complete so that the program will check at lines  126  to determine if the print line counter X is equal to 1. During the first pass through the program, X will be equal to 1 so that the program will branch to  128  to set the printhead counter X=3. The program then increments N by 1 at  134  and returns to step  114  where data from image memory address column − 1  (since X=3 and N=2) is loaded into printhead line  3 , which corresponds to line  20 , as shown in FIG.  2 . The microprocessor  30  then causes line  20  to print in steps  116 - 120  and advance the paper at step  122  before progressing to  126 . At  126 , the program branches to  130  since X was previously set to 3 at step  128 . For this reason, the program will now branch to step  132  to set the program line counter equal to 2 before increment N by 1 at  132  and returning to step  114 . At  114 , the program loads data from memory address column  1  (since X=2 and N=3) into printhead line  2 , which corresponds to printhead line  18  in FIG.  2 . The microprocessor  30  once again causes the printhead line  18  to print in advance of the paper one line before progressing through  126  to  130 . Since X is now equal to 2, the program will branch to  136  and reset X=1 then N is incremented at  134 , and the program branches back to  114 . At this time, data from memory location  3  (since N=4 and X=1) is loaded into printhead line  1  corresponding to printhead line  16  in FIG.  2 . Printhead line  16  is then caused to print at steps  116 - 120  and the paper is advanced one line at  122 . The program then loops as explained above until the program determines at  124  that the image is complete. The program then returns to  110  to await image data for the next image via bus  32 . 
     As mentioned above, the inventive thermal printer is capable of variable density printing. With reference FIG. 9, a single line  150  of an image is printed. The line  150  contains 10 pixels, each of which is printed with an image density between 0 and 7 as indicated by the decimal numbers shown to the right of the image line  150 . The binary numbers for the optical density are shown in the three columns to the right of the decimal column. The binary printhead data shown in FIG. 9 can be stored in memory as shown in FIG.  10 . The printhead data is shown as a three-dimensional array where “X” corresponds to the column of printhead data, “Y” corresponds to each printing element, and the “Z” corresponds to the 3 bits used to determine the density of the printed pixel. However, it will be understood that the data need not be stored as illustrated in FIG. 10, as long as it is loaded into the printhead  12  in the form illustrated in FIG.  10 . The inventive thermal printer is able to print with variable image density because the printing elements in each printhead line  16 - 20  (FIG. 1) print with different image densities. In the example illustrated, the printing elements of printhead line  16  have a relative density of 4, the printing elements of printhead line  18  print with a relative density of 2 and the printing elements of printhead line  20  print with a relative density of 1. Thus, by combining correspondingly positioned printing elements in each of the three printhead lines  16 - 20 , eight different image densities may be printed for each pixel of the image. 
     A flow chart of software for causing the microprocessor  30  (FIG. 2) to operate as shown in FIG. 9 is illustrated in FIG.  11 . As before, the program is entered through an initialization step  170 , and the printhead and density data shown in FIG. 10 is stored in the image memory  34  at step  172 . At  174 , the microprocessor  30  loads data bit D N,Y,1  from a memory address column N, row i, and bit  1  into printhead line  1 , which corresponds to line  16  of FIG.  2 . In the example given, the data “1011110001” would be loaded from memory  134  into printhead line  16 . Thus, data corresponding to the most significant bit of the image density is loaded into printhead at line  16 . At  176 , the data bits from column  0  (which had been reset to zero) are loaded into printhead line  2 , which corresponds to printhead line  18  of FIG.  2 . Finally, at  178 , data from column − 2  is loaded into printhead line  3 , which corresponds to printhead line  20  of FIG.  2 . The microprocessor then determines the value of a strobe signal for each printhead line  16 - 20  at  180 , outputs the strobe data to the counter timers  46 - 50  at  182  and then triggers the counter timers  46 - 50  at  184 . After generating a paper advance pulse at  186  as described above, the program checks at  188  to determine if the image has been printed. In the first pass through of steps  174 - 178 , only the first printhead line  16  contains data since the image line  150  is then positioned adjacent the printhead line  16 . Since the image is not yet complete, the scan line counter is incremented to 1 at  190  before returning to  174 . A column of image memory data  2  (which, as illustrated in FIG. 9, is zero) is loaded into printhead line  16  at  174 . At  176 , printhead data in column  1  (N−1 where N=2) bit  2  is loaded into printhead line  2  which corresponds to printhead line  18  of FIG.  2 . In the above example, the data in column  1 , bit  2  is “1100110111.” Thus, when the program steps through  180 - 184 , printhead line  18  will print the pixels on image line  150  with a relative image density of 2. After the scan line counter  1  is incremented again at  190 , the program causes the printhead line  20  to print the pixels of image line  150  with a relative image density of 1 at step  178 . At  178 , data from column  1  (N −2 where N=3) bit  3  is loaded into printhead line  3 , which corresponds to printhead line  20 . In the above example, the data in column  1 , bit  3 , are “1000111101.” As mentioned above, this data causes the printhead line  20  to print the pixels of image line  150  with a relative image density of 1. Thus, after the image line  150  has been printed by all three printed lines  16 - 20 , the image density of each printed pixel has density between 0 and 7. After the image has been completely printed, the program branches from  188  back to the initialization step at  170  to await additional image data via bus  32  (FIG.  2 ). 
     Another embodiment of the inventive multiple print line thermal printer is illustrated in FIG.  12 . The printer  200  of FIG. 12 is similar to the printer  10  of FIG. 1 except that it includes means for identifying the failure of individual printing elements of a print line and taking corrective action to allow the printer to continue to operate properly despite the failure. With reference to FIG. 12, the printhead  12  is identical to the printhead  12  of FIG. 1, and it is thus then provided with the same reference numerals  16 ,  18  and  20  to identify the three print lines. The printhead is supplied with data by conventional microprocessor  202  which is connected to an image memory  204  and a counter timer  206  which operate in essentially the same manner as the printhead control system  14  of FIG.  2 . However, the printhead control system of FIG. 12 utilizes a switch  210  operated by a control bit from the microprocessor  202  to switch the power terminals of the printhead  12  between either the normally supplied 24 volt source and a 5 volt source supplied to the switch  210  through resistor  212 . When the switch  210  connects the printhead to the ±5 volt source, the resistor  212  serves as a current-sensing resistor to generate a voltage that is proportional to the resistance of the printing elements that are energized. By energizing one printing element at a time, the voltage input to the switch across the resistor  212  is proportional to the resistance of the energized printing element. This voltage is read by a conventional analog-to-digital converter  216  which supplies a data byte to the microprocessor  202  indicative of the printing element&#39;s resistance. 
     In operation, the microprocessor  202  sequentially applies a logic “1” through the data lines D 1 -D 3  to each printing element of each print line  16 - 20  in sequence so that only one printing element is energized at a time. As each printing element is energized, the voltage drop across resistor  212  is measured by the analog-to-digital converter  216 . The output of the analog-to-digital converter  216  is then read by the microprocessor  202  so that the microprocessor  202  can determine the resistance of each printing element. The microprocessor  202  then alters the printing operation of the printer in the event that any of the printing elements are found to have an excessively high resistance. 
     The resistance checking operation can be performed in a variety of manners. For example, the microprocessor can check the resistance of each printing element during an initialization phase prior to starting a printing operation. However, in order to minimize the time required to perform the resistance checking operation, the microprocessor  202  preferably first checks the resistance of each printing element of the first print line  16 . If any of the printing elements in print line  16  are found to have an excessively high resistance, then the microprocessor  202  checks the resistance of the corresponding printing element in print line  18 . If any of those printing elements in print line  18  have an excessively high resistance, then the microprocessor  202  checks the corresponding printing elements in print line  20 . Using this approach, the microprocessor  202  checks all of the printing elements of print line  16 , and only checks the printing elements of print lines  18  and  20  if needed because of an excessively high resistance of a printing element in an earlier check print line. 
     A flow chart of the software for controlling the resistance checking and printing operations of the microprocessor  202  is illustrated in FIG.  13 . The program is entered at  230  in an initialization step in which various internal registers, counters and flags are cleared. At  232 , the microprocessor  202  causes the switch  210  to connect the ±5 volt current sensing voltage to the power input of the printhead  12 , as explained above. At  234 , the microprocessor  202  programs the counter/timer  206  so that it will generate a predetermined strobe signal when triggered. The microprocessor  202  then loads printing element N of the first printhead  16  with a test bit at  240 . As explained above, the microprocessor  202  loads all but the N printing element with a logic “0”, and it loads printing element N with a logic “1”. The strobe signal is generated at  242  when the microprocessor  202  triggers the counter/timer  206 . As explained above, current then flows through the resistor  212  in proportion to the resistance of the N printing element of line  16 , and this resistance is read at  242  when the microprocessor  202  samples the output of the analog-to-digital converter. The microprocessor then checks at  242  to determine if the resistance of printing element N is larger than a predetermined value R MAX . R MAX  is a resistance value which serves as the dividing line between a printing element considered to have an acceptable resistance and a printing element considered to have an excessively high resistance. If the resistance of printing element N is not excessively high, the program sets a flag at  244  to provide an indication that printing element N of printhead  16  has an acceptably low resistance for use in a subsequent printing operation. If the resistance of printing element N is excessively high, the program bypasses step  244  so that no flag is set for printing element N of printhead  16 . Regardless of whether a flag is set for printing element N of printhead  16 , the program checks at  250  to determine if N has been incremented to N MAX . N MAX  corresponds to the number of printing elements in printhead  16 . During the initial pass through steps  230 - 244 , N will be less than N MAX  so that the program will branch from  250  to  252  in order to increment N by 1 and will then return to  240  to perform a resistance test on the next printing element of printhead  16 , as described above. When all of the printing elements of print line  16  have been checked, N will be equal to N MAX , thereby causing the program to branch from  250  to  254  where the printing element index N is reset to 1. At this stage, all of the printing elements of print line  16  have been checked. 
     The program then proceeds to  260  to check the resistance of printing elements of the remaining print lines  18  and  20  if the corresponding element of print line  16  has not been flagged. At  260 , the program determines if printing element  1  (N having been reset to 1 at  254 ) of print line  16  has been flagged. If not, the corresponding printing element of print line  18  is checked by first loading printing element N of print line  18  with a test bit at  262 . This step is performed in the same manner as described above with reference to step  240  except that it is performed on print line  18  instead of print line  16 . The microprocessor  202  then triggers the counter/timer  206  at  264  in the same manner as at step  240 . The analog-to-digital converter  216  is similarly sampled at  266  in the same manner as in step  240 , and the resistance of printing element N of print line  18  is compared to R MAX  at  268 . If the printing element N of print line  18  has an acceptably low resistance, a flag is set for that printing element at  270 . The program then checks at  272  to determine if the printing element index N has reached it maximum value. If the resistance of printing element N of print line  18  is too high, the program proceeds directly from  268  to  272  without first setting the flag for that print element. Thus, in steps  260 - 272 , the printing elements of print line  18  corresponding to the printing elements of print line  16  that had an excessively high resistance are checked and flagged if they are suitable for use in printing. After the printing element N is checked for its maximum value, it is either incremented at  274  to repeat steps  260 - 272  until the final printing element is reached at which point the program proceeds from  272  to a sequence of printing steps, described below. 
     If the flag has not been set for a printing element of print line  16 , and a flag has not been set to the corresponding printing element of print line  18 , then that printing element has an excessively high resistance in both print line  16  and print line  18 . Accordingly, the program defaults to using the corresponding printing element of print line  20  as described below. Alternatively, the print line  20  may also be checked before it is used for printing using substantially the same steps that were used to check the print lines  16 ,  18 . 
     The printing operation begins with step  280  in which the microprocessor  202  causes the switch  210  to apply the +24 volt power to the printhead  12 . The program then causes the microprocessor  202  to generate printhead data corresponding to the energization pattern of the printed elements on the printhead  12  and store that data in the image memory  204  at step  282 . The printing element index N is then set to 1, and a scan line index M is set to the starting column of the printhead data in the memory  204  at  284 . The program then begins the printing operation by determining if printing element  1  (since N is now equal to 1) of print line  16  is flagged. If so, the program causes the microprocessor  202  to load a data bit for scan line M (i.e., the first column of data) into printing element  1  of print line  16 . Thus, at the end of step  288 , printing element  1  of scan line  16  has been programmed if its resistance was found to be acceptably low in the steps described above. If the program determines at  286  that printing element  1  of print line  16  was not flagged, the program checks at  290  to determine if printing element  1  of print line  18  has been flagged. If so, data for scan line M- 1  is loaded into printing element  1  of print line  18  at  292 . The reason that the data is loaded into scan line M- 1  is that the data in memory must be offset by one scan line to correspond to the spatial offset of print line  18  from print line  16 . Specifically, the printhead data for scan line M is not loaded into print line  18  until the image formed by other printing elements of print line  16  has reached print line  18 . At this time, the printhead data for the next scan line is being loaded into print line  16 . 
     If the program determines at steps  286  and  290  that printing element N of neither print line  16  nor print line  18  are flagged, the program defaults to using the corresponding printing element of print line  20 , as mentioned above. Accordingly, at step  292  data for scan line M- 2  is loaded into printing element N of print line  20 . Once again, the printhead data being loaded into print line  20  is offset by two scan lines from the printhead data being loaded into print line  16  because print line  20  is spatially offset from print line  16  by two scan lines. Alternatively, as mentioned above, the print line  20  may be checked before being used and, if found to be defective, the printer may be disabled. 
     After the data bit for the first printing element has been programmed, the program checks at  296  to determine if the printing element index N is equal to N MAX . As before, N MAX  corresponds to the final printing element of the printhead  12 . After the initial pass through steps  280 - 292 , N will not be equal to N MAX  so that the program will increment N by 1 at  298  and return to  286  to program the next printing element of the printhead  12 . When the final printing element has been programmed, the program will progress from  296  to  300 . At that point, all of the printing element of the printhead  12  that are to be used in printing an image have been programmed. At step  300 , the microprocessor  202  programs the counter/timer so that it can generate an appropriate strobe signal when triggered. However, the counter/timer  206  is not triggered until  302  when the microprocessor  202  generates an appropriate strobe signal. The program then causes the microprocessor to output a paper advance pulse at  304  on an output line  320  of the microprocessor  202 . This pulse causes other portions of the printer not forming part of this invention to advance the print media pass the printhead  12  by a distance equal to the distance between adjacent print lines  16 - 20 . The program then checks at  308  to determine if the image has been completely printed. If not, the scan line index M is incremented by 1 and N is set to 0 at  310 , and the program returns to  286  to program the printing elements of the print lines  16 - 20 . As mentioned above, because of the spatial offset between the print lines  16 - 20 , the printing elements of print line  16  will be programmed with the incremented value of scan line M, while the printing elements of print line  18  will be programmed with printhead data from scan line M- 1  and the printing elements of print line  20  will be programmed with printhead data from scan line M- 2 . When the program determines at  308  that the image has been completely printed, the program returns to  282  to generate and store printhead data for the next image to be printed, as explained above. 
     The inventive printhead control system of FIGS. 12 and 13A is thus able to continue operating despite the failure of the same printing element in up to two different print lines.

Technology Classification (CPC): 1