Print head pre-alignment systems and methods
View Patent ↗Systems and methods for pre-aligning print head(s) to alignment adapter(s) to increase print resolution of printed matter, and to reduce offline time of a printing system due to print head alignment, include the use of an alignment adapter to which a print head is pre-aligned and which includes precision alignment features which precisely engage cooperating precision alignment features on the print head carriage mounting plate of the print head carriage. Print head(s) can be pre-aligned and fine-tuned to alignment adapter(s) even while the printing system is still in print production. Pre-aligned print head/alignment adapter assemblies can then be quickly mounted on the print head carriage using the cooperating precision alignment features of the adapter and print head carriage mounting plate. Duplicate sets of print head mounting sockets can include print heads aligned at different relative offsets (e.g., half a pixel) to increase the print resolution.
1. A method for pre-aligning a print head to an alignment adapter, the print head comprising a plurality of nozzles through which ink is ejected during printing, comprising:
placing a print head in a predetermined position on the alignment adapter;
obtaining a camera image of the print head nozzles relative to one or more features of the alignment adapter;
locating a first nozzle in the image;
locating a first row of nozzles in the image of the print head nozzles;
adjusting a position of the print head to align a first nozzle of the print head to a target position based on image feedback showing changes to the position of the first nozzle of the print head based on the positional adjustments;
adjusting a rotational angle of the print head to align the first row of nozzles to a target angle based on image feedback showing changes to the position of the first nozzle of the print head based on the positional adjustments.
2. The method of claim 1 , further comprising:
locating a plurality of additional nozzles in the image;
performing linear regression based on positions of the first nozzle and plurality of additional nozzles to locate the first row of nozzles in the image.