Single motor dynamic ribbon feedback system for a printer

Description

FIELD OF THE INVENTION

The present invention relates to controlling the forces on a print ribbon in a printer, especially, but not limited to ribbons employed in thermal transfer printers.

BACKGROUND

Generally speaking changes in ribbon forces will dramatically affect the print registration ability of any thermal transfer printer. This is easily observed especially when the ribbon diameter changes from a fresh ribbon roll to an empty roll. Having the ability to control the ribbon tension dynamically as the diameter of ribbon changes greatly improves the print registration capability.

There are printers with the ability to control the ribbon tension dynamically. Usually this is accomplished by using an individual DC motor on each of the ribbon rewind and ribbon supply spindles with a two-encoder feedback system. Print precision on these performance class printers is excellent. However, having two motors affects final product cost and system complication.

Therefore, a need exists for a printer where the ribbon tension can be controlled using a single motor.

SUMMARY

Accordingly, in one aspect, the present invention embraces a printer for printing media.

In an exemplary embodiment, the printer comprises a rotatable ribbon supply spindle; a rotatable take-up ribbon spindle; at least one sensor that outputs ribbon width and diameter of a ribbon loaded on the rotatable ribbon supply spindle; and a sensor which outputs ribbon diameter on the ribbon loaded on the rotatable take-up ribbon spindle. The printer is comprised of a drive system configured to rotate the rotatable take-up ribbon spindle. The drive system provides rotation to the rotatable ribbon supply via tension on the ribbon loaded on the rotatable ribbon supply spindle and taken-up on the rotatable take-up ribbon spindle. The printer is also provided with firmware. The firmware is communicatively linked to the at least one sensor for determining ribbon width and diameter of the ribbon loaded on the rotatable ribbon supply spindle, and communicatively linked to the sensor for determining ribbon diameter on the ribbon loaded on the rotatable take-up ribbon spindle. The firmware is further communicatively linked to the drive system. The firmware is configured to calculate ribbon tension at the ribbon supply spindle from the output of the at least one sensor on the rotatable ribbon supply spindle. The firmware is further configured to calculate the torque required on the ribbon on the rotatable ribbon take-up spindle to match the ribbon tension at the take-up spindle to the ribbon tension at the rotatable ribbon supply spindle based upon the calculated total tension at the rotatable ribbon supply spindle and the output from the sensor on the ribbon take-up spindle. The firmware being configured to adjust the drive system so that the torque at the rotatable take-up spindle is the calculated torque required to match the ribbon tension at the rotatable ribbon take-up spindle to the ribbon tension at the rotatable ribbon supply spindle.

In another exemplary embodiment, the at least one sensor that outputs ribbon width and diameter of a ribbon loaded on the rotatable ribbon supply spindle is comprised of an encoder sensor that outputs the diameter of the ribbon loaded on the rotatable ribbon supply spindle and a second sensor that outputs the width of the ribbon loaded on the rotatable ribbon supply spindle. The encoder sensor is disposed on a base of the rotatable ribbon supply spindle. The second sensor is disposed on the rotatable ribbon supply spindle.

In another exemplary embodiment, the ribbon width is proportional to the torque at the rotatable ribbon supply spindle.

In another exemplary embodiment, the encoder sensor rotates with the rotatable supply spindle. The encoder sensor having a rotation rate proportional to the radius of the ribbon loaded on the rotatable ribbon supply spindle. The encoder sensor on the ribbon supply spindle is configured to determine the rotation rate based upon a number of encoder interrupts for a given period.

In another exemplary embodiment of the printer, the sensor which outputs ribbon diameter on the ribbon loaded on the rotatable take-up ribbon spindle is an encoder sensor that rotates with the rotatable ribbon take-up spindle. The encoder sensor at the rotatable ribbon take-up spindle has a rotation rate proportional to the ribbon radius at the rotatable ribbon take-up spindle. The encoder sensor at the rotatable ribbon take-up spindle is configured determine the rotation rate based upon a number of encoder interrupts for a given period.

In yet another exemplary embodiment, the firmware calculation for ribbon tension at the rotatable ribbon supply spindle is SRT/SRR, where SRT is the torque at the supply ribbon spindle, and SRR is the supply ribbon radius.

In another exemplary embodiment, the firmware calculation of torque on the ribbon on the rotatable ribbon take-up spindle required to match the ribbon tension at the take-up spindle to the ribbon tension at the rotatable ribbon supply spindle is (SRT/SRR)*TRR, where TRR is the radius of the ribbon at the rotatable ribbon take-up spindle.

In another exemplary embodiment, the drive system is an electronic motor. The firmware is configured to adjust current to the motor so that the torque at the rotatable take-up spindle is the calculated torque required to match the ribbon tension at the rotatable ribbon take-up spindle to the ribbon tension at the rotatable ribbon supply spindle.

In yet another exemplary embodiment, the printer further includes spring wraps on the rotatable ribbon supply spindle. The spring wraps provide torque to the ribbon on the rotatable ribbon supply spindle.

In yet another exemplary embodiment, the firmware is configured to periodically adjust the drive system based upon periodic calculations of the torque on the ribbon on the rotatable ribbon take-up spindle required to match the ribbon tension at the take-up spindle to the ribbon tension at the rotatable ribbon supply spindle based upon the calculated total tension at the rotatable ribbon supply spindle and the output from the sensor on the ribbon take-up spindle.

In another aspect, the present invention embraces a printer with a dynamic ribbon feedback system.

In an exemplary embodiment, the printer comprises a rotatable ribbon supply spindle; an encoder sensor for determining the diameter of a ribbon loaded on the ribbon supply spindle; a sensor for determining width of the ribbon loaded on the ribbon supply spindle; a rotatable ribbon take-up spindle for taking up the ribbon; an encoder sensor on the ribbon take-up spindle for determining the diameter of the ribbon on the take-up spindle; and a drive system configured to rotate the ribbon take-up spindle. The drive system is powered by an electric power supply. The drive system further provides rotation to the rotatable ribbon supply spindle via tension on a ribbon loaded on the rotatable ribbon supply spindle and taken-upon the rotatable take-up ribbon spindle. The printer further comprises firmware which is communicatively linked to receive sensor outputs from the encoder sensor on the ribbon supply spindle, the sensor for determining ribbon width, and the encoder sensor on the ribbon take-up spindle. The firmware is configured to determine torque in the ribbon at the supply spindle based upon the output from the sensor for determining width of the ribbon on the ribbon supply spindle. The firmware is configured to calculate the total tension in the ribbon supply based upon the torque determined at in the ribbon at the supply spindle and based upon the output from the encoder sensor on the ribbon supply spindle. The firmware calculation is: SRT/SRR, where SRT is Supply Ribbon Torque and SRR is Supply Ribbon Radius. The firmware is further configured to calculate the torque in the rotatable ribbon take-up spindle required to match the ribbon tension in the take-up spindle to the ribbon tension in the supply spindle based upon the calculated total tension in the ribbon supply and the output from the encoder sensor on the ribbon take-up spindle. The firmware calculation is: (SRT/SRR)*TRR, where TRR is the radius of the ribbon at the take-up spindle. The firmware is communicatively linked to the electric power supply and configured to control current supplied to the drive system. The current is proportional to a rate of rotation of the drive system and the take-up spindle. The firmware is further configured to adjust the current supplied to the drive system so that the torque at the take-up spindle is the calculated torque required to match the ribbon tension in the take-up spindle to the ribbon tension in the supply spindle.

In another exemplary embodiment, the printer further comprises spring wraps on the rotatable ribbon supply spindle. The spring wraps secure the ribbon on the rotatable ribbon supply spindle.

In another exemplary embodiment, the ribbon width is proportional to the torque at the rotatable ribbon supply spindle.

In another exemplary embodiment, the rotatable ribbon supply spindle is comprised of multiple segments. The first segment of the multiple segments is adjacent to a base. Each subsequent segment of the multiple segments being adjacent to the previous segment of the multiple segments. The sensor for determining ribbon width is comprised of a commutator disposed circumferentially on the first segment of the spindle; at least two brushes connected to a voltage source and disposed generally on either side of and in electrical contact the commutator. The voltage source, the brushes, and the commutator form a closed electrical circuit. The sensor further comprises a c-shaped conductive spring disposed on each of the multiple segments. The c-shaped conductive spring has two ends and a center portion. The c-shaped conductive springs are in an uncompressed state in the absence of a printer ribbon over the one or more c-shaped conductive springs. The c-shaped conductive springs are in a compressed state in the presence of a printer ribbon positioned over the one or more c-shaped conductive springs. The c-shaped conductive spring on each segment of the multiple segments has a length such that when the c-shaped conductive spring is in the compressed state, the two ends of the c-shaped conductive spring make electrical contact with the commutator or the c-shaped conductive spring of a previous segment completing an additional electrical circuit in parallel with the closed electrical circuit. The sensor further includes a resistor. The resister is disposed proximate to the center portions of each of the c-shaped conductive springs and in electrical contact with the center portion of the c-shaped conductive springs. Also provided is a resistance meter. The resistance meter is connected to the closed electrical circuit, such that the reading on the meter indicates how many additional parallel circuits are completed; the number of additional parallel circuits completed indicating the approximate ribbon width.

In another exemplary embodiment, the encoder sensor on the rotatable ribbon supply spindle is disposed on the base of the rotatable ribbon supply spindle and rotates with the rotatable ribbon supply spindle. The encoder sensor rotation rate is proportional to the ribbon radius. The encoder sensor on the ribbon supply spindle is configured to determine the rotation rate based upon a number of encoder interrupts for a given period.

In yet another exemplary embodiment, the encoder sensor on the ribbon take-up spindle has a rotation rate proportional to the ribbon radius. The encoder sensor on the ribbon take-up spindle is configured to determine the rotation rate based upon a number of encoder interrupts for a given period.

In another aspect, the present invention embraces a method of controlling ribbon tension on a printer of the type a rotatable ribbon supply spindle, a rotatable ribbon take-up spindle, and a motor driving the ribbon take-up spindle.

In an exemplary embodiment, the method includes the steps of: sensing the diameter of the ribbon on the ribbon supply spindle; sensing the ribbon width on the ribbon supply spindle; calculating tension on the ribbon at the ribbon supply spindle, the tension based upon the first and second sensing steps; sensing the ribbon diameter of the ribbon at ribbon take-up spindle; calculating the torque required to match tensions between the ribbon supply and the ribbon take-up based upon the first calculating step and the third sensing step; and adjusting the motor driving the ribbon take-up spindle to supply the required torque found in the second calculating step.

In another exemplary embodiment of the method, the first calculating step is accomplished with firmware. The first calculating step is comprised of the steps of: receiving information about the diameter of the ribbon on the ribbon supply spindle from the first sensing step; receiving information about the width of the ribbon on the ribbon supply spindle from the second sensing step; converting the information about the width of the ribbon into a torque; and dividing the torque by the ribbon radius derived from the information about diameter or the ribbon to obtain a supply ribbon tension.

In another exemplary embodiment of the method, the second calculating step is accomplished with the firmware. The second calculating step is comprised of the steps of: receiving information about the diameter of the ribbon on the take-up spindle from the third sensing step; and multiplying the ribbon radius on the take-up spindle by the supply ribbon tension.

In yet another exemplary embodiment of the method, the adjusting step is accomplished with the firmware. The firmware is configured to control current supplied to the motor.

The foregoing illustrative summary, as well as other exemplary objectives and/or advantages of the invention, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically depicts an exemplary embodiment of a front view of the printer in accordance with the present invention.

FIG. 2 schematically depicts an exemplary embodiment of a back view of the printer in accordance with the present invention.

FIG. 3 schematically depicts an exemplary embodiment of a ribbon supply spindle and the sensor for determining supply ribbon width in accordance with the present invention.

FIG. 4 schematically depicts an exemplary embodiment of the base of the ribbon supply spindle and the sensor for determining supply spindle diameter depicted in FIG. 3 in accordance with the present invention.

FIG. 5 schematically depicts an exemplary embodiment of the communicative links between the firmware, the supply ribbon spindle sensors, the ribbon rewind sensor, and the ribbon rewind drive system in accordance with the present invention.

FIG. 6 schematically depicts in a flow chart an exemplary embodiment of the firmware functions to match supply ribbon torque and rewind ribbon torque in accordance with the present invention.

FIG. 7 schematically depicts in a flow chart, a method of controlling ribbon tension on a printer in accordance with the present invention.

FIG. 8 schematically depicts in a flow chart, the first calculating step of the method of controlling ribbon tension on a printer of FIG. 7 in accordance with the present invention.

FIG. 9 schematically depicts in a flow chart, the second calculating step of the method of controlling ribbon tension on a printer of FIG. 7 in accordance with the present invention.

DETAILED DESCRIPTION

The present invention embraces a printer with a single motor system to match torques between ribbon supply and ribbon take-up.

FIGS. 1 and 2 depict a front and back view of a printer in accordance with an exemplary embodiment of the invention. Referring to the FIG. 1, a printer (100) is provided with a rotatable ribbon supply spindle (200) and a rotatable take-up ribbon spindle (400). A media holder (120) with width adjustment (130) and print mechanism (140) is provided.

Looking at FIG. 2, the printer includes a drive system (420) configured to rotate the rotatable take-up ribbon spindle (400). The drive system (420) further provides rotation to the rotatable ribbon supply (200) via tension on a ribbon loaded on the rotatable ribbon supply spindle (200) and taken-up on the rotatable take-up ribbon spindle (400). The drive system (420) is a single motor which can provide rotation to the take-up spindle (400) via gear mechanisms as shown or by other means known in the art. For example, the drive system 420) is preferably an electric motor.

A sensor (410) which outputs ribbon diameter on the ribbon loaded on the rotatable take-up ribbon spindle (400) is part of the drive system (420).

In an exemplary embodiment, the sensor (410) which outputs ribbon diameter on the ribbon loaded on the rotatable take-up ribbon spindle (400) is an encoder sensor that rotates with the rotatable ribbon take-up spindle (400). The encoder sensor (410) has a rotation rate proportional to the ribbon radius at the rotatable ribbon take-up spindle (400). The encoder sensor (410) is configured to determine the rotation rate based upon a number of encoder interrupts for a given period.

FIGS. 3 and 4 depict details of the ribbon supply spindle (200). The ribbon supply spindle (200) shown in FIG. 3 is comprised of a base (205) and multiple segments, 210a-210d, although more or less segments are possible. The Figure shows a ribbon (140) loaded onto the ribbon supply spindle (200). The ribbon (140) only covers two segments, (210a-210b) of the ribbon supply spindle (200). The segments should preferably be of equal length, for example, each segment (210a-210d) could be 1 inch. Each segment (210a-210d) is provided with spring wraps (260a-260d). Each spring wrap (260a-260d) provides an equal amount of torque to the ribbon (140) loaded over the corresponding segments. For example, a spring wrap on each segment could provide 20 N-m (Newton-meters) of torque for each segment a ribbon is loaded on. Using this example, in FIG. 3, the ribbon (140) covers two segments (210a and 210b) with spring wraps (260a and 260b), thus providing 40 N-m of torque to the ribbon (140).

The printer (100) includes a sensor which outputs the width and diameter of the ribbon loaded on the ribbon supply spindle (200). In the exemplary embodiment depicted in FIGS. 1-4, the sensor is two sensors. The sensor outputting the diameter of the ribbon can be seen in FIG. 4. The ribbon diameter sensor is an encoder sensor (250), that is preferably a rotary encoder, disposed on the base (205) of the ribbon supply spindle (200). The encoder sensor (250) has a rotation rate proportional to the half the diameter (or the radius) of the ribbon (140) loaded on the ribbon supply spindle (200). The encoder sensor (250) is configured to determine the rotation rate and therefore the ribbon diameter, based upon a number of encoder interrupts in a given rotation period.

A sensor that outputs a ribbon width when the ribbon is loaded on the rotatable ribbon supply spindle (200) is comprised of several components, some of which are depicted in FIG. 3, and some of which are best depicted in FIG. 4. Referring to FIG. 4, the sensor is comprised, in part, of a commutator in two parts (310a and 310b) which is disposed circumferentially on the base (205) proximate to the first segment (210a) of the supply spindle (200). Two brushes (320a, 320b) are in electrical contact with corresponding commutator sections (310a and 310b) and are connected to a voltage source (330). Referring now back to FIG. 3, the sensor further comprises c-shaped conductive springs (340a-340h) disposed on each of the segments (210a-210h). One c-shaped conductive spring corresponds to each segment (210a-210h) of the ribbon supply spindle (200). Each c-shaped conductive spring (340a-340d) has two ends and a center portion. The c-shaped conductive springs (340a-340d) are in an uncompressed state in the absence of a printer ribbon loaded onto the ribbon supply spindle (200). The c-shaped conductive springs (340a-340d) are in a compressed state when a printer ribbon is positioned over one or more of the c-shaped conductive springs (340a-340d). That is, if the printer ribbon is the length of two segments, then c-shaped conductive springs (340a) and (340b) will be in a compressed state.

Each of the c-shaped conductive spring (340a-340d) on each segment (210a-210d) of the multiple segments has a length such that when the c-shaped conductive spring (340a-340d) is in the compressed state, the two ends of the c-shaped conductive spring (340a-340d) make electrical contact with the commutator (310a and 310b) or the c-shaped conductive spring of a previous segment, therefore completing an additional electrical circuit in parallel with the closed electrical circuit.

Each of the center portions of the c-shaped conductive springs (340a-340d) includes a resistive element (343a-343d) which forms part of the conductive path in the c-shaped conductive springs (340a-340d). A resistance meter (not shown) may be connected to the closed electrical circuit, such that the reading on the meter indicates how many additional parallel circuits are completed. The number of additional parallel circuits completed indicates the approximate ribbon width.

It is to be understood that even if a ribbon only covers a portion of the segment (210a-210d), the sensor cannot distinguish between partial segments and full segments. Therefore, if for example, each segment is one inch long, and a ribbon is loaded on the ribbon supply spindle which is 1.25 inches, the ribbon width sensor will output a 2 inch width ribbon. Because the width of the ribbon on the supply spindle will be used to help match torques between the supply spindle and the take-up spindle, potential errors due to partial segment coverage by the ribbon is possible. However, any error caused by this will be within the objective of matching torques between supply and take-up.

The printer, in accordance with exemplary embodiments of the present invention includes firmware. FIG. 5 depicts the relationship between the firmware and other printer components.

Referring to FIG. 5, firmware (500) may be contained in a central processing unit (CPU) (590) on the printer or a similar control entity as is known in the art. The firmware is communicatively linked to the sensor for determining ribbon width (300) and the encoder sensor for determining ribbon diameter (250) of the ribbon loaded on the rotatable ribbon supply spindle (200). The firmware (500) is also communicatively linked to the sensor for determining ribbon diameter (410) on the ribbon loaded on the take-up ribbon spindle (400). Finally, the firmware (500) is communicatively linked to the drive system (420).

FIG. 6 depicts an exemplary embodiment of the firmware (500) functions in flow chart form. The firmware (500) is configured to (510) receive the ribbon width sensor output on the supply spindle and correlate the width to supply ribbon torque (SRT). The firmware (500) is configured also (520) to receive the ribbon diameter sensor output on the supply spindle, correlating encoder interrupts to diameter of the ribbon and thus interpolating to get the supply ribbon radius (SRR). The firmware (500) is configured then (530) to calculate tension at the ribbon supply spindle by dividing SRT/SRR. The firmware (500) is further configured (540) to receive the output of the ribbon diameter sensor at the take-up spindle, correlating encoder interrupts to ribbon diameter and interpolating to determine rewind (take-up) ribbon radius (TRR). The firmware (500) is further configured to (550) calculate the torque required at ribbon take-up to match the torque at ribbon supply by: (SRT/SRR)*TRR. Finally, the firmware (500) is configured to (560) adjust the current in the drive system, the drive system comprising an electric motor as described hereinbefore, to match the take-up ribbon torque to the supply ribbon torque.

The present invention also embraces a method of controlling ribbon tension on a printer, such as a printer described hereinbefore in conjunction with FIGS. 1-6.

In an exemplary embodiment, referring to FIG. 7, the method (600) comprises the steps of: (610) sensing the diameter of the ribbon on the ribbon supply spindle; (620) sensing the ribbon width on the ribbon supply spindle; (630) calculating tension on the ribbon at the ribbon supply spindle, the tension based upon the first and second sensing steps; (640) sensing the ribbon diameter of the ribbon at ribbon take-up spindle; (650) calculating the torque required to match tensions between the ribbon supply and the ribbon take-up based upon the first calculating step and the third sensing step; and (660) adjusting the motor driving the ribbon take-up spindle to supply the required torque found in the second calculating step.

Referring now to FIG. 8, the first calculating step (630) from FIG. 7, comprises the steps of: (631) receiving information about the diameter of the ribbon on the ribbon supply spindle from the first sensing step; (632) receiving information about the width of the ribbon on the ribbon supply spindle from the second sensing step; (633) converting the information about the width of the ribbon into a torque; and (634) dividing the torque by the ribbon radius derived from the information about diameter or the ribbon to obtain a supply ribbon tension. The first calculating step (630) is preferably accomplished with firmware provided to the printer as described hereinbefore.

Referring now to FIG. 9, the second calculating step (650) is comprised of the steps of: (651) receiving information about the diameter of the ribbon on the take-up spindle from the third sensing step; and (652) multiplying the ribbon radius on the take-up spindle by the supply ribbon tension. The second calculating step (650) is also accomplished with firmware provided to the printer.

Thus, the method (600) as described in conjunction with FIGS. 7-9 allows the printer to match ribbon torque and tensions between the ribbon supply spindle and the ribbon take-up spindle by adjusting the current to the drive system.

To supplement the present disclosure, this application incorporates entirely by reference the following commonly assigned patents, patent application publications, and patent applications:

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In the specification and/or figures, typical embodiments of the invention have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation.