U.S. patent application number 11/778569 was filed with the patent office on 2007-12-20 for method of manufacturing printhead modules for combination as pagewidth printhead.
This patent application is currently assigned to Silverbrook Research Pty Ltd. Invention is credited to Richard Thomas Plunkett, Mark Jackson Pulver, John Robert Sheahan, Kia Silverbrook, Simon Robert Walmsley, Michael John Webb.
Application Number | 20070289131 11/778569 |
Document ID | / |
Family ID | 36315861 |
Filed Date | 2007-12-20 |
United States Patent
Application |
20070289131 |
Kind Code |
A1 |
Silverbrook; Kia ; et
al. |
December 20, 2007 |
Method Of Manufacturing Printhead Modules For Combination As
Pagewidth Printhead
Abstract
A method of manufacturing printhead modules which can be
combined to form a pagewidth printhead is provided which includes
laying out each of the printhead modules on a wafer substrate to be
either right-handed or left-handed. At least one of the printhead
modules is larger than a reticle step used in laying out that
printhead module.
Inventors: |
Silverbrook; Kia; (Balmain,
AU) ; Pulver; Mark Jackson; (Balmain, AU) ;
Walmsley; Simon Robert; (Balmain, AU) ; Webb; Michael
John; (Balmain, AU) ; Plunkett; Richard Thomas;
(Balmain, AU) ; Sheahan; John Robert; (Balmain,
AU) |
Correspondence
Address: |
SILVERBROOK RESEARCH PTY LTD
393 DARLING STREET
BALMAIN
2041
AU
|
Assignee: |
Silverbrook Research Pty
Ltd
|
Family ID: |
36315861 |
Appl. No.: |
11/778569 |
Filed: |
July 16, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10854487 |
May 27, 2004 |
7281330 |
|
|
11778569 |
Jul 16, 2007 |
|
|
|
Current U.S.
Class: |
29/890.1 |
Current CPC
Class: |
Y10T 29/49128 20150115;
B41J 2/145 20130101; Y10T 29/49156 20150115; Y10T 29/49401
20150115; Y10T 29/49155 20150115; Y10T 29/4913 20150115 |
Class at
Publication: |
029/890.1 |
International
Class: |
B21D 53/76 20060101
B21D053/76 |
Claims
1. A method of manufacturing printhead modules which can be
combined to form a pagewidth printhead, the method comprising the
step of laying out each of the printhead modules on a wafer
substrate to be either right-handed or left-handed, at least one of
the printhead modules being larger than a reticle step used in
laying out that printhead module.
2. A method according to claim 1, further comprising assembling
pairs of the printhead modules to form pagewidth printheads, each
of the printhead modules in pair being shorter than the
pagewidth.
3. A method according to claim 2, wherein the printhead modules of
at least one of the pagewidth printheads are of relatively
different lengths.
4. A method according to claim 2, wherein the printhead modules of
at least one of the pagewidth printheads are of the same
length.
5. A method according to claim 2, wherein the printhead modules of
at least one of the pagewidth printheads are of relatively
different lengths, and the printhead modules of at least another of
the pagewidth printheads are of the same length.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser.
No. 10/854,487 filed on May 27, 2004 all of which are herein
incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a printhead having
printhead module for use in a printer. The invention has primarily
been developed for use in a pagewidth inkjet printer, comprising a
printhead that includes one or more of the printhead modules, and
will be described with reference to this example. However, it will
be appreciated that the invention is not limited to any particular
type of printing technology, and is not limited to use in, for
example, pagewidth and inkjet printing.
CO-PENDING APPLICATIONS
[0003] TABLE-US-00001 10/854521 10/854522 10/854488 10/854487
10/854503 10/854504 10/854509 7188928 7093989 10/854497 10/854495
10/854498 10/854511 10/854512 10/854525 10/854526 10/854516
10/854508 10/854507 10/854515 10/854506 10/854505 10/854493
10/854494 10/854489 10/854490 10/854492 10/854528 10/854523
10/854527 10/854524 10/854520 10/854514 10/854519 10/854513
10/854499 10/854501 10/854500 10/854502 10/854518 10/854517
[0004] The disclosures of these co-pending applications are
incorporated herein by cross-reference. Various methods, systems
and apparatus relating to the present invention are disclosed in
the following co-pending applications filed by the applicant or
assignee of the present invention. The disclosures of all of these
co-pending applications are incorporated herein by cross-reference.
TABLE-US-00002 09/517539 6566858 6331946 6246970 6442525 09/517384
09/505951 6374354 09/517608 6816968 6757832 6334190 6745331
09/517541 10/636263 10/636283 10/407212 10/407207 10/683064
10/683041 10/727181 10/727162 10/727163 10/727245 7121639 7165824
7152942 10/727157 7181572 7096137 10/727257 10/727238 7188282
10/727159 10/727180 10/727179 10/727192 10/727274 10/727164
10/727161 10/727198 10/727158 10/754536 10/754938 10/727227
10/727160 6795215 6859289 6977751 6398332 6394573 6622923 6747760
6921144 10/780624 7194629 10/791792 7182267 7025279 6857571 6817539
6830198 6992791 7038809 6980323 7148992 7139091 6947173
BACKGROUND OF THE INVENTION
[0005] Manufacturing a printhead that has relatively high
resolution and print-speed raises a number of problems.
[0006] Difficulties in manufacturing pagewidth printheads of any
substantial size arise due to the relatively small dimensions of
standard silicon wafers that are used in printhead (or printhead
module) manufacture. For example, if it is desired to make an
8-inch wide pagewidth printhead, only one such printhead can be
laid out on a standard 8-inch wafer, since such wafers are circular
in plan. Manufacturing a pagewidth printhead from two or more
smaller modules can reduce this limitation to some extent, but
raises other problems related to providing a joint between adjacent
printhead modules that is precise enough to avoid visible artefacts
(which would typically take the form of noticeable lines) when the
printhead is used. The problem is exacerbated in relatively
high-resolution applications because of the tight tolerances
dictated by the small spacing between nozzles.
[0007] The quality of a joint region between adjacent printhead
modules relies on factors including a precision with which the
abutting ends of each module can be manufactured, the accuracy with
which they can be aligned when assembled into a single printhead,
and other more practical factors such as management of ink channels
behind the nozzles. It will be appreciated that the difficulties
include relative vertical displacement of the printhead modules
with respect to each other.
[0008] Whilst some of these issues may be dealt with by careful
design and manufacture, the level of precision required renders it
relatively expensive to manufacture printheads within the required
tolerances. It would be desirable to provide a solution to one or
more of the problems associated with precision manufacture and
assembly of multiple printhead modules to form a printhead, and
especially a pagewidth printhead.
SUMMARY OF THE INVENTION
[0009] In a first aspect the present invention provides method of
manufacturing printhead modules which can be combined to form a
pagewidth printhead, the method comprising laying out each of the
printhead modules on a wafer substrate to be either right-handed or
left-handed, at least one of the printhead modules being larger
than a reticle step used in laying out that printhead module.
[0010] In a second aspect the present invention provides a method
of manufacturing a plurality of pagewidth printheads, the method
comprising the steps of:
[0011] manufacturing a plurality of printhead modules in accordance
with claim 1; and
[0012] assembling pairs of at least some of the printhead modules
to form pagewidth printheads, wherein each of the printhead modules
in each pagewidth printhead is shorter than the pagewidth.
[0013] Optionally the printhead modules of at least one of the
pagewidth printheads are of relatively different lengths.
[0014] Optionally the printhead modules of at least one of the
pagewidth printheads are of the same length.
[0015] Optionally the printhead modules of at least one of the
pagewidth printheads are of relatively different lengths, and the
printhead modules of at least another of the pagewidth printheads
are of the same length.
[0016] Optionally at least some of the printhead modules are larger
than a reticle step used in laying out those printhead modules.
[0017] Optionally the method includes the step of laying out a
plurality of left-handed and right-handed printhead modules.
[0018] Optionally the method includes the step of laying out a
plurality of different lengths of left-handed and right-handed
printhead modules.
[0019] Optionally, the method at least partially compensating for
errors in ink dot placement by at least one of a plurality of
nozzles due to erroneous rotational displacement of a printhead
module relative to a carrier, the nozzles being disposed on the
printhead module, the method comprising the steps of:
(a) determining the rotational displacement;
(b) determining at least one correction factor that at least
partially compensates for the ink dot displacement; and
(c) using the correction factor to alter the output of the ink dots
to at least partially compensate for the rotational
displacement.
[0020] Optionally, the method including expelling ink from a
printhead module including at least one row that comprises a
plurality of adjacent sets of n adjacent nozzles, each of the
nozzles being configured to expel ink in response to a fire signal,
the method comprising providing, for each set of nozzles, a fire
signal in accordance with the sequence: [nozzle position 1, nozzle
position n, nozzle position 2, nozzle position (n-1), . . . ,
nozzle position x], wherein nozzle position x is at or adjacent the
centre of the set of nozzles.
[0021] Optionally, the method including expelling ink from a
printhead module including at least one row that comprises a
plurality of sets of n adjacent nozzles, each of the nozzles being
configured to expel ink in response to a fire signal, the method
comprising the steps of:
(a) providing a fire signal to nozzles at a first and nth position
in each set of nozzles;
(b) providing a fire signal to the next inward pair of nozzles in
each set;
(c) in the event n is an even number, repeating step (b) until all
of the nozzles in each set has been fired; and
(d) in the event n is an odd number, repeating step (b) until all
of the nozzles but a central nozzle in each set have been fired,
and then firing the central nozzle.
[0022] Optionally, the method being performed in conjunction with a
printhead module including:
[0023] at least one row of print nozzles;
[0024] at least two shift registers for shifting in dot data
supplied from a data source to each of the at least one rows,
wherein each print nozzle obtains dot data to be fired from an
element of one of the shift registers.
[0025] Optionally, the method being performed in a printer
comprising:
[0026] a printhead comprising at least a first elongate printhead
module, the at least one printhead module including at least one
row of print nozzles for expelling ink; and
[0027] at least first and second printer controllers configured to
receive print data and process the print data to output dot data to
the printhead, wherein the first and second printer controllers are
connected to a common input of the printhead.
[0028] Optionally, the method being performed in a printer
comprising:
[0029] a printhead comprising first and second elongate printhead
modules, the printhead modules being parallel to each other and
being disposed end to end on either side of a join region;
[0030] at least first and second printer controllers configured to
receive print data and process the print data to output dot data to
the printhead, wherein the first printer controller outputs dot
data only to the first printhead module and the second printer
controller outputs dot data only to the second printhead module,
wherein the printhead modules are configured such that no dot data
passes between them.
[0031] Optionally, the method being performed in a printer
comprising:
[0032] a printhead comprising first and second elongate printhead
modules, the printhead modules being parallel to each other and
being disposed end to end on either side of a join region, wherein
the first printhead module is longer than the second printhead
module;
[0033] at least first and second printer controllers configured to
receive print data and process the print data to output dot data to
the printhead, wherein: the first printer controller outputs dot
data to both the first printhead module and the second printhead
module; and the second printer controller outputs dot data only to
the second printhead module.
[0034] Optionally, the method being performed in a printer
comprising:
[0035] a printhead comprising first and second elongate printhead
modules, the printhead modules being parallel to each other and
being disposed end to end on either side of a join region, wherein
the first printhead module is longer than the second printhead
module;
[0036] at least first and second printer controllers configured to
receive print data and process the print data to output dot data
for the printhead, wherein: the first printer controller outputs
dot data to both the first printhead module and the second
controller; and the second printer controller outputs dot data to
the second printhead module, wherein the dot data output by the
second printer controller includes dot data it generates and at
least some of the dot data received from the first printer
controller.
[0037] Optionally, the method being performed in conjunction with a
printer controller for supplying dot data to at least one printhead
module and at least partially compensating for errors in ink dot
placement by at least one of a plurality of nozzles on the
printhead module due to erroneous rotational displacement of the
printhead module relative to a carrier, the printer being
configured to:
[0038] access a correction factor associated with the at least one
printhead module;
[0039] determine an order in which at least some of the dot data is
supplied to at least one of the at least one printhead modules, the
order being determined at least partly on the basis of the
correction factor, thereby to at least partially compensate for the
rotational displacement; and
[0040] supply the dot data to the printhead module.
[0041] Optionally, the method being performed in conjunction with a
printer controller for supplying dot data to a printhead module
having a plurality of nozzles for expelling ink, the printhead
module including a plurality of thermal sensors, each of the
thermal sensors being configured to respond to a temperature at or
adjacent at least one of the nozzles, the printer controller being
configured to modify operation of at least some of the nozzles in
response to the temperature rising above a first threshold.
[0042] Optionally, the method being performed in conjunction with a
printer controller for controlling a printhead comprising at least
one monolithic printhead module, the at least one printhead module
having a plurality of rows of nozzles configured to extend, in use,
across at least part of a printable pagewidth of the printhead, the
nozzles in each row being grouped into at least first and second
fire groups, the printhead module being configured to sequentially
fire, for each row, the nozzles of each fire group, such that each
nozzle in the sequence from each fire group is fired simultaneously
with respective corresponding nozzles in the sequence in the other
fire groups, wherein the nozzles are fired row by row such that the
nozzles of each row are all fired before the nozzles of each
subsequent row, wherein the printer controller is configured to
provide one or more control signals that control the order of
firing of the nozzles.
[0043] Optionally, the method being performed in conjunction with a
printer controller for outputting to a printhead module:
[0044] dot data to be printed with at least two different inks;
and
[0045] control data for controlling printing of the dot data;
[0046] the printer controller including at least one communication
output, each or the communication output being configured to output
at least some of the control data and at least some of the dot data
for the at least two inks.
[0047] Optionally, the method being performed in conjunction with a
printhead module including at least one row of printhead nozzles,
at least one row including at least one displaced row portion, the
displacement of the row portion including a component in a
direction normal to that of a pagewidth to be printed.
[0048] Optionally, the method being performed in conjunction with a
printer controller for supplying print data to at least one
printhead module capable of printing a maximum of n of channels of
print data, the at least one printhead module being configurable
into:
[0049] a first mode, in which the printhead module is configured to
receive data for a first number of the channels; and
[0050] a second mode, in which the printhead module is configured
to receive print data for a second number of the channels, wherein
the first number is greater than the second number; wherein the
printer controller is selectively configurable to supply dot data
for the first and second modes.
[0051] Optionally, the method being performed in conjunction with a
printer controller for supplying data to a printhead comprising a
plurality of printhead modules, the printhead being wider than a
reticle step used in forming the modules, the printhead comprising
at least two types of the modules, wherein each type is determined
by its geometric shape in plan.
[0052] Optionally, the method being used in conjunction with a
printer controller for supplying one or more control signals to a
printhead module, the printhead module including at least one row
that comprises a plurality of sets of n adjacent nozzles, each of
the nozzles being configured to expel ink in response to a fire
signal, such that:
(a) providing a fire signal to nozzles at a first and nth position
in each set of nozzles;
(b) providing a fire signal to the next inward pair of nozzles in
each set;
(c) in the event n is an even number, repeating step (b) until all
of the nozzles in each set has been fired; and
(d) in the event n is an odd number, repeating step (b) until all
of the nozzles but a central nozzle in each set have been fired,
and then firing the central nozzle.
[0053] Optionally, the method being used in conjunction with a
printer controller for supplying one or more control signals to a
printhead module, the printhead module including at least one row
that comprises a plurality of adjacent sets of n adjacent nozzles,
each of the nozzles being configured to expel ink in response to a
fire signal, the method comprising providing, for each set of
nozzles, a fire signal in accordance with the sequence: [nozzle
position 1, nozzle position n, nozzle position 2, nozzle position
(n-1), . . . , nozzle position x], wherein nozzle position x is at
or adjacent the centre of the set of nozzles.
[0054] Optionally, the method being performed in conjunction with a
printer controller for supplying dot data to a printhead module
comprising at least first and second rows configured to print ink
of a similar type or color, at least some nozzles in the first row
being aligned with respective corresponding nozzles in the second
row in a direction of intended media travel relative to the
printhead, the printhead module being configurable such that the
nozzles in the first and second pairs of rows are fired such that
some dots output to print media are printed to by nozzles from the
first pair of rows and at least some other dots output to print
media are printed to by nozzles from the second pair of rows, the
printer controller being configurable to supply dot data to the
printhead module for printing.
[0055] Optionally, the method being performed in conjunction with a
printer controller for supplying dot data to at least one printhead
module, the at least one printhead module comprising a plurality of
rows, each of the rows comprising a plurality of nozzles for
ejecting ink, wherein the printhead module includes at least first
and second rows configured to print ink of a similar type or color,
the printer controller being configured to supply the dot data to
the at least one printhead module such that, in the event a nozzle
in the first row is faulty, a corresponding nozzle in the second
row prints an ink dot at a position on print media at or adjacent a
position where the faulty nozzle would otherwise have printed
it.
[0056] Optionally, the method being performed in conjunction with a
printer controller for receiving first data and manipulating the
first data to produce dot data to be printed, the print controller
including at least two serial outputs for supplying the dot data to
at least one printhead, wherein each of the serial outputs is
configured to supply dot data for at least two channels of the at
least one printhead.
[0057] Optionally, the method being performed in conjunction with a
printhead module including:
at least one row of print nozzles;
[0058] at least first and second shift registers for shifting in
dot data supplied from a data source, wherein each shift register
feeds dot data to a group of nozzles, and wherein each of the
groups of the nozzles is interleaved with at least one of the other
groups of the nozzles.
[0059] Optionally, the method being performed in conjunction with a
printhead capable of printing a maximum of n of channels of print
data, the printhead being configurable into: a first mode, in which
the printhead is configured to receive print data for a first
number of the channels; and
[0060] a second mode, in which the printhead is configured to
receive print data for a second number of the channels, wherein the
first number is greater than the second number.
[0061] Optionally, the method being performed in conjunction with a
printhead comprising a plurality of printhead modules, the
printhead being wider than a reticle step used in forming the
modules, the printhead comprising at least two types of the
modules, wherein each type is determined by its geometric shape in
plan.
[0062] Optionally, the method being performed in conjunction with a
printhead module including at least one row that comprises a
plurality of sets of n adjacent nozzles, each of the nozzles being
configured to expel ink in response to a fire signal, such that,
for each set of nozzles, a fire signal is provided in accordance
with the sequence: [nozzle position 1, nozzle position n, nozzle
position 2, nozzle position (n-1), . . . , nozzle position x],
wherein nozzle position x is at or adjacent the centre of the set
of nozzles.
[0063] Optionally, the method being performed in conjunction with a
printhead module including at least one row that comprises a
plurality of adjacent sets of n adjacent nozzles, each of the
nozzles being configured to expel the ink in response to a fire
signal, the printhead being configured to output ink from nozzles
at a first and nth position in each set of nozzles, and then each
next inward pair of nozzles in each set, until:
[0064] in the event n is an even number, all of the nozzles in each
set has been fired; and
[0065] in the event n is an odd number, all of the nozzles but a
central nozzle in each set have been fired, and then to fire the
central nozzle.
[0066] Optionally, the method being performed in conjunction with a
printhead module for receiving dot data to be printed using at
least two different inks and control data for controlling printing
of the dot data, the printhead module including a communication
input for receiving the dot data for the at least two colors and
the control data.
[0067] Optionally, the method being performed in conjunction with a
printhead module including at least one row of printhead nozzles,
at least one row including at least one displaced row portion, the
displacement of the row portion including a component in a
direction normal to that of a pagewidth to be printed.
[0068] Optionally, the method being performed in conjunction with a
printhead module having a plurality of rows of nozzles configured
to extend, in use, across at least part of a printable pagewidth,
the nozzles in each row being grouped into at least first and
second fire groups, the printhead module being configured to
sequentially fire, for each row, the nozzles of each fire group,
such that each nozzle in the sequence from each fire group is fired
simultaneously with respective corresponding nozzles in the
sequence in the other fire groups, wherein the nozzles are fired
row by row such that the nozzles of each row are all fired before
the nozzles of each subsequent row.
[0069] Optionally, the method being performed in conjunction with a
printhead module comprising at least first and second rows
configured to print ink of a similar type or color, at least some
nozzles in the first row being aligned with respective
corresponding nozzles in the second row in a direction of intended
media travel relative to the printhead, the printhead module being
configurable such that the nozzles in the first and second pairs of
rows are fired such that some dots output to print media are
printed to by nozzles from the first pair of rows and at least some
other dots output to print media are printed to by nozzles from the
second pair of rows.
[0070] Optionally, the method being performed in conjunction with a
printer controller for providing data to a printhead module that
includes:
[0071] at least one row of print nozzles;
[0072] at least first and second shift registers for shifting in
dot data supplied from a data source, wherein each shift register
feeds dot data to a group of nozzles, and wherein each of the
groups of the nozzles is interleaved with at least one of the other
groups of the nozzles.
[0073] Optionally, the method being performed in conjunction with a
printhead module having a plurality of nozzles for expelling ink,
the printhead module including a plurality of thermal sensors, each
of the thermal sensors being configured to respond to a temperature
at or adjacent at least one of the nozzles, the printhead module
being configured to modify operation of the nozzles in response to
the temperature rising above a first threshold.
[0074] Optionally, the method being performed in conjunction with a
printhead module comprising a plurality of rows, each of the rows
comprising a plurality of nozzles for ejecting ink, wherein the
printhead module includes at least first and second rows configured
to print ink of a similar type or color, and being configured such
that, in the event a nozzle in the first row is faulty, a
corresponding nozzle in the second row prints an ink dot at a
position on print media at or adjacent a position where the faulty
nozzle would otherwise have printed it.
BRIEF DESCRIPTION OF THE DRAWINGS
[0075] FIG. 1. Single SoPEC A4 Simplex
[0076] FIG. 2. Dual SoPEC A4 Simplex system
[0077] FIG. 3. Dual SoPEC A4 Duplex system
[0078] FIG. 4. Dual SoPEC A3 simplex system
[0079] FIG. 5. Quad SoPEC A3 duplex system
[0080] FIG. 6. SoPEC A4 Simplex system with extra SoPEC used as
DRAM storage
[0081] FIG. 7. SoPEC A4 Simplex system with network connection to
Host PC
[0082] FIG. 8. Document data flow
[0083] FIG. 9. Pages containing different numbers of bands
[0084] FIG. 10. Contents of a page band
[0085] FIG. 11. Page data path from host to SoPEC
[0086] FIG. 12. Page structure
[0087] FIG. 13. SoPEC System Top Level partition
[0088] FIG. 14. Proposed SoPEC CPU memory map (not to scale)
[0089] FIG. 15. Possible USB Topologies for Multi-SoPEC systems
[0090] FIG. 16. CPU block diagram
[0091] FIG. 17. Printhead Nozzle Layout for conceptual 36 Nozzle AB
single segment printhead
[0092] FIG. 18. Paper and printhead nozzles relationship (example
with D.sub.1=D.sub.2=5)
[0093] FIG. 19. Dot line store logical representation
[0094] FIG. 20. Conceptual view of 2 adjacent printhead segments
possible row alignment
[0095] FIG. 21. Conceptual view of 2 adjacent printhead segments
row alignment (as seen by the LLU)
[0096] FIG. 22. Even dot order in DRAM (13312 dot wide line)
[0097] FIG. 23. High level data flow diagram of LLU in context
[0098] FIG. 24. Paper and printhead nozzles relationship (example
with D.sub.1=D.sub.2=5)
[0099] FIG. 25. Conceptual view of vertically misaligned printhead
segment rows (external)
[0100] FIG. 26. Conceptual view of vertically misaligned printhead
segment rows (internal)
[0101] FIG. 27. Conceptual view of color dependent vertically
misaligned printhead segment rows (internal)
[0102] FIG. 28. Conceptual horizontal misalignment between
segments
[0103] FIG. 29. Relative positions of dot fired (example cases)
[0104] FIG. 30. PHI to linking printhead connection (Single
SOPEC)
[0105] FIG. 31. PHI to linking printhead connection (2 SoPECs)
[0106] FIG. 32. CPU command word format
[0107] FIG. 33. Example data and command sequence on a print head
channel
[0108] FIG. 34. PHI block partition
[0109] FIG. 35. Data generator state diagram
[0110] FIG. 36. PHI mode Controller
[0111] FIG. 37. Encoder RTL diagram
[0112] FIG. 38. 28-bit scrambler
[0113] FIG. 39. Printing with 1 SoPEC
[0114] FIG. 40. Printing with 2 SoPECs (existing hardware)
[0115] FIG. 41. Each SoPEC generates dot data and writes directly
to a single printhead
[0116] FIG. 42. Each SoPEC generates dot data and writes directly
to a single printhead
[0117] FIG. 43. Two SoPECs generate dots and transmit directly to
the larger printhead
[0118] FIG. 44. Serial Load
[0119] FIG. 45. Parallel Load
[0120] FIG. 46. Two SoPECs generate dot data but only one transmits
directly to the larger printhead
[0121] FIG. 47. Odd and Even nozzles on same shift register
[0122] FIG. 48. Odd and Even nozzles on different shift
registers
[0123] FIG. 49. Interwoven shift registers
[0124] FIG. 50. Linking Printhead Concept
[0125] FIG. 51. Linking Printhead 30 ppm
[0126] FIG. 52. Linking Printhead 60 ppm
[0127] FIG. 53. Theoretical 2 tiles assembled as
A-chip/A-chip-right angle join
[0128] FIG. 54. Two tiles assembled as A-chip/A-chip
[0129] FIG. 55. Magnification of color n in A-chip/A-chip
[0130] FIG. 56. A-chip/A-chip growing offset
[0131] FIG. 57. A-chip/A-chip aligned nozzles, sloped chip
placement
[0132] FIG. 58. Placing multiple segments together
[0133] FIG. 59. Detail of a single segment in a multi-segment
configuration
[0134] FIG. 60. Magnification of inter-slope compensation
[0135] FIG. 61. A-chip/B-chip
[0136] FIG. 62. A-chip/B-chip multi-segment printhead
[0137] FIG. 63. Two A-B-chips linked together
[0138] FIG. 64. Two A-B-chips with on-chip compensation
[0139] FIG. 65. Print construction and Nozzle position
[0140] FIG. 66. Conceptual horizontal misplacement between
segments
[0141] FIG. 67. Printhead row positioning and default row firing
order
[0142] FIG. 68. Firing order of fractionally misaligned segment
[0143] FIG. 69. Example of yaw in printhead IC misplacement
[0144] FIG. 70. Vertical nozzle spacing
[0145] FIG. 71. Single printhead chip plus connection to second
chip
[0146] FIG. 72. Two printheads connected to form a larger
printhead
[0147] FIG. 73. Colour arrangement.
[0148] FIG. 74. Nozzle Offset at Linking Ends
[0149] FIG. 75. Bonding Diagram
[0150] FIG. 76. MEMS Representation.
[0151] FIG. 77. Line Data Load and Firing, properly placed
Printhead,
[0152] FIG. 78. SimpleFire order
[0153] FIG. 79. Micro positioning
[0154] FIG. 80. Measurement convention
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
[0155] Various aspects of the preferred and other embodiments will
now be described.
[0156] Also throughout this description, "printhead module" and
"printhead" are used somewhat interchangeably. Technically, a
"printhead" comprises one or more "printhead modules", but
occasionally the former is used to refer to the latter. It should
be clear from the context which meaning should be allocated to any
use of the word "printhead".
[0157] The SoPEC ASIC (Small office home office Print Engine
Controller) is described which is suitable for use in price
sensitive SoHo printer products. The SoPEC ASIC is intended to be a
relatively low cost solution for linking printhead control,
replacing the multichip solutions in larger more professional
systems with a single chip. The increased cost competitiveness is
achieved by integrating several systems such as a modified PEC1
printing pipeline, CPU control system, peripherals and memory
sub-system onto one SoC ASIC, reducing component count and
simplifying board design. SoPEC contains features making it
suitable for multifunction or "all-in-one" devices as well as
dedicated printing systems.
[0158] Basic features of the preferred embodiment of SoPEC include:
[0159] Continuous 30 ppm operation for 1600 dpi output at
A4/Letter. [0160] Linearly scalable (multiple SoPECs) for increased
print speed and/or page width. [0161] 192 MHz internal system clock
derived from low-speed crystal input [0162] PEP processing
pipeline, supports up to 6 color channels at 1 dot per channel per
clock cycle [0163] Hardware color plane decompression, tag
rendering, halftoning and compositing [0164] Data formatting for
Linking Printhead [0165] Flexible compensation for dead nozzles,
printhead misalignment etc. [0166] Integrated 20 Mbit (2.5 MByte)
DRAM for print data and CPU program store [0167] LEON SPARC v8
32-bit RISC CPU [0168] Supervisor and user modes to support
multi-threaded software and security [0169] 1 kB each of I-cache
and D-cache, both direct mapped, with optimized 256-bit fast cache
update. [0170] 1.times.USB2.0 device port and 3.times.USB2.0 host
ports (including integrated PHYs) [0171] Support high speed (480
Mbit/sec) and full speed (12 Mbit/sec) modes of USB2.0 [0172]
Provide interface to host PC, other SoPECs, and external devices
e.g. digital camera [0173] Enable alternative host PC interfaces
e.g. via external USB/ethernet bridge [0174] Glueless high-speed
serial LVDS interface to multiple Linking Printhead chips [0175] 64
remappable GPIOs, selectable between combinations of integrated
system control components: [0176] 2.times.LSS interfaces for QA
chip or serial EEPROM [0177] LED drivers, sensor inputs, switch
control outputs [0178] Motor controllers for stepper and brushless
DC motors [0179] Microprogrammed multi-protocol media interface for
scanner, external RAM/Flash, etc. [0180] 112-bit unique ID plus
112-bit random number on each device, combined for security
protocol support [0181] IBM Cu-11 0.13 micron CMOS process, 1.5V
core supply, 3.3V IO. [0182] 208 pin Plastic Quad Flat Pack
[0183] The preferred embodiment linking printhead produces 1600 dpi
bi-level dots. On low-diffusion paper, each ejected drop forms a
22.5 .quadrature.m diameter dot. Dots are easily produced in
isolation, allowing dispersed-dot dithering to be exploited to its
fullest. Since the preferred form of the linking printhead is
pagewidth and operates with a constant paper velocity, color planes
are printed in good registration, allowing dot-on-dot printing.
Dot-on-dot printing minimizes `muddying` of midtones caused by
inter-color bleed.
[0184] A page layout may contain a mixture of images, graphics and
text. Continuous-tone (contone) images and graphics are reproduced
using a stochastic dispersed-dot dither. Unlike a clustered-dot (or
amplitude-modulated) dither, a dispersed-dot (or
frequency-modulated) dither reproduces high spatial frequencies
(i.e. image detail) almost to the limits of the dot resolution,
while simultaneously reproducing lower spatial frequencies to their
full color depth, when spatially integrated by the eye. A
stochastic dither matrix is carefully designed to be free of
objectionable low-frequency patterns when tiled across the image.
As such its size typically exceeds the minimum size required to
support a particular number of intensity levels (e.g.
16.quadrature.168 bits for 257 intensity levels).
[0185] Human contrast sensitivity peaks at a spatial frequency of
about 3 cycles per degree of visual field and then falls off
logarithmically, decreasing by a factor of 100 beyond about 40
cycles per degree and becoming immeasurable beyond 60 cycles per
degree. At a normal viewing distance of 12 inches (about 300 mm),
this translates roughly to 200-300 cycles per inch (cpi) on the
printed page, or 400-600 samples per inch according to Nyquist's
theorem.
[0186] In practice, contone resolution above about 300 ppi is of
limited utility outside special applications such as medical
imaging. Offset printing of magazines, for example, uses contone
resolutions in the range 150 to 300 ppi. Higher resolutions
contribute slightly to color error through the dither.
[0187] Black text and graphics are reproduced directly using
bi-level black dots, and are therefore not anti-aliased (i.e.
low-pass filtered) before being printed. Text should therefore be
supersampled beyond the perceptual limits discussed above, to
produce smoother edges when spatially integrated by the eye. Text
resolution up to about 1200 dpi continues to contribute to
perceived text sharpness (assuming low-diffusion paper).
[0188] A Netpage printer, for example, may use a contone resolution
of 267 ppi (i.e. 1600 dpi 6), and a black text and graphics
resolution of 800 dpi. A high end office or departmental printer
may use a contone resolution of 320 ppi (1600 dpi/5) and a black
text and graphics resolution of 1600 dpi. Both formats are capable
of exceeding the quality of commercial (offset) printing and
photographic reproduction.
[0189] The SoPEC device can be used in several printer
configurations and architectures.
[0190] In the general sense, every preferred embodiment SoPEC-based
printer architecture will contain: [0191] One or more SoPEC
devices. [0192] One or more linking printheads. [0193] Two or more
LSS busses. [0194] Two or more QA chips. [0195] Connection to host,
directly via USB2.0 or indirectly. [0196] Connections between
SoPECs (when multiple SoPECs are used).
[0197] The linking printhead is constructed by abutting a number of
printhead ICs together. Each SoPEC can drive up to 12 printhead ICs
at data rates up to 30 ppm or 6 printhead ICs at data rates up to
60 ppm. For higher data rates, or wider printheads, multiple SoPECs
must be used.
[0198] In a multi-SoPEC system, the primary communication channel
is from a USB2.0 Host port on one SoPEC (the ISCMaster), to the
USB2.0 Device port of each of the other SoPECs (ISCSlaves). If
there are more ISCSlave SoPECs than available USB Host ports on the
ISCMaster, additional connections could be via a USB Hub chip, or
daisy-chained SoPEC chips. Typically one or more of SoPEC's GPIO
signals would also be used to communicate specific events between
multiple SoPECs.
[0199] In FIG. 1, a single SoPEC device is used to control a
linking printhead with 11 printhead ICs. The SoPEC receives
compressed data from the host through its USB device port. The
compressed data is processed and transferred to the printhead. This
arrangement is limited to a speed of 30 ppm. The single SoPEC also
controls all printer components such as motors, LEDs, buttons etc,
either directly or indirectly.
[0200] In FIG. 2, two SoPECs control a single linking printhead, to
provide 60 ppm A4 printing. Each SoPEC drives 5 or 6 of the
printheads ICs that make up the complete printhead. SoPEC #0 is the
ISCMaster, SoPEC #1 is an ISCSlave. The ISCMaster receives all the
compressed page data for both SoPECs and re-distributes the
compressed data for the ISCSlave over a local USB bus. There is a
total of 4 MBytes of page store memory available if required. Note
that, if each page has 2 MBytes of compressed data, the USB2.0
interface to the host needs to run in high speed (not full speed)
mode to sustain 60 ppm printing. (In practice, many compressed
pages will be much smaller than 2 MBytes). The control of printer
components such as motors, LEDs, buttons etc, is shared between the
2 SoPECs in this configuration.
[0201] In FIG. 3, two SoPEC devices are used to control two
printheads. Each printhead prints to opposite sides of the same
page to achieve duplex printing. SoPEC #0 is the ISCMaster, SoPEC
#1 is an ISCSlave. The ISCMaster receives all the compressed page
data for both SoPECs and re-distributes the compressed data for the
ISCSlave over a local USB bus. This configuration could print 30
double-sided pages per minute.
[0202] In FIG. 4, two SoPEC devices are used to control one A3
linking printhead, constructed from 16 printhead ICs. Each SoPEC
controls 8 printhead ICs. This system operates in a similar manner
to the 60 ppm A4 system in FIG. 2, although the speed is limited to
30 ppm at A3, since each SoPEC can only drive 6 printhead ICs at 60
ppm speeds. A total of 4 Mbyte of page store is available, this
allows the system to use compression rates as in a single SoPEC A4
architecture, but with the increased page size of A3.
[0203] In FIG. 5 a four SoPEC system is shown. It contains 2 A3
linking printheads, one for each side of an A3 page. Each printhead
contain 16 printhead ICs, each SoPEC controls 8 printhead ICs.
SoPEC #0 is the ISCMaster with the other SoPECs as ISCSlaves. Note
that all 3 USB Host ports on SoPEC #0 are used to communicate with
the 3 ISCSlave SoPECs. In total, the system contains 8 Mbytes of
compressed page store (2 Mbytes per SOPEC), so the increased page
size does not degrade the system print quality, from that of an A4
simplex printer. The ISCMaster receives all the compressed page
data for all SoPECs and re-distributes the compressed data over the
local USB bus to the ISCSlaves. This configuration could print 30
double-sided A3 sheets per minute.
[0204] Extra SoPECs can be used for DRAM storage e.g. in FIG. 6 an
A4 simplex printer can be built with a single extra SoPEC used for
DRAM storage. The DRAM SoPEC can provide guaranteed bandwidth
delivery of data to the printing SoPEC. SoPEC configurations can
have multiple extra SoPECs used for DRAM storage.
[0205] FIG. 7 shows a configuration in which the connection from
the host PC to the printer is an ethernet network, rather than USB.
In this case, one of the USB Host ports on SoPEC interfaces to a
external device that provide ethernet-to-USB bridging. Note that
some networking software support in the bridging device might be
required in this configuration. A Flash RAM will be required in
such a system, to provide SoPEC with driver software for the
Ethernet bridging function.
[0206] Because of the page-width nature of the linking printhead,
each page must be printed at a constant speed to avoid creating
visible artifacts. This means that the printing speed can't be
varied to match the input data rate. Document rasterization and
document printing are therefore decoupled to ensure the printhead
has a constant supply of data. A page is never printed until it is
fully rasterized. This can be achieved by storing a compressed
version of each rasterized page image in memory.
[0207] This decoupling also allows the RIP(s) to run ahead of the
printer when rasterizing simple pages, buying time to rasterize
more complex pages.
[0208] Because contone color images are reproduced by stochastic
dithering, but black text and line graphics are reproduced directly
using dots, the compressed page image format contains a separate
foreground bi-level black layer and background contone color layer.
The black layer is composited over the contone layer after the
contone layer is dithered (although the contone layer has an
optional black component). A final layer of Netpage tags (in
infrared, yellow or black ink) is optionally added to the page for
printout.
[0209] FIG. 8 shows the flow of a document from computer system to
printed page.
[0210] At 267 ppi for example, an A4 page (8.26 inches C 11.7
inches) of contone CMYK data has a size of 26.3 MB. At 320 ppi, an
A4 page of contone data has a size of 37.8 MB. Using lossy contone
compression algorithms such as JPEG, contone images compress with a
ratio up to 10:1 without noticeable loss of quality, giving
compressed page sizes of 2.63 MB at 267 ppi and 3.78 MB at 320
ppi.
[0211] At 800 dpi, an A4 page of bi-level data has a size of 7.4
MB. At 1600 dpi, a Letter page of bi-level data has a size of 29.5
MB. Coherent data such as text compresses very well. Using lossless
bi-level compression algorithms such as SMG4 fax, ten-point plain
text compresses with a ratio of about 50:1. Lossless bi-level
compression across an average page is about 20:1 with 10:1 possible
for pages which compress poorly. The requirement for SoPEC is to be
able to print text at 10:1 compression. Assuming 10:1 compression
gives compressed page sizes of 0.74 MB at 800 dpi, and 2.95 MB at
1600 dpi.
[0212] Once dithered, a page of CMYK contone image data consists of
116 MB of bi-level data. Using lossless bi-level compression
algorithms on this data is pointless precisely because the optimal
dither is stochastic--i.e. since it introduces hard-to-compress
disorder.
[0213] Netpage tag data is optionally supplied with the page image.
Rather than storing a compressed bi-level data layer for the
Netpage tags, the tag data is stored in its raw form. Each tag is
supplied up to 120 bits of raw variable data (combined with up to
56 bits of raw fixed data) and covers up to a 6 mm.quadrature.6 mm
area (at 1600 dpi). The absolute maximum number of tags on a A4
page is 15,540 when the tag is only 2 mm.quadrature.2 mm (each tag
is 126 dots.quadrature.126 dots, for a total coverage of 148
tags105 tags). 15,540 tags of 128 bits per tag gives a compressed
tag page size of 0.24 MB.
[0214] The multi-layer compressed page image format therefore
exploits the relative strengths of lossy JPEG contone image
compression, lossless bi-level text compression, and tag encoding.
The format is compact enough to be storage-efficient, and simple
enough to allow straightforward real-time expansion during
printing.
[0215] Since text and images normally don't overlap, the normal
worst-case page image size is image only, while the normal
best-case page image size is text only. The addition of worst case
Netpage tags adds 0.24 MB to the page image size. The worst-case
page image size is text over image plus tags. The average page size
assumes a quarter of an average page contains images. The Host PC
rasterizes and compresses the incoming document on a page by page
basis. The page is restructured into bands with one or more bands
used to construct a page. The compressed data is then transferred
to the SoPEC device directly via a USB link, or via an external
bridge e.g. from ethernet to USB. A complete band is stored in
SoPEC embedded memory. Once the band transfer is complete the SoPEC
device reads the compressed data, expands the band, normalizes
contone, bi-level and tag data to 1600 dpi and transfers the
resultant calculated dots to the linking printhead.
[0216] The document data flow is [0217] The RIP software rasterizes
each page description and compress the rasterized page image.
[0218] The infrared layer of the printed page optionally contains
encoded Netpage tags at a programmable density. [0219] The
compressed page image is transferred to the SoPEC device via the
USB (or ethernet), normally on a band by band basis. [0220] The
print engine takes the compressed page image and starts the page
expansion. [0221] The first stage page expansion consists of 3
operations performed in parallel [0222] expansion of the
JPEG-compressed contone layer [0223] expansion of the SMG4 fax
compressed bi-level layer [0224] encoding and rendering of the
bi-level tag data. [0225] The second stage dithers the contone
layer using a programmable dither matrix, producing up to four
bi-level layers at full-resolution. [0226] The third stage then
composites the bi-level tag data layer, the bi-level SMG4 fax
de-compressed layer and up to four bi-level JPEG de-compressed
layers into the full-resolution page image. [0227] A fixative layer
is also generated as required. [0228] The last stage formats and
prints the bi-level data through the linking printhead via the
printhead interface.
[0229] The SoPEC device can print a full resolution page with 6
color planes. Each of the color planes can be generated from
compressed data through any channel (either JPEG compressed,
bi-level SMG4 fax compressed, tag data generated, or fixative
channel created) with a maximum number of 6 data channels from page
RIP to linking printhead color planes.
[0230] The mapping of data channels to color planes is
programmable. This allows for multiple color planes in the
printhead to map to the same data channel to provide for redundancy
in the printhead to assist dead nozzle compensation.
[0231] Also a data channel could be used to gate data from another
data channel. For example in stencil mode, data from the bilevel
data channel at 1600 dpi can be used to filter the contone data
channel at 320 dpi, giving the effect of 1600 dpi edged contone
images, such as 1600 dpi color text.
[0232] The SoPEC is a page rendering engine ASIC that takes
compressed page images as input, and produces decompressed page
images at up to 6 channels of bi-level dot data as output. The
bi-level dot data is generated for the Memjet linking printhead.
The dot generation process takes account of printhead construction,
dead nozzles, and allows for fixative generation.
[0233] A single SoPEC can control up to 12 linking printheads and
up to 6 color channels at >10,000 lines/sec, equating to 30
pages per minute. A single SoPEC can perform full-bleed printing of
A4 and Letter pages. The 6 channels of colored ink are the expected
maximum in a consumer SOHO, or office Memjet printing environment:
[0234] CMY, for regular color printing. [0235] K, for black text,
line graphics and gray-scale printing. [0236] IR (infrared), for
Netpage-enabled applications. [0237] F (fixative), to enable
printing at high speed. Because the Memjet printer is capable of
printing so fast, a fixative may be required on specific media
types (such as calendared paper) to enable the ink to dry before
the page touches a previously printed page. Otherwise the pages may
bleed on each other. In low speed printing environments, and for
plain and photo paper, the fixative is not be required.
[0238] SoPEC is color space agnostic. Although it can accept
contone data as CMYX or RGBX, where X is an optional 4th channel
(such as black), it also can accept contone data in any print color
space. Additionally, SoPEC provides a mechanism for arbitrary
mapping of input channels to output channels, including combining
dots for ink optimization, generation of channels based on any
number of other channels etc. However, inputs are typically CMYK
for contone input, K for the bi-level input, and the optional
Netpage tag dots are typically rendered to an infra-red layer. A
fixative channel is typically only generated for fast printing
applications.
[0239] SoPEC is resolution agnostic. It merely provides a mapping
between input resolutions and output resolutions by means of scale
factors. The expected output resolution is 1600 dpi, but SoPEC
actually has no knowledge of the physical resolution of the linking
printhead.
[0240] SoPEC is page-length agnostic. Successive pages are
typically split into bands and downloaded into the page store as
each band of information is consumed and becomes free.
[0241] SoPEC provides mechanisms for synchronization with other
SoPECs. This allows simple multi-SoPEC solutions for simultaneous
A3/A4/Letter duplex printing. However, SoPEC is also capable of
printing only a portion of a page image. Combining synchronization
functionality with partial page rendering allows multiple SoPECs to
be readily combined for alternative printing requirements including
simultaneous duplex printing and wide format printing. Table 1
lists some of the features and corresponding benefits of SoPEC.
TABLE-US-00003 TABLE 1 Feature Benefits Optimised print 30 ppm full
page photographic architecture in quality color printing from a
hardware desktop PC 0.13 micron CMOS High speed (>36 million Low
cost transistors) High functionality 900 Million dots Extremely
fast page per second generation >10,000 lines 0.5 A4/Letter
pages per SoPEC per second at chip per second 1600 dpi 1 chip
drives up Low cost page-width printers to 92,160 nozzles 1 chip
drives up 99% of SoHo printers can use to 6 color planes 1 SoPEC
device Integrated DRAM No external memory required, leading to low
cost systems Power saving SoPEC can enter a power saving sleep mode
sleep mode to reduce power dissipation between print jobs JPEG
expansion Low bandwidth from PC Low memory requirements in printer
Lossless bit- High resolution text and line plane expansion art
with low bandwidth from PC. Netpage tag Generates interactive paper
expansion Stochastic di- Optically smooth image quality spersed dot
dither No moire effects Hardware Pages composited in real-time
compositor for 6 image planes Dead nozzle Extends printhead life
and yield compensation Reduces printhead cost Color space
Compatible with all inksets and agnostic image sources including
RGB, CMYK, spot, CIE L*a*b*, hexa- chrome, YCrCbK, sRGB and other
Color space Higher quality/lower bandwidth conversion USB 2.0
device Direct, high speed (480 Mb/s) interface interface to host
PC. USB 2.0 host Enables alternative host PC interface connection
types (IEEE 1394, Ethernet, WiFi, Bluetooth etc.). Enables direct
printing from digital camera or other device. Media Interface
Direct connection to a wide range of external devices e.g. scanner
Integrated motor Saves expensive external hard- controllers ware.
Cascadable in Printers of any resolution resolution Cascadable in
Special color sets e.g. hexa- color depth chrome can be used
Cascadable in Printers of any width image size Cascadable in
Printers can print both sides pages simultaneously Cascadable in
Higher speeds are possible by speed having each SoPEC print one
vertical strip of the page. Fixative channel Extremely fast ink
drying data generation without wastage Built-in security Revenue
models are protected Undercolor removal Reduced ink usage on
dot-by-dot basis Does not require No font substitution or missing
fonts for high fonts speed operation Flexible printhead Many
configurations of printheads configuration are supported by one
chip type Drives linking No print driver chips required, printheads
results in lower cost directly Determines dot Removes need for
physical ink mon- accurate ink itoring system in ink cartridges
usage
[0242] The required printing rate for a single SoPEC is 30 sheets
per minute with an inter-sheet spacing of 4 cm. To achieve a 30
sheets per minute print rate, this requires:
[0243] 300 mm.times.63 (dot/mm)/2 sec=105.8.quadrature. seconds per
line, with no inter-sheet gap.
[0244] 340 mm.times.63 (dot/mm)/2 sec=93.3.quadrature. seconds per
line, with a 4 cm inter-sheet gap.
[0245] A printline for an A4 page consists of 13824 nozzles across
the page. At a system clock rate of 192 MHz, 13824 dots of data can
be generated in 69.2 .quadrature.seconds. Therefore data can be
generated fast enough to meet the printing speed requirement.
[0246] Once generated, the data must be transferred to the
printhead. Data is transferred to the printhead ICs using a 288 MHz
clock (3/2 times the system clock rate). SoPEC has 6 printhead
interface ports running at this clock rate. Data is 8b/10b encoded,
so the thoughput per port is 0.8.times.288=230.4 Mb/sec. For 6
color planes, the total number of dots per printhead IC is
1280.times.6=7680, which takes 33.3.quadrature. seconds to
transfer. With 6 ports and 11 printhead ICs, 5 of the ports address
2 ICs sequentially, while one port addresses one IC and is idle
otherwise. This means all data is transferred on 66.7.quadrature.
seconds (plus a slight overhead). Therefore one SoPEC can transfer
data to the printhead fast enough for 30 ppm printing.
[0247] From the highest point of view the SoPEC device consists of
3 distinct subsystems [0248] CPU Subsystem [0249] DRAM Subsystem
[0250] Print Engine Pipeline (PEP) Subsystem
[0251] See FIG. 13 for a block level diagram of SoPEC.
[0252] The CPU subsystem controls and configures all aspects of the
other subsystems. It provides general support for interfacing and
synchronising the external printer with the internal print engine.
It also controls the low speed communication to the QA chips. The
CPU subsystem contains various peripherals to aid the CPU, such as
GPIO (includes motor control), interrupt controller, LSS Master,
MMI and general timers. The CPR block provides a mechanism for the
CPU to powerdown and reset individual sections of SoPEC. The UDU
and UHU provide high-speed USB2.0 interfaces to the host, other
SoPEC devices, and other external devices. For security, the CPU
supports user and supervisor mode operation, while the CPU
subsystem contains some dedicated security components.
[0253] The DRAM subsystem accepts requests from the CPU, UHU, UDU,
MMI and blocks within the PEP subsystem. The DRAM subsystem (in
particular the DIU) arbitrates the various requests and determines
which request should win access to the DRAM. The DIU arbitrates
based on configured parameters, to allow sufficient access to DRAM
for all requesters. The DIU also hides the implementation specifics
of the DRAM such as page size, number of banks, refresh rates
etc.
[0254] The Print Engine Pipeline (PEP) subsystem accepts compressed
pages from DRAM and renders them to bi-level dots for a given print
line destined for a printhead interface that communicates directly
with up to 12 linking printhead ICs.
[0255] The first stage of the page expansion pipeline is the CDU,
LBD and TE. The CDU expands the JPEG-compressed contone (typically
CMYK) layer, the LBD expands the compressed bi-level layer
(typically K), and the TE encodes Netpage tags for later rendering
(typically in IR, Y or K ink). The output from the first stage is a
set of buffers: the CFU, SFU, and TFU. The CFU and SFU buffers are
implemented in DRAM.
[0256] The second stage is the HCU, which dithers the contone
layer, and composites position tags and the bi-level spot0 layer
over the resulting bi-level dithered layer. A number of options
exist for the way in which compositing occurs. Up to 6 channels of
bi-level data are produced from this stage. Note that not all 6
channels may be present on the printhead. For example, the
printhead may be CMY only, with K pushed into the CMY channels and
IR ignored. Alternatively, the position tags may be printed in K or
Y if IR ink is not available (or for testing purposes).
[0257] The third stage (DNC) compensates for dead nozzles in the
printhead by color redundancy and error diffusing dead nozzle data
into surrounding dots.
[0258] The resultant bi-level 6 channel dot-data (typically
CMYK-IRF) is buffered and written out to a set of line buffers
stored in DRAM via the DWU.
[0259] Finally, the dot-data is loaded back from DRAM, and passed
to the printhead interface via a dot FIFO. The dot FIFO accepts
data from the LLU up to 2 dots per system clock cycle, while the
PHI removes data from the FIFO and sends it to the printhead at a
maximum rate of 1.5 dots per system clock cycle.
[0260] Looking at FIG. 13, the various units are described here in
summary form: TABLE-US-00004 TABLE 2 Unit Sub- Acrony Unit system m
Name Description DRAM DIU DRAM Provides the interface for DRAM
interface read and write access for the various unit PEP units CPU,
UDU, UHU and MMI. The DIU provides arbitration between competing
units controls DRAM access. DRAM Embedded 20 Mbits of embedded
DRAM, DRAM CPU CPU Central CPU for system configuration and
Processing control Unit MMU Memory Limits access to certain memory
Management address areas in CPU user mode Unit RDU Real-time
Facilitates the observation of the Debug contents of most of the
CPU Unit addressable registers in SoPEC in addition to some
pseudo-registers in realtime. TIM General Contains watchdog and
general Timer system timers LSS Low Speed Low level controller for
interfacing Serial with the QA chips Interfaces GPIO General
General IO controller, with built-in Purpose Motor control unit,
LED pulse units IOs and de-glitch circuitry MMI Multi- Generic
Purpose Engine for protocol Media generation and control with
Interface integrated DMA controller. ROM Boot ROM 16 KBytes of
System Boot ROM code ICU Interrupt General Purpose interrupt
controller Controller with configurable priority, and Unit masking.
CPR Clock, Central Unit for controlling and Power and generating
the system clocks and Reset block resets and powerdown mechanisms
PSS Power Save Storage retained while system is Storage powered
down USB Universal USB multiport (4) physical interface. Serial PHY
Bus (USB) Physical UHU USB Host USB host controller interface with
Unit integrated DIU DMA controller UDU USB Device USB Device
controller interface with Unit integrated DIU DMA controller Print
PCU PEP Provides external CPU with the Engine controller means to
read and write PEP Unit Pipe- registers, and read and write DRAM
line in single 32-bit chunks. (PEP) CDU Contone Expands JPEG
compressed contone decoder layer and writes decompressed unit
contone to DRAM CFU Contone Provides line buffering between FIFO
Unit CDU and HCU LBD Lossless Expands compressed bi-level layer.
Bi-level Decoder SFU Spot FIFO Provides line buffering between Unit
LBD and HCU TE Tag encoder Encodes tag data into line of tag dots.
TFU Tag FIFO Provides tag data storage between Unit TE and HCU HCU
Halftoner Dithers contone layer and compositor composites the
bi-level spot 0 and unit position tag dots. DNC Dead Nozzle
Compensates for dead nozzles by Compensator color redundancy and
error diffusing dead nozzle data into surrounding dots. DWU Dotline
Writes out the 6 channels of dot data Writer for a given printline
to the line store Unit DRAM LLU Line Loader Reads the expanded page
image from Unit line store, formatting the data appropriately for
the linking printhead. PHI PrintHead Is responsible for sending dot
data to Interface the linking printheads and for providing line
synchronization between multiple SoPECs. Also provides test
interface to printhead such as temperature monitoring and Dead
Nozzle Identification.
[0261] SoPEC must address [0262] 20 Mbit DRAM. [0263] PCU addressed
registers in PEP. [0264] CPU-subsystem addressed registers.
[0265] SoPEC has a unified address space with the CPU capable of
addressing all CPU-subsystem and PCU-bus accessible registers (in
PEP) and all locations in DRAM. The CPU generates byte-aligned
addresses for the whole of SoPEC. 22 bits are sufficient to byte
address the whole SoPEC address space.
[0266] The embedded DRAM is composed of 256-bit words. Since the
CPU-subsystem may need to write individual bytes of DRAM, the DIU
is byte addressable. 22 bits are required to byte address 20 Mbits
of DRAM.
[0267] Most blocks read or write 256-bit words of DRAM. For these
blocks only the top 17 bits i.e. bits 21 to 5 are required to
address 256-bit word aligned locations.
[0268] The exceptions are [0269] CDU which can write 64-bits so
only the top 19 address bits i.e. bits 21-3 are required. [0270]
The CPU-subsystem always generates a 22-bit byte-aligned DIU
address but it will send flags to the DIU indicating whether it is
an 8, 16 or 32-bit write. [0271] The UHU and UDU generate 256-bit
aligned addresses, with a byte-wise write mask associated with each
data word, to allow effective byte addressing of the DRAM.
[0272] Regardless of the size no DIU access is allowed to span a
256-bit aligned DRAM word boundary.
[0273] PEP Unit configuration registers which specify DRAM
locations should specify 256-bit aligned DRAM addresses i.e. using
address bits 21:5. Legacy blocks from PEC1 e.g. the LBD and TE may
need to specify 64-bit aligned DRAM addresses if these reused
blocks DRAM addressing is difficult to modify. These 64-bit aligned
addresses require address bits 21:3. However, these 64-bit aligned
addresses should be programmed to start at a 256-bit DRAM word
boundary.
[0274] Unlike PEC1, there are no constraints in SoPEC on data
organization in DRAM except that all data structures must start on
a 256-bit DRAM boundary. If data stored is not a multiple of
256-bits then the last word should be padded.
[0275] The CPU subsystem bus supports 32-bit word aligned read and
write accesses with variable access timings.
[0276] The PCU only supports 32-bit register reads and writes for
the PEP blocks. As the PEP blocks only occupy a subsection of the
overall address map and the PCU is explicitly selected by the MMU
when a PEP block is being accessed the PCU does not need to perform
a decode of the higher-order address bits.
[0277] The CPU block consists of the CPU core, caches, MMU, RDU and
associated logic. The principal tasks for the program running on
the CPU to fulfill in the system are:
[0278] Communications: [0279] Control the flow of data to and from
the USB interfaces to and from the DRAM [0280] Communication with
the host via USB [0281] Communication with other USB devices (which
may include other SoPECs in the system, digital cameras, additional
communication devices such as ethernet-to-USB chips) when SoPEC is
functioning as a USB host [0282] Communication with other devices
(utilizing the MMI interface block) via miscellaneous protocols
(including but not limited to Parallel Port, Generic 68K/i960 CPU
interfaces, serial interfaces Intel SBB, Motorola SPI etc.). [0283]
Running the USB device drivers [0284] Running additional protocol
stacks (such as ethernet)
[0285] PEP Subsystem Control: [0286] Page and band header
processing (may possibly be performed on host PC) [0287] Configure
printing options on a per band, per page, per job or per power
cycle basis [0288] Initiate page printing operation in the PEP
subsystem [0289] Retrieve dead nozzle information from the
printhead and forward to the host PC or process locally [0290]
Select the appropriate firing pulse profile from a set of
predefined profiles based on the printhead characteristics [0291]
Retrieve printhead information (from printhead and associated
serial flash)
[0292] Security: [0293] Authenticate downloaded program code [0294]
Authenticate printer operating parameters [0295] Authenticate
consumables via the PRINTER QA and INK QA chips [0296] Monitor ink
usage [0297] Isolation of OEM code from direct access to the system
resources
[0298] Other: [0299] Drive the printer motors using the GPIO pins
[0300] Monitoring the status of the printer (paper jam, tray empty
etc.) [0301] Driving front panel LEDs and/or other display devices
[0302] Perform post-boot initialisation of the SoPEC device [0303]
Memory management (likely to be in conjunction with the host PC)
[0304] Handling higher layer protocols for interfaces implemented
with the MMI [0305] Image processing functions such as image
scaling, cropping, rotation, white-balance, color space conversion
etc. for printing images directly from digital cameras (e.g. via
PictBridge application software) [0306] Miscellaneous housekeeping
tasks
[0307] To control the Print Engine Pipeline the CPU is required to
provide a level of performance at least equivalent to a 16-bit
Hitachi H8-3664 microcontroller running at 16 MHz. An as yet
undetermined amount of additional CPU performance is needed to
perform the other tasks, as well as to provide the potential for
such activity as Netpage page assembly and processing, RIPing etc.
The extra performance required is dominated by the signature
verification task, direct camera printing image processing
functions (i.e. color space conversion) and the USB (host and
device) management task. A number of CPU cores have been evaluated
and the LEON P1754 is considered to be the most appropriate
solution. A diagram of the CPU block is shown in FIG. 16.
[0308] The Dotline Writer Unit (DWU) receives 1 dot (6 bits) of
color information per cycle from the DNC. Dot data received is
bundled into 256-bit words and transferred to the DRAM. The DWU (in
conjunction with the LLU) implements a dot line FIFO mechanism to
compensate for the physical placement of nozzles in a printhead,
and provides data rate smoothing to allow for local complexities in
the dot data generate pipeline.
[0309] The physical placement of nozzles in the printhead means
that in one firing sequence of all nozzles, dots will be produced
over several print lines. The printhead consists of up to 12 rows
of nozzles, one for each color of odd and even dots. Nozzles rows
of the same color are separated by D.sub.1 print lines and nozzle
rows of different adjacent colors are separated by D.sub.2 print
lines. See FIG. 17 for reference. The first color to be printed is
the first row of nozzles encountered by the incoming paper. In the
example this is color 0 odd, although is dependent on the printhead
type. Paper passes under printhead moving upwards.
[0310] Due to the construction limitations the printhead can have
nozzles mildly sloping over several lines, or a vertical alignment
discontinuity at potentially different horizontal positions per row
(D.sub.3). The DWU doesn't need any knowledge of the
discontinuities only that it stores sufficient lines in the dot
store to allow the LLU to compensate.
[0311] FIG. 17 shows a possible vertical misalignment of rows
within a printhead segment. There will also be possible vertical
and horizontal misalignment of rows between adjacent printhead
segments.
[0312] The DWU compensates for horizontal misalignment of nozzle
rows within printhead segments, and writes data out to half line
buffers so that the LLU is able to compensate for vertical
misalignments between and within printhead segments. The LLU also
compensates for the horizontal misalignment between a printhead
segment.
[0313] For example if the physical separation of each half row is
80.quadrature.m equating to D.sub.1=D.sub.2=5 print lines at 1600
dpi. This means that in one firing sequence, color 0 odd nozzles
1-17 will fire on dotline L, color 0 even nozzles 0-16 will fire on
dotline L-D.sub.1, color 1 odd nozzles 1-17 will fire on dotline
L-D.sub.1-D.sub.2 and so on over 6 color planes odd and even
nozzles. The total number of physical lines printed onto over a
single line time is given as (0+5+5 . . . +5)+1=11.times.5+1=56.
See FIG. 18 for example diagram.
[0314] It is expected that the physical spacing of the printhead
nozzles will be 80 .quadrature.m (or 5 dot lines), although there
is no dependency on nozzle spacing. The DWU is configurable to
allow other line nozzle spacings.
[0315] The DWU block is required to compensate for the physical
spacing between lines of nozzles. It does this by storing dot lines
in a FIFO (in DRAM) until such time as they are required by the LLU
for dot data transfer to the printhead interface. Colors are stored
separately because they are needed at different times by the LLU.
The dot line store must store enough lines to compensate for the
physical line separation of the printhead but can optionally store
more lines to allow system level data rate variation between the
read (printhead feed) and write sides (dot data generation
pipeline) of the FIFOs.
[0316] A logical representation of the FIFOs is shown in FIG. 19,
where N is defined as the optional number of extra half lines in
the dot line store for data rate de-coupling.
[0317] If the printhead contains nozzles sloping over X lines or a
vertical misalignment of Y lines then the DWU must store N>X and
N>Y lines in the dotstore to allow the LLU to compensate for the
nozzle slope and any misalignment. It is also possible that the
effects of a slope, and a vertical misalignment are accumulative,
in such cases N>(X+Y).
[0318] The DNC and the DWU concept of line lengths can be
different. The DNC can be programmed to produce less dots than the
DWU expects per line, or can be programmed to produce an odd number
of dots (the DWU always expect an even number of dots per line).
The DWU produces NozzleSkewPadding more dots than it excepts from
the DNC per line. If the DNC is required to produce an odd number
of dots, the NozzleSkewPadding value can be adjusted to ensure the
output from the DWU is still even. The relationship of line lengths
between DWU and DNC must always satisfy:
(LineSize+1)*2-NozzleSkewPadding==DncLineLength
[0319] For an arbitrary page width of d dots (where d is even), the
number of dots per half line is d/2.
[0320] For interline spacing of D.sub.2 and inter-color spacing of
D.sub.1, with C colors of odd and even half lines, the number of
half line storage is (C-1)(D.sub.2+D.sub.1)+D.sub.1.
[0321] For N extra half line stores for each color odd and even,
the storage is given by (N*C*2).
[0322] The total storage requirement is
((C-1)(D.sub.2+D.sub.1)+D.sub.1+(N*C*2))*d/2 in bits.
[0323] Note that when determining the storage requirements for the
dot line store, the number of dots per line is the page width and
not necessarily the printhead width. The page width is often the
dot margin number of dots less than the printhead width. They can
be the same size for full bleed printing.
[0324] For example in an A4 page a line consists of 13824 dots at
1600 dpi, or 6912 dots per half dot line. To store just enough dot
lines to account for an inter-line nozzle spacing of 5 dot lines it
would take 55 half dot lines for color 5 odd, 50 dot lines for
color 5 even and so on, giving 55+50+45 . . . 10+5+0=330 half dot
lines in total. If it is assumed that N=4 then the storage required
to store 4 extra half lines per color is 4.times.12=48, in total
giving 330+48=378 half dot lines. Each half dot line is 6912 dots,
at 1 bit per dot give a total storage requirement of 6912
dots.times.378 half dot lines/8 bits=Approx 319 Kbytes. Similarly
for an A3 size page with 19488 dots per line, 9744 dots per half
line.times.378 half dot lines/8=Approx 450 Kbytes.
[0325] The potential size of the dot line store makes it unfeasible
to be implemented in on-chip SRAM, requiring the dot line store to
be implemented in embedded DRAM. This allows a configurable dotline
store where unused storage can be redistributed for use by other
parts of the system.
[0326] Due to construction limitations of the printhead it is
possible that nozzle rows within a printhead segment may be
misaligned relative to each other by up to 5 dots per half line,
which means 56 dot positions over 12 half lines (i.e. 28 dot
pairs). Vertical misalignment can also occur but is compensated for
in the LLU and not considered here. The DWU is required to
compensate for the horizontal misalignment.
[0327] Dot data from the HCU (through the DNC) produces a dot of 6
colors all destined for the same physical location on paper. If the
nozzle rows in the within a printhead segment are aligned as shown
in FIG. 17 then no adjustment of the dot data is needed.
[0328] A conceptual misaligned printhead is shown in FIG. 20. The
exact shape of the row alignment is arbitrary, although is most
likely to be sloping (if sloping, it could be sloping in either
direction).
[0329] The DWU is required to adjust the shape of the dot streams
to take into account the relative horizontal displacement of
nozzles rows between 2 adjacent printhead segments. The LLU
compensates for the vertical skew between printhead segments, and
the vertical and horizontal skew within printhead segments. The
nozzle row skew function aligns rows to compensate for the seam
between printhead segments (as shown in FIG. 20) and not for the
seam within a printhead (as shown in FIG. 17). The DWU nozzle row
function results in aligned rows as shown in the example in FIG.
21.
[0330] To insert the shape of the skew into the dot stream, for
each line we must first insert the dots for non-printable area 1,
then the printable area data (from the DNC), and then finally the
dots for non-printable area 2. This can also be considered as:
first produce the dots for non-printable area 1 for line n, and
then a repetition of: [0331] produce the dots for the printable
area for line n (from the DNC) [0332] produce the dots for the
non-printable area 2 (for line n) followed by the dots of
non-printable area 1 (for line n+1)
[0333] The reason for considering the problem this way is that
regardless of the shape of the skew, the shape of non-printable
area 2 merged with the shape of non-printable area 1 will always be
a rectangle since the widths of non-printable areas 1 and 2 are
identical and the lengths of each row are identical. Hence step 2
can be accomplished by simply inserting a constant number
(NozzleSkewPadding) of 0 dots into the stream.
[0334] For example, if the color n even row non-printable area 1 is
of length X, then the length of color n even row non-printable area
2 will be of length NozzleSkewPadding-X. The split between
non-printable areas 1 and 2 is defined by the NozzleSkew
registers.
[0335] Data from the DNC is destined for the printable area only,
the DWU must generate the data destined for the non-printable
areas, and insert DNC dot data correctly into the dot data stream
before writing dot data to the fifos. The DWU inserts the shape of
the misalignment into the dot stream by delaying dot data destined
to different nozzle rows by the relative misalignment skew
amount.
[0336] An embedded DRAM is expected to be of the order of 256 bits
wide, which results in 27 words per half line of an A4 page, and 39
words per half line of A3. This requires 27 words.times.12 half
colors (6 colors odd and even)=324.times.256-bit DRAM accesses over
a dotline print time, equating to 6 bits per cycle (equal to DNC
generate rate of 6 bits per cycle). Each half color is required to
be double buffered, while filling one buffer the other buffer is
being written to DRAM. This results in 256 bits.times.2
buffers.times.12 half colors i.e. 6144 bits in total. With 2.times.
buffering the average and peak DRAM bandwidth requirement is the
same and is 6 bits per cycle.
[0337] Should the DWU fail to get the required DRAM access within
the specified time, the DWU will stall the DNC data generation. The
DWU will issue the stall in sufficient time for the DNC to respond
and still not cause a FIFO overrun. Should the stall persist for a
sufficiently long time, the PHI will be starved of data and be
unable to deliver data to the printhead in time. The sizing of the
dotline store FIFO and internal FIFOs should be chosen so as to
prevent such a stall happening.
[0338] The dot data shift register order in the printhead is shown
in FIG. 17 (the transmit order is the opposite of the shift
register order). In the example shown dot 1, dot 3, dot 5, . . . ,
dot 33, dot 35 would be transmitted to the printhead in that order.
As data is always transmitted to the printhead in increasing order
it is beneficial to store the dot lines in increasing order to
facilitate easy reading and transfer of data by the LLU and
PHI.
[0339] For each line in the dot store the order is the same
(although for odd lines the numbering will be different the order
will remain the same). Dot data from the DNC is always received in
increasing dot number order. The dot data is bundled into 256-bit
words and written in increasing order in DRAM, word 0 first, then
word 1, and so on to word N, where N is the number of words in a
line. The starting point for the first dot in a DRAM word is
configured by the AlignmentOffset register.
[0340] The dot order in DRAM is shown in FIG. 22.
[0341] The start address for each half color N is specified by the
ColorBaseAdr[N] registers and the end address (actually the end
address plus 1) is specified by the ColorBaseAdr[N+J]. Note there
are 12 colors in total, 0 to 11, the ColorBaseAdr[12] register
specifies the end of the color 11 dot FIFO and not the start of a
new dot FIFO. As a result the dot FIFOs must be specified
contiguously and increasing in DRAM.
[0342] As each line is written to the FIFO, the DWU increments the
FifoFillLevel register, and as the LLU reads a line from the FIFO
the FifoFillLevel register is decremented. The LLU indicates that
it has completed reading a line by a high pulse on the
llu_dwu_line_rd line.
[0343] When the number of lines stored in the FIFO is equal to the
MaxWriteAhead value the DWU will indicate to the DNC that it is no
longer able to receive data (i.e. a stall) by deasserting the
dwu_dnc_ready signal.
[0344] The ColorEnable register determines which color planes
should be processed, if a plane is turned off, data is ignored for
that plane and no DRAM accesses for that plane are generated.
[0345] The Line Loader Unit (LLU) reads dot data from the line
buffers in DRAM and structures the data into even and odd dot
channels destined for the same print time. The blocks of dot data
are transferred to the PHI and then to the printhead. FIG. 23 shows
a high level data flow diagram of the LLU in context.
[0346] The DWU re-orders dot data into 12 separate dot data line
FIFOs in the DRAM. Each FIFO corresponds to 6 colors of odd and
even data. The LLU reads the dot data line FIFOs and sends the data
to the printhead interface. The LLU decides when data should be
read from the dot data line FIFOs to correspond with the time that
the particular nozzle on the printhead is passing the current line.
The interaction of the DWU and LLU with the dot line FIFOs
compensates for the physical spread of nozzles firing over several
lines at once. FIG. 24 shows the physical relationship between
nozzle rows and the line time the LLU starts reading from the dot
line store. A printhead is constructed from printhead segments. One
A4 printhead can be constructed from up to 11 printhead segments. A
single LLU needs to be capable of driving up to 11 printhead
segments, although it may be required to drive less. The LLU will
read this data out of FIFOs written by the DWU, one FIFO per
half-color.
[0347] The PHI needs to send data out over 6 data lines, each data
line may be connected to up to two segments. When printing A4
portrait, there will be 11 segments. This means five of the data
lines will have two segments connected and one will have a single
segment connected (any printhead channel could have a single
segment connected). In a dual SoPEC system, one of the SoPECs will
be connected to 5 segments, while the other is connected to 6
segments.
[0348] Focusing for a moment on the single SoPEC case, SoPEC
maintains a data generation rate of 6 bits per cycle throughout the
data calculation path. If all 6 data lines broadcast for the entire
duration of a line, then each would need to sustain 1 bit per cycle
to match SoPECs internal processing rate. However, since there are
11 segments and 6 data lines, one of the lines has only a single
segment attached. This data line receives only half as much data
during each print line as the other data lines. So if the broadcast
rate on a line is 1 bit per cycle, then we can only output at a
sustained rate of 5.5 bits per cycle, thus not matching the
internal generation rate. These lines therefore need an output rate
of at least 6/5.5 bits per cycle.
[0349] Due to clock generation limitations in SoPEC the PHI
datalines can transport data at 6/5 bits per cycle, slightly faster
than required.
[0350] While the data line bandwidth is slightly more than is
needed, the bandwidth needed is still slightly over 1 bit per
cycle, and the LLU data generators that prepare data for them must
produce data at over 1 bit per cycle. To this end the LLU will
target generating data at 2 bits per cycle for each data line.
[0351] The LLU will have 6 data generators. Each data generator
will produce the data for either a single segment, or for 2
segments. In cases where a generator is servicing multiple segments
the data for one entire segment is generated first before the next
segments data is generated. Each data generator will have a basic
data production rate of 2 bits per cycle, as discussed above. The
data generators need to cater to variable segment width. The data
generators will also need to cater for the full range of printhead
designs currently considered plausible. Dot data is generated and
sent in increasing order.
[0352] What has to be dealt with in the LLU is summarized here.
[0353] The generators need to be able to cope with segments being
vertically offset. This could be due to poor placement and assembly
techniques, or due to each printhead segment being placed slightly
above or below the previous printhead segment.
[0354] They need to be able to cope with the segments being placed
at mild slopes. The slopes being discussed and planned for are of
the order of 5-10 lines across the width of the printhead (termed
Sloped Step).
[0355] It is necessary to cope with printhead segments that have a
single internal step of 3-10 lines thus avoiding the need for
continuous slope. Note the term step is used to denote when the LLU
changes the dot line it is reading from in the dot line store. To
solve this we will reuse the mild sloping facility, but allow the
distance stepped back to be arbitrary, thus it would be several
steps of one line in most mild sloping arrangements and one step of
several lines in a single step printhead. SoPEC should cope with a
broad range of printhead sizes. It is likely that the printheads
used will be 1280 dots across. Note this is 640 dots/nozzles per
half color.
[0356] It is also necessary that the LLU be able to cope with a
single internal step, where the step position varies per nozzle row
within a segment rather than per segment (termed Single Step).
[0357] The LLU can compensate for either a Sloped Step or Single
Step, and must compensate all segments in the printhead with the
same manner.
[0358] Due to construction limitations of the linking printhead it
is possible that nozzle rows may be misaligned relative to each
other. Odd and even rows, and adjacent color rows may be
horizontally misaligned by up to 5 dot positions relative to each
other. Vertical misalignment can also occur between printhead
segments used to construct the printhead. The DWU compensates for
some horizontal misalignment issues, and the LLU compensates for
the vertical misalignments and some horizontal misalignment.
[0359] The vertical skew between printhead segments can be
different between any 2 segments. For example the vertical
difference between segment A and segment B (Vertical skew AB) and
between segment B and segment C (Vertical skew BC) can be
different.
[0360] The LLU compensates for this by maintaining a different set
of address pointers for each segment. The segment offset register
(SegDRAMOffset) specifies the number of DRAM words offset from the
base address for a segment. It specifies the number of DRAM words
to be added to the color base address for each segment, and is the
same for all odd colors and even colors within that segment. The
SegDotOffset specifies the bit position within that DRAM word to
start processing dots, there is one register for all even colors
and one for all odd colors within that segment. The segment offset
is programmed to account for a number of dot lines, and compensates
for the printhead segment mis-alignment. For example in the diagram
above the segment offset for printhead segment B is
SegWidth+(LineLength*3) in DRAM words.
[0361] Vertical skew within a segment can take the form of either a
single step of 3-10 lines, or a mild slope of 5-10 lines across the
length of the printhead segment. Both types of vertical skew are
compensated for by the LLU using the same mechanism, but with
different programming.
[0362] Within a segment there may be a mild slope that the LLU must
compensate for by reading dot data from different parts of the dot
store as it produces data for a segment. Every SegSpan number of
dot pairs the LLU dot generator must adjust the address pointer by
StepOffset. The StepOffset is added to the address pointer but a
negative offset can be achieved by setting StepOffset sufficiently
large enough to wrap around the dot line store. When a dot
generator reaches the end of a segment span and jumps to the new
DRAM word specified by the offset, the dot pointer (pointing to the
dot within a DRAM word) continues on from the same position it
finished. It is possible (and likely) that the span step will not
align with a segment edge. The span counter must start at a
configured value (Color SpanStart) to compensate for the
mis-alignment of the span step and the segment edge.
[0363] The programming of the Color SpanStart, StepOffset and
SegSpan can be easily reprogrammed to account for the single step
case.
[0364] All segments in a printhead are compensated using the same
Color SpanStart, StepOffset and SegSpan settings, no parameter can
be adjusted on a per segment basis.
[0365] With each step jump not aligned to a 256-bit word boundary,
data within a DRAM word will be discarded. This means that the LLU
must have increased DRAM bandwidth to compensate for the bandwidth
lost due to data getting discarded.
[0366] The LLU is also required to compensate for color row
dependant vertical step offset. The position of the step offset is
different for each color row and but the amount of the offset is
the same per color row. Color dependent vertical skew will be the
same for all segments in the printhead.
[0367] The color dependant step compensation mechanism is a
variation of the sloped and single step mechanisms described
earlier. The step offset position within a printhead segment varies
per color row. The step offset position is adjusted by setting the
span counter to different start values depending on the color row
being processed. The step offset is defined as SegSpan-Color
SpanStart[N] where N specifies the color row to process. In the
skewed edge sloped step case it is likely the mechansim will be
used to compensate for effects of the shape of the edge of the
printhead segment. In the skewed edge single step case it is likely
the mechansim will be used to compensate for the shape of the edge
of the printhead segment and to account for the shape of the
internal edge within a segment.
[0368] The LLU is required to compensate for horizontal
misalignments between printhead segments. FIG. 28 shows possible
misalignment cases.
[0369] In order for the LLU to compensate for horizontal
misalignment it must deal with 3 main issues [0370] Swap odd/even
dots to even/odd nozzle rows (case 2 and 4) [0371] Remove
duplicated dots (case 2 and 4) [0372] Read dots on a dot boundary
rather than a dot pair
[0373] In case 2 the second printhead segment is misaligned by one
dot. To compensate for the misalignment the LLU must send odd
nozzle data to the even nozzle row, and even nozzle data to the odd
nozzle row in printhead segment 2. The OddAligned register
configures if a printhead segment should have odd/even data
swapped, when set the LLU reads even dot data and transmits it to
the odd nozzle row (and visa versa).
[0374] When data is swapped, nozzles in segment 2 will overlap with
nozzles in segment 1 (indicated in FIG. 28), potentially causing
the same dot data to be fired twice to the same position on the
paper. To prevent this the LLU provides a mechanism whereby the
first dots in a nozzle row in a segment are zeroed or prevented
from firing. The SegStartDotRemove register configures the number
of starting dots (up to a maximum of 3 dots) in a row that should
be removed or zeroed out on a per segment basis. For each segment
there are 2 registers one for even nozzle rows and one for odd
nozzle rows.
[0375] Another consequence of nozzle row swapping, is that nozzle
row data destined for printhead segment 2 is no longer aligned.
Recall that the DWU compensates for a fixed horizontal skew that
has no knowledge of odd/even nozzle data swapping. Notice that in
Case 2b in FIG. 28 that odd dot data destined for the even nozzle
row of printhead segment 2 must account for the 3 missing dots
between the printhead segments, whereas even dot data destined for
the odd nozzle row of printhead segment 2 must account for the 2
duplicate dots at the start of the nozzle row. The LLU allows for
this by providing different starting offsets for odd and even
nozzles rows and a per segment basis. The SegDRAMOffset and
SegDotOffset registers have 12 sets of 2 registers, one set per
segment, and within a set one register per odd/even nozzle row. The
SegDotOffset register allows specification of dot offsets on a dot
boundary.
[0376] The LLU (in conjunction with sub-line compensation in
printhead segments) is required to compensate for sub-line vertical
skew between printhead segments.
[0377] FIG. 29 shows conceptual example cases to illustrate the
sub-line compensation problem.
[0378] Consider a printhead segment with 10 rows each spaced
exactly 5 lines apart. The printhead segment takes 100 us to fire a
complete line, 10 us per row. The paper is moving continuously
while the segment is firing, so row 0 will fire on line A, row 1
will 10 us later on Line A+0.1 of a line, and so on until to row 9
which is fire 90 us later on line A+0.9 of a line (note this
assumes the 5 line row spacing is already compensated for). The
resultant dot spacing is shown in case 1A in FIG. 29.
[0379] If the printhead segment is constructed with a row spacing
of 4.9 lines and the LLU compensates for a row spacing of 5 lines,
case 1B will result with all nozzle rows firing exactly on top of
each other. Row 0 will fire on line A, row 1 will fire 10 us later
and the paper will have moved 0.1 line, but the row separation is
4.9 lines resulting in row 1 firing on line A exactly, (line A+4.9
lines physical row spacing-5 lines due to LLU row spacing
compensation+0.1 lines due to 10 us firing delay=line A).
[0380] Consider segment 2 that is skewed relative to segment 1 by
0.3 of a line. A normal printhead segment without sub-line
adjustment would print similar to case 2A. A printhead segment with
sub-line compensation would print similar to case 2B, with dots
from all nozzle rows landing on Line A+segment skew (in this case
0.3 of a line).
[0381] If the firing order of rows is adjusted, so instead of
firing rows 0, 1, 2 . . . 9, the order is 3, 4, 5 . . . 8, 9, 0, 1,
2, and a printhead with no sub-line compensation is used a pattern
similar to case 2C will result. A dot from nozzle row 3 will fire
at line A+segment skew, row 4 at line A+segment skew+0.1 of a line
etc. (note that the dots are now almost aligned with segment 1). If
a printhead with sub-line compensation is used, a dot from nozzle
row 3 will fire on line A, row 4 will fire on line A and so on to
row 9, but rows 0, 1, 2 will fire on line B (as shown in case
2D).
[0382] The LLU is required to compensate for normal row spacing (in
this case spacing of 5 lines), it needs to also compensate on a per
row basis for a further line due to sub-line compensation
adjustments in the printhead. In case 2D, the firing pattern and
resulting dot locations for rows 0, 1, 2 means that these rows
would need to be loaded with data from the following line of a page
in order to be printing the correct dot data to the correct
position. When the LLU adjustments are applied and a sub-line
compensating printhead segment is used a dot pattern as shown in
case 2E will result, compensating for the sub-line skew between
segment 1 and 2.
[0383] The LLU is configured to adjust the line spacing on a per
row per segment basis by programming the SegColorRowInc registers,
one register per segment, and one bit per row.
[0384] The specific sub-line placement of each row, and subsequent
standard firing order is dependant on the design of the printhead
in question. However, for any such firing order, a different
ordering can be constructed, like in the above sample, that results
in sub-line correction. And while in the example above it is the
first three rows which required adjustment it might equally be the
last three or even three non-contiguous rows that require different
data than normal when this facility is engaged. To support this
flexibly the LLU needs to be able to specify for each segment a set
of rows for which the data is loaded from one line further into the
page than the default programming for that half-color.
[0385] The LLU provides a mechanism for generating left and right
margin dot data, for transmission to the printhead. In the margin
areas the LLU will generate zero data and will not read data from
DRAM for margin dots, saving some DRAM bandwidth.
[0386] The left margin is specified by the LeftMarginEnd and
LeftMarginSegment registers. The LeftMarginEnd specifies the dot
position that the left margin ends, and the LeftMarginSegment
register specifies which segment the margin ends in. The
LeftMarginEnd allows a value up the segment size, but larger
margins can be specified by selecting further in segments in the
printhead, and disabling interim segments.
[0387] The right margin is specified by the RightMarginStart and
RightMarginSegment registers. The RightMarginStart specifies the
dot position that the right margin starts, and the
RightMarginSegment register specifies which segment the margin
start in.
[0388] The LLU contains 6 dot generators, each of which generate
data in a fixed but configurable order for easy transmission to the
printhead. Each dot generator can produce data for 0, 1 or 2
printhead segments, and is required to produce dots at a rate of 2
dots per cycle. The number of printhead segments is configured by
the SegConfig register. The SegConfig register is a map of active
segments. The dot generators will produce zero data for inactive
segments and dot data for active segments. Register 0, bits 5:0 of
SegConfig specifies group 0 active segments, and register 1 bits
5:0 specify group 1 active segments (in each case one bit per
generator). The number of groups of segments is configured by the
MaxSegment register.
[0389] Group 0 segments are defined as the group of segments that
are supplied with data first from each generator (segments 0, 2, 4,
6, 8, 10), and group 1 segments are supplied with data second from
each generator (segments 1, 3, 5, 7, 9, 11).
[0390] The 6 dot generators transfer data to the PHI together,
therefore they must generate the same volume of data regardless of
the number of segments each is driving. If a dot generator is
configured to drive 1 segment then it must generate zero data for
the remaining printhead segment.
[0391] If MaxSegment is set to 0 then all generators will generate
data for one segment only, if it's set to 1 then all generators
will produce data for 2 segments. The SegConfig register controls
if the data produced is dot data or zero data.
[0392] For each segment that a generator is configured for, it will
produce up to N half colors of data configured by the MaxColor
register. The MaxColor register should be set to values less than
12 when GenerateOrder is set to 0 and less then 6 when
GenerateOrder is 1.
[0393] For each color enabled the dot generators will transmit one
half color of dot data (possibly even data) first in increasing
order, and then one half color of dot data in increasing order
(possibly odd data). The number of dots produced for each half
color (i.e. an odd or even color) is configured by the SegWidth
register.
[0394] The half color generation order is configured by the
OddAligned and GenerateOrder registers. The GenerateOrder register
effects all generators together, whereas the OddAligned register
configures the generation order on a per segment basis.
[0395] At the start of a page the LLU must wait for the dot line
store in DRAM to fill to a configured level (given by
FifoReadThreshold) before starting to read dot data. Once the LLU
starts processing dot data for a page it must continue until the
end of a page, the DWU (and other PEP blocks in the pipeline) must
ensure there is always data in the dot line store for the LLU to
read, otherwise the LLU will stall, causing the PHI to stall and
potentially generate a print error. The FifoReadThreshold should be
chosen to allow for data rate mismatches between the DWU write side
and the LLU read side of the dot line FIFO. The LLU will not
generate any dot data until the FifoReadThreshold level in the dot
line FIFO is reached.
[0396] Once the FifoReadThreshold is reached the LLU begins page
processing, the FifoReadThreshold is ignored from then on.
[0397] For each dot line FIFO there are conceptually 12 pointers
(one per segment) reading from it, each skewed by a number of dot
lines in relation to the other (the skew amount could be positive
or negative). Determining the exact number of valid lines in the
dot line store is complicated by having several pointers reading
from different positions in the FIFO. It is convenient to remove
the problem by pre-zeroing the dot line FIFOs effectively removing
the need to determine exact data validity. The dot FIFOs can be
initialized in a number of ways, including [0398] the CPU writing
0s, [0399] the LBD/SFU writing a set of 0 lines (16 bits per
cycle), [0400] the HCU/DNC/DWU being programmed to produce 0
data
[0401] The LLU is required to generate data for feeding to the
printhead interface, the rate required is dependent on the
printhead construction and on the line rate configured. Each dot
generator in the LLU can generate dots at a rate of 2 bits per
cycle, this gives a maximum of 12 bits per cycle (for 6 dot
generators). The SoPEC data generation pipeline (including the DWU)
maintains a data rate of 6 bits per cycle.
[0402] The PHI can transfer data to each printhead segment at
maximum raw rate of 288 Mb/s, but allowing for line sync and
control word overhead of .about.2%, and 8b10b encoding, the
effective bandwidth is 225 Mb/s or 1.17 bits per pclk cycle per
generator. So a 2 dots per cycle generation rate easily meets the
LLU to PHI bandwidth requirements.
[0403] To keep the PHI fully supplied with data the LLU would need
to produce 1.17.times.6=7.02 bits per cycle. This assumes that
there are 12 segments connected to the PHI. The maximum number of
segments the PHI will have connected is 11, so the LLU needs to
produce data at the rate of 11/12 of 7.02 or approx 6.43 bits per
cycle. This is slightly greater than the front end pipeline rate of
6 bits per cycle.
[0404] The printhead construction can introduce a gentle slope (or
line discontinuities) that is not perfectly 256 bit aligned (the
size of a DRAM word), this can cause the LLU to retrieve 256 bits
of data from DRAM but only use a small amount of it, the remainder
resulting in wasted DRAM bandwidth. The DIU bandwidth allocation to
the LLU will need to be increased to compensate for this wasted
bandwidth.
[0405] For example if the LLU only uses on average 128 bits out of
every 256 bits retrieved from the DRAM, the LLU bandwidth
allocation in the DIU will need to be increased to
2.times.6.43=12.86 bits per cycle.
[0406] It is possible in certain localized cases the LLU will use
only 1 bit out of some DRAM words, but this would be local peak,
rather than an average. As a result the LLU has quad buffers to
average out local peak bandwidth requirements.
[0407] Note that while the LLU and PHI could produce data at
greater than 6 bits per cycle rate, the DWU can only produce data
at 6 bits per cycle rate, therefore a single SoPEC will only be
able to sustain an average of 6 bits per cycle over the page print
duration (unless there are significant margins for the page). If
there are significant margins the LLU can operate at a higher rate
than the DWU on average, as the margin data is generated by the LLU
and not written by the DWU. The start address for each half color N
is specified by the ColorBaseAdr[N] registers and the end address
(actually the end address plus 1) is specified by the
ColorBaseAdr[N+1]. Note there are 12 colors in total, 0 to 11, the
ColorBaseAdr[12] register specifies the end of the color 11 dot
FIFO and not the start of a new dot FIFO. As a result the dot FIFOs
must be specified contiguously and increasing in DRAM.
[0408] The LLU keeps a dot usage count for each of the color planes
(called AccumDotCount). If a dot is used in a particular color
plane the corresponding counter is incremented. Each counter is 32
bits wide and saturates if not reset. A write to the
InkDotCountSnap register causes the AccumDotCount[N] values to be
transferred to the InkDotCount[N] registers (where N is 5 to 0, one
per color). The AccumDotCount registers are cleared on value
transfer.
[0409] The InkDotCount[N] registers can be written to or read from
by the CPU at any time. On reset the counters are reset to
zero.
[0410] The dot counter only counts dots that are passed from the
LLU through the PHI to the printhead. Any dots generated by direct
CPU control of the PHI pins will not be counted.
[0411] The Printhead interface (PHI) accepts dot data from the LLU
and transmits the dot data to the printhead, using the printhead
interface mechanism. The PHI generates the control and timing
signals necessary to load and drive the printhead. A printhead is
constructed from a number of printhead segments. The PHI has 6
transmission lines (printhead channel), each line is capable of
driving up to 2 printhead segments, allowing a single PHI to drive
up to 12 printhead segments. The PHI is capable of driving any
combination of 0, 1 or 2 segments on any printhead channel. The PHI
generates control information for transmission to each printhead
segment. The control information can be generated automatically by
the PHI based on configured values, or can be constructed by the
CPU for the PHI to insert into the data stream.
[0412] The PHI transmits data to printhead segments at a rate of
288 Mhz, over 6 LVDS data lines synchronous to 2 clocks. Both
clocks are in phase with each other. In order to assist sampling of
data in the printhead segments, each data line is encoded with
8b10b encoding, to minimize the maximum number of bits without a
transition. Each data line requires a continuous stream of symbols,
if a data line has no data to send it must insert IDLE symbols to
enable the receiving printhead to remain synchronized. The data is
also scrambled to reduce EMI effects due to long sequences of
identical data sent to the printhead segment (i.e. IDLE symbols
between lines). The descrambler also has the added benefit in the
receiver of increasing the chance single bit errors will be seen
multiple times. The 28-bit scrambler is self-synchronizing with a
feedback polynomial of 1+x.sup.15+x.sup.28.
[0413] The PHI needs to send control commands to each printhead
segment as part of the normal line and page download to each
printhead segment. The control commands indicate line position,
color row information, fire period, line sync pulses etc. to the
printhead segments.
[0414] A control command consists of one control symbol, followed
by 0 or more data or control symbols. A data or control symbol is
defined as a 9-bit unencoded word. A data symbol has bit 8 set to
0, the remaining 8 bits represent the data character. A control
symbol has bit 8 set to 1, with the 8 remaining bits set to a
limited set of other values to complete the 8b10b code set.
[0415] Each command is defined by CmdCfg[CMD_NAME] register. The
command configuration register configures 2 pointers into a symbol
array (currently the symbol array is 32 words, but could be
extended). Bits 4:0 of the command configuration register indicate
the start symbol, and bits 9:5 indicate the end symbol. Bit 10 is
the empty string bit and is used to indicate that the command is
empty, when set the command is ignored and no symbols are sent.
When a command is transmitted to a printhead segment, the symbol
pointed to by the start pointer is send first, then the start
pointer+1 etc. and all symbols to the end symbol pointer. If the
end symbol pointer is less than the start symbol pointer the PHI
will send all symbols from start to stop wrapping at 32.
[0416] The IDLE command is configured differently to the others. It
is always only one symbol in length and cannot be configured to be
empty. The IDLE symbol value is defined by the IdleCmdCfg
register.
[0417] The symbol array can be programmed by accessing the
SymbolTable registers. Note that the symbol table can be written to
at any time, but can only be read when Go is set to 0.
[0418] The PHI provides a mechanism for the CPU to send data and
control words to any individual segment or to broadcast to all
segments simultaneously. The CPU writes commands to the command
FIFO, and the PHI accepts data from the command FIFO, and transmits
the symbols to the addressed printhead segment, or broadcasts the
symbols to all printhead segments.
[0419] The CPU command is of the form:
[0420] The 9-bit symbol can be a control or data word, the segment
address indicates which segment the command should be sent to.
Valid segment addresses are 0-11 and the broadcast address is 15.
There is a direct mapping of segment addresses to printhead data
lines, segment addresses 0 and 1 are sent out printhead channel 0,
addresses 2 and 3 are sent out printhead channel 1, and so on to
addresses 10 and 11 which are send out printhead channel 5. The end
of command (EOC) flag indicates that the word is the last word of a
command. In multi-word commands the segment address for the first
word determines which printhead channel the command gets sent to,
the segment address field in subsequent words is ignored.
[0421] The PHI operates in 2 modes, CPU command mode and data mode.
A CPU command always has higher priority than the data stream (or a
stream of idles) for transmission to the printhead. When there is
data in the command FIFO, the PHI will change to CPU command mode
as soon as possible and start transmitting the command word. If the
PHI detects data in the command FIFO, and the PHI is in the process
of transmitting a control word the PHI waits for the control word
to complete and then switches to CPU command mode. Note that idles
are not considered control words. The PHI will remain in CPU
command mode until it encounters a command word with the EOC flag
set and no other data in the command FIFO.
[0422] The PHI must accept data for all printhead channels from the
LLU together, and transmit all data to all printhead segments
together. If the CPU command FIFO wants to send data to a
particular printhead segment, the PHI must stall all data channels
from the LLU, and send IDLE symbols to all other print channels not
addressed by the CPU command word. If the PHI enters CPU command
mode and begins to transmit command words, and the command FIFO
becomes empty but the PHI has not encountered an EOC flag then the
PHI will continue to stall the LLU and insert IDLE symbols into the
print streams. The PHI remains in CPU command mode until an EOC
flag is encountered.
[0423] To prevent such stalling the command FIFO has an enable bit
CmdFIFOEnable which enables the PHI reading the command FIFO. It
allows the CPU to write several words to the command FIFO without
the PHI beginning to read the FIFO. If the CPU disables the FIFO
(setting CmdFIFOEnable to 0) and the PHI is currently in CPU
command mode, the PHI will continue transmitting the CPU command
until it encounters an EOC flag and will then disable the FIFO.
When the PHI is switching from CPU command mode to data transfer
mode, it sends a RESUME command to the printhead channel group data
transfer that was interrupted. This enables each printhead to
easily differentiate between control and data streams. For example
if the PHI is transmitting data to printhead group B and is
interrupted to transmit a CPU command, then upon return to data
mode the PHI must send a RESUME_B control command. If the PHI was
between pages (when Go=0) transmitting IDLE commands and was
interrupted by a CPU command, it doesn't need to send any resume
command before returning to transmit IDLE.
[0424] The command FIFO can be written to at any time by the CPU by
writing to the CmdFifo register. The CmdFiFO register allows FIFO
style access to the command FIFO. Writing to the CmdFIFO register
will write data to the command FIFO address pointed to by the write
pointer and will increment the write pointer. The CmdFIFO register
can be read at any time but will always return the command FIFO
value pointed to by the internal read pointer.
[0425] The current fill level of the CPU command FIFO can be read
by accessing the CmdFIFOLevel register.
[0426] The command FIFO is 32 words.times.14 bits.
[0427] The PHI synchronizes line data transmission with sync pulses
generated by the GPIO block (which in turn could be synchronized to
the GPIO block in another SoPEC). The PHI waits for a line sync
pulse and then transmits line data and the FIRE command to all
printhead segments.
[0428] It is possible that when a line sync pulse arrives at the
PHI that not all the data has finished being sent to the
printheads. If the PHI were to forward this signal on then it would
result in an incorrect print of that line, which is an error
condition. This would indicate a buffer underflow in PEC1.
[0429] However, in SoPEC the printhead segments can only receive
line sync signals from the SoPEC providing them data. Thus it is
possible that the PHI could delay in sending the line sync pulse
until it had finished providing data to the printhead. The effect
of this would be a line that is printed slightly after where it
should be printed. In a single SoPEC system this effect would
probably not be noticeable, since all printhead segments would have
undergone the same delay. In a multi-SoPEC system delays would
cause a difference in the location of the lines, if the delay was
great this may be noticeable.
[0430] If a line sync is early the PHI records it as a pending line
sync and will send the corresponding next line and FIRE command at
the next available time (i.e. when the current line of data is
finished transferring to the printhead). It is possible that there
may be multiple pending line syncs, whether or not this is an error
condition is printer specific. The PHI records all pending line
syncs (LineSyncPend register), and if the level of pending lines
syncs rises over a configured level (LineSyncMaxPend register) the
PHI will set the MaxSyncPend bit in the PhiStatus register which if
enabled can cause an interrupt. The CPU interrupt service routine
can then evaluate the appropriate response, which could involve
halting the PHI.
[0431] The PHI also has 2 print speed limitation mechanisms. The
LineTimeMin register specifies the minimum line time period in pclk
cycles and the DynLineTimeMin register which also specifies the
minimum line time period in pclk cycles but is updated dynamically
after each FIRE command is transmitted. The PHI calculates
DynLineTimeCalcMin value based on the last line sync period
adjusted by a scale factor specified by the DynLineTimeMinScaleNum
register. When a FIRE command is transmitted to the printhead the
PHI moves the DynLineTimeCalcMin to the DynLineTimeMin register to
limit the next line time. The DynLineTimeCalcMin value is updated
for each new line sync (same as the FirePeriodCalc) whereas the
DynLineTimeMin register is updated when a FIRE command is
transmitted to the printhead (same as the FirePeriod register). The
dynamic minimum line time is intended to ensure the previous
calculated fire period will have sufficient time to fire a complete
line before the PHI begins sending the next line of data.
[0432] The scale factor is defined as the ratio of the
DynLineTimeMinScaleNum numerator value to a fixed denominator value
of 0x10000, allowing a maximum scale factor of 1.
[0433] The PHI also provides a mechanism where it can generate an
interrupt to the ICU (phi_icu_line_irq) after a fixed number of
line syncs are received or a fixed number of FIRE commands are sent
to the printhead. The LineInterrupt register specifies the number
of line syncs (or FIRE commands) to count before the interrupt is
generated and the LineInterruptSrc register selects if the count
should be line syncs or FIRE commands.
[0434] The PHI sends data to each printhead segment in a fixed
order inserting the appropriate control command sequences into the
data stream at the correct time. The PHI receives a fixed data
stream from the LLU, it is the responsibility of the PHI to
determine which data is destined for which line, color nozzle row
and printhead segment, and to insert the correct command
sequences.
[0435] The SegWidth register specifies the number of dot pairs per
half color nozzle row. To avoid padding to the nearest 8 bits (data
symbol input amount) the SegWidth must be programmed to a multiple
of 8.
[0436] The MaxColor register specifies the number of half nozzle
rows per printhead segment.
[0437] The MaxSegment specifies the maximum number segments per
printhead channel. If MaxSegment is set to 0 then all enabled
channels will generate a data stream for one segment only. If
MaxSegment is set to 1 then all enabled channels will generate data
for 2 segments. The LLU will generate null data for any missing
printhead segments.
[0438] The PageLenLine register specifies the number of lines of
data to accept from the LLU and transfer to the printhead before
setting the page finished flag (PhiPageFinish) in the PhiStatus
register.
[0439] Printhead segments are divided into 2 groups, group A
segments are 0, 2, 4, 6, 8, 10 and group B segments are 1, 3, 5, 7,
9, 11. For any printhead channel, group A segment data is
transmitted first then group B.
[0440] Each time a line sync is received from the GPIO, the PHI
sends a line of data and a fire (FIRE) command to all printhead
segments.
[0441] The PHI first sends a next color command (NC_A) for the
first half color nozzle row followed by nozzle data for the first
half color dots. The number of dots transmitted (and accepted from
the LLU) is configured by SegWidth register. The PHI then sends a
next color command indicating to the printhead to reconfigure to
accept the next color nozzle data. The PHI then sends the next half
color dots. The process is repeated for MaxColor number of half
nozzle rows. After all dots for a particular segment are
transmitted, the PHI sends a next color B (NC_B) command to
indicate to the group B printheads to prepare to accept nozzle row
data. The command and data sequence is repeated as before. The line
transmission to the printhead is completed with the transmission of
a FIRE command.
[0442] The PHI can optionally insert a number of IDLE symbols
before each next color command. The number of IDLE symbols inserted
is configured by the IdleInsert register. If it's set to zero no
symbols will be inserted.
[0443] When a line is complete, the PHI decrements the PageLenLine
counter, and waits for the next line sync pulse from the GPIO
before beginning the next line of data.
[0444] The PHI continues sending line data until the PageLenLine
counter is 0 indicating the last line. When the last line is
transmitted to the printhead segments, the PHI sets a page finished
flag (PhiPageFinish) in the PhiStatus register. The PHI will then
wait until the Go bit is toggled before sending the next page to
the printhead.
[0445] Before starting printing SoPEC must configure the printhead
segments. If there is more than one printhead segment on a
printline, the printhead segments must be assigned a unique ID per
print line. The IDs are assigned by holding one group of segments
in reset while the other group is programmed by a CPU command
stream issued through the PHI. The PHI does not directly control
the printhead reset lines. They are connected to CPR block output
pins and are controlled by the CPU through the CPR.
[0446] The printhead also provides a mechanism for reading data
back from each individual printhead segment. All printhead segments
use a common data back channel, so only one printhead segment can
send data at a time. SoPEC issues a CPU command stream directed at
a particular printhead segment, which causes the segment to return
data on the back channel. The back channel is connected to a GPIO
input, and is sampled by the CPU through the GPIO.
[0447] If SoPEC is being used in a multi-SoPEC printing system, it
is possible that not all print channels, or clock outputs are being
used. Any unused data outputs can be disabled by programming the
PhiDataEnable register, or unused clock outputs disabled by
programming the PhiClkEnable.
[0448] The CPU when enabling or disabling the clock or data outputs
must ensure that the printhead segments they are connected to are
held in a benign state while toggling the enable status of the
output pins.
[0449] The PHI calculates the fire period needed in the printhead
segments based on the last line sync period, adjusted by a
fractional amount. The fractional factor is dependant on the way
the columns in the printhead are grouped, the particular clock used
within the printhead to count this period and the proportion of a
line time over which the nozzles for that line must be fired. For
example, one current plan has fire groups consisting of 32 nozzle
columns which are physically located in a way that require them to
be fired over a period of around 96% of the line time. A count is
needed to indicate a period of (linetime/32)*96% for a 144 MHz
clock.
[0450] The fractional amount the fire period is adjusted by is
configured by the FireScaleNum register. The scale factor is the
ratio of the configurable FireScaleNum numerator register and a
fixed denominator of 0x10000. Note that the fire period is
calculated in the pclk domain, but is used in the phiclk domain.
The fractional registers will need to be programmed to take account
of the ratio of the pclk and phiclk frequencies.
[0451] A new fire period is calculated with every new line sync
pulse from the GPIO, regardless of whether the line sync pulse
results in a new line of data being send to the printhead segments,
or the line sync pending level. The latest calculated fire period
by can read by accessing the FirePeriodCalc register.
[0452] The PHI transfers the last calculated fire period value
(FirePeriodCalc) to the FirePeriod register immediately before the
FIRE command is sent to the printhead. This prevents the FirePeriod
value getting updated during the transfer of a FIRE command to the
printhead, possibly sending an incorrect fire period value to the
printhead.
[0453] The PHI can optionally send the calculated fire period by
placing META character symbols in a command stream (either a CPU
command, or a command configured in the command table). The META
symbols are detected by the PHI and replaced with the calculated
fire period. Currently 2 META characters are defined.
[0454] The last calculated fire period can be accessed by reading
the FirePeriod register.
[0455] Immediately after the PHI leaves its reset it will start
sending IDLE commands to all printhead data channels. The PHI will
not accept any data from the LLU until the Go bit is set. Note the
command table can be programmed at any time but cannot be used by
the internal PHY when Go is 0.
[0456] When Go is set to 1 the PHI will accept data from the LLU.
When data actually arrives in the data buffer the PHI will set the
PhiDataReady bit in the PhiStatus register. The PHI will not start
sending data to the printhead until it receives 2 line syncs from
the GPIO (gpio_phi_line_sync). The PHI needs to wait for 2 line
syncs to allow it to calculate the fire period value. The first
line sync will not become pending, and will not result in a
corresponding FIRE command. Note that the PHI does not need to wait
for data from the LLU before it can calculate the fire period. If
the PHI is waiting for data from the LLU any line syncs it receives
from the GPIO (except the first one) will become pending.
[0457] Once data is available and the fire period is calculated the
PHI will start producing print streams. For each line transmitted
the PHI will wait for a line sync pulse (or the minimum line time
if a line sync is pending) before sending the next line of data to
the printheads. The PHI continues until a full page of data has
been transmitted to the printhead (as specified by the PageLenLine
register). When the page is complete the PHI will automatically
clear the Go bit and will set the PhiPageFinish flag in the
PhiStatus register. Any bit in the PhiStatus register can be used
to generate an interrupt to the ICU.
[0458] The bi-lithic printhead (as distinct from the linking
printhead) is now described from the point of view of printing 30
ppm from a SoPEC ASIC, as well as architectures that solve the 60
ppm printing requirement using the bi-lithic printhead model.
[0459] To print at 30 ppm, the printheads must print a single page
within 2 seconds. This would include the time taken to print the
page itself plus any inter-page gap (so that the 30 ppm target
could be met). The required printing rate assumes an inter-sheet
spacing of 4 cm.
[0460] A baseline SoPEC system connecting to two printhead segments
is shown in FIG. 39. The two segments (A and B) combine to form a
printhead of typical width 13,824 nozzles per color.
[0461] We assume decoupling of data generation, transmission to the
printhead, and firing.
[0462] A single SoPEC produces the data for both printheads for the
entire page. Therefore it has the entire line time in which to
generate the dot data.
[0463] A Letter page is 11 inches high. Assuming 1600 dpi and a 4
cm inter-page gap, there are 20,120 lines. This is a line rate of
10.06 KHz (a line time of 99.4 us).
[0464] The printhead is 14,080 dots wide. To calculate these dots
within the line time, SoPEC requires a 140.8 MHz dot generation
rate. Since SoPEC is run at 160 MHz and generates 1 dot per cycle,
it is able to meet the Letter page requirement and cope with a
small amount of stalling during the dot generation process.
[0465] An A4 page is 297 mm high. Assuming 62.5 dots/mm and a 4 cm
inter-page gap, there are 21,063 lines. This is a line rate of
10.54 KHz (a line time of 94.8 us).
[0466] The printhead is 14,080 dots wide. To calculate these dots
within the line time, SoPEC requires a 148.5 MHz dot generation
rate. Since SoPEC is run at 160 MHz and generates 1 dot per cycle,
it is able to meet the A4 page requirement and cope with minimal
stalling.
[0467] Assuming an n-color printhead, SoPEC must transmit 14,080
dots.quadrature.n-bits within the line time. i.e. n.quadrature.the
data generation rate=n-bits.quadrature.14,080 dots.quadrature.10.54
KHz. Thus a 6-color printhead requires 874.2 Mb/sec.
[0468] The transmission time is further constrained by the fact
that no data must be transmitted to the printhead segments during a
window around the linesync pulse. Assuming a 1% overhead for
linesync overhead (being very conservative), the required
transmission bandwidth for 6 colors is 883 Mb/sec.
[0469] However, the data is transferred to both segments
simultaneously. This means the longest time to transfer data for a
line is determined by the time to transfer print data to the
longest print segment. There are 9744 nozzles per color across a
type7 printhead. We therefore must be capable of transmitting
6-bits.quadrature.9744 dots at the line rate i.e.
6-bits.quadrature.9744.quadrature.10.54 KHz=616.2 Mb/sec. Again,
assuming a 1% overhead for linesync overhead, the required
transmission bandwidth to each printhead is 622.4 Mb/sec.
[0470] The connections from SoPEC to each segment consist of
2.quadrature.1-bit data lines that operate at 320 MHz each. This
gives a total of 640 Mb/sec.
[0471] Therefore the dot data can be transmitted at the appropriate
rate to the printhead to meet the 30 ppm requirement.
[0472] The dot data is accepted by the printhead at 2-bits per
cycle at 320 MHz. 6 bits are available after 3 cycles at 320 MHz,
and these 6-bits are then clocked into the shift registers within
the printhead at a rate of 106 MHz.
[0473] Thus the data movement within the printhead shift registers
is able to keep up with the rate at which data arrives in the
printhead.
[0474] The issues introduced by printing at 60 ppm are now
described, with the cases of 4, 5, and 6 colors in the printhead.
The arrangement is shown in FIG. 40.
[0475] A 60 ppm printer is 1 page per second. i.e [0476] A4=21,063
lines. This is a line rate of 21.06 KHz (a line time of 47.4 us)
[0477] Letter=20,120 lines. This is a line rate of 20.12 KHz (a
line time of 49.7 us)
[0478] If each SoPEC is responsible for generating the data for its
specific printhead, then the worst case for dot generation is the
largest printhead.
[0479] Since the preferred embodiment of SoPEC is run at 160 MHz,
it is only able to meet the dot requirement rate for the 5:5
printhead, and not the 6:4 or 7:3 printheads.
[0480] Each SoPEC must transmit a printhead's worth of bits per
color to the printhead per line. The transmission time is further
constrained by the fact that no data must be transmitted to the
printhead segments during a window around the linesync pulse.
Assuming that the line sync overhead is constant regardless of
print speed, then a 1% overhead at 30 ppm translates into a 2%
overhead at 60 ppm.
[0481] Since we have 2 lines to the printhead operating at 320 MHz
each, the total bandwidth available is 640 Mb/sec. The existing
connection to the printhead will only deliver data to a 4-color 5:5
arrangement printhead fast enough for 60 ppm. The connection speed
in the preferred embodiment is not fast enough to support any other
printhead or color configuration.
[0482] The dot data is currently accepted by the printhead at
2-bits per cycle at 320 MHz. Although the connection rate is only
fast enough for 4 color 5:5 printing, the data must still be moved
around in the shift registers once received.
[0483] The 5:5 printer 4-color dot data is accepted by the
printhead at 2-bits per cycle at 320 MHz. 4 bits are available
after 2 cycles at 320 MHz, and these 4-bits would then need to be
clocked into the shift registers within the printhead at a rate of
160 MHz.
[0484] Since the 6:4 and 7:3 printhead configuration schemes
require additional bandwidth etc., the printhead needs some change
to support these additional forms of 60 ppm printing.
[0485] Given the problems described above, the following issues
have been addressed for 60 ppm printing based on the earlier SoPEC
architecture: [0486] rate of data generation [0487] transmission to
the printhead [0488] shift register setup within the printhead.
[0489] Assuming the current bi-lithic printhead, there are 3 basic
classes of solutions to allow 60 ppm:
a. Each SoPEC generates dot data and transmits that data to a
single printhead connection, as shown in FIG. 41.
b. One SoPEC generates data and transmits to the smaller printhead,
but both SoPECs generate and transmit directly to the larger
printhead, as shown in FIG. 42.
c. Same as (b) except that SoPEC A only transmits to printhead B
via SoPEC B (i.e. instead of directly), as shown in FIG. 43.
[0490] This solution class is where each SoPEC generates dot data
and transmits that data to a single printhead connection, as shown
in FIG. 41. The existing SoPEC architecture is targeted at this
class of solution.
[0491] To achieve 60 ppm using the same basic architecture as
currently implemented, the following needs to occur: [0492]
Increase effective dot generation rate to 206 MHz [0493] Increase
bandwidth to printhead to 1256 Mb/sec [0494] Increase bandwidth of
printhead shift registers to match transmission bandwidth
[0495] It should be noted that even when all these speed
improvements are implemented, one SoPEC will still be producing 40%
more dots than it would be under a 5:5 scheme. i.e. this class of
solution is not load balanced.
[0496] In a scenario of connecting the printheads together to
appear logically as a 5:5, each SoPEC generates data as if for a
5:5 printhead, and the printhead, even though it is physically a
5:5, 6:4 or 7:3 printhead, maintains a logical appearance of a 5:5
printhead.
[0497] There are a number of means of accomplishing this logical
appearance, but they all rely on the two printheads being connected
in some way, as shown in FIG. 42.
[0498] In this embodiment, the dot generation rate no longer needs
to be addressed as only the 5:5 dot generation rate is required,
and the current speed of 160 MHz is sufficient.
[0499] One SoPEC can generate data and transmit to the smaller
printhead, but both SoPECs generate and transmit directly to the
larger printhead, as shown in FIG. 43. i.e. SoPEC A transmits to
printheads A and B, while SoPEC B transmits only to printhead B.
The intention is to allow each SoPEC to generate the dot data for a
type 5 printhead, and thereby to balance the dot generation
load.
[0500] Since the connections between SoPEC and printhead are
point-to-point, it requires a doubling of printhead connections on
the larger printhead (one connection set goes to SoPEC A and the
other goes to SoPEC B).
[0501] Two connections on the printhead can be connected to the
same shift register to form a serial load. Thus the shift register
can be driven by either SoPEC, as shown in FIG. 44.
[0502] The 2 SoPECs take turns (under synchronisation) in
transmitting on their individual lines as follows: [0503] SoPEC B
transmits even (or odd) data for 5 segments [0504] SoPEC A
transmits data for 5-printhead A segments even and odd [0505] SoPEC
B transmits the odd (or even) data for 5 segments.
[0506] Meanwhile SoPEC A is transmitting the data for printhead A,
which will be length 3, 4, or 5.
[0507] Note that SoPEC A is transmitting as if to a printhead
combination of N:5-N, which means that the dot generation pathway
(other than synchronization) is already as defined.
[0508] Although the dot generation problem is resolved by this
scenario (each SoPEC generates data for half the page width and
therefore it is load balanced), the transmission speed for each
connection must be sufficient to deliver to a type7 printhead i.e.
1256 Mb/sec. In addition, the bandwidth of the printhead shift
registers must be altered to match the transmission bandwidth.
[0509] The two connections on the printhead can be connected to
different shift registers to form a parallel load, as shown in FIG.
45. Thus the two SoPECs can write to the printhead in parallel.
Note that SoPEC A is transmitting as if to a printhead combination
of N:5-N, which means that the dot generation pathway is already as
defined.
[0510] The dot generation problem is resolved by this scenario
since each SoPEC generates data for half the page width and
therefore it is load balanced.
[0511] Since the connections operate in parallel, the transmission
speed required is that required to address 5:5 printing, i.e. 891
Mb/sec. In addition, the bandwidth of the printhead shift registers
must be altered to match the transmission bandwidth.
[0512] SoPEC A may only transmit to printhead B via SoPEC B (i.e.
instead of directly), as shown in FIG. 46 i.e. SoPEC A transmits
directly to printhead A and indirectly to printhead B via SoPEC B,
while SoPEC B transmits only to printhead B.
[0513] This class of architecture has the attraction that a
printhead is driven by a single SoPEC, which minimizes the number
of pins on a printhead. However it requires receiver connections on
SoPEC B. It becomes particularly practical (costwise) if those
receivers are currently unused (i.e. they would have been used for
transmitting to the second printhead in a single SoPEC system). Of
course this assumes that the pins are not being used to achieve the
higher bandwidth.
[0514] Although the dot generation problem is resolved by this
scenario (each SoPEC generates data for half the page width and
therefore it is load balanced), the transmission speed for each
connection must be sufficient to deliver to a type7 printhead i.e.
1256 Mb/sec. In addition, the bandwidth of the printhead shift
registers must be altered to match the transmission bandwidth.
[0515] If SoPEC B provides at least a line buffer for the data
received from SoPEC A, then the transmission between SoPEC A and
printhead A is decoupled, and although the bandwidth from SoPEC B
to printhead B must be 1256 Mb/sec, the bandwidth between the two
SoPECs can be lower i.e. enough to transmit 2 segments worth of
data (359 Mb/sec).
[0516] Architecture A has the problem that no matter what the
increase in speed, the solution is not load balanced, leaving
architecture B or C the more preferred solution where
load-balancing between SoPEC chips is desirable or necessary. The
main advantage of an architecture A style solution is that it
reduces the number of connections on the printhead.
[0517] All architectures require the increase in bandwidth to the
printhead, and a change to the internal shift register structure of
the printhead.
[0518] Other architectures can be used where different printhead
modules are used. For example, in one embodiment, the dot data is
provided from a single printed controller (SOPEC) via multiple
serial links to a printhead. Preferably, the links in this
embodiment each carry dot data for more than one channel (color,
etc) of the printhead. For example, one link can carry CMY dot data
from the printer controller and the other channel can carry K, IR
and fixative channels.
[0519] 60 ppm printing using bi-lithic printheads is risky due to
increased CPU requirements, increased numbers of pins, and the high
data rates at which the transmission occurs. It also relies on
stitching working correctly on the printheads to allow the creation
of long printheads over several reticles.
[0520] Therefore an alternative to 60 ppm printing via bi-lithic
printheads should be found.
[0521] The basic idea of the linking printhead is that we create a
printhead from tiles each of which can be fully formed within the
reticle. The printheads are linked together as shown in FIG. 50 to
form the page-width printhead. For example, an A4/Letter page is
assembled from 11 tiles. The printhead is assembled by linking or
butting up tiles next to each other. The physical process used for
linking means that wide-format printheads are not readily
fabricated (unlike the 21 mm tile). However printers up to around
A3 portrait width (12 inches) are expected to be possible. The
nozzles within a single segment are grouped physically to reduce
ink supply complexity and wiring complexity. They are also grouped
logically to minimize power consumption and to enable a variety of
printing speeds, thereby allowing speed/power consumption
trade-offs to be made in different product configurations.
[0522] Each printhead segment contains a constant number of nozzles
per color (currently 1280), divided into half (640) even dots and
half (640) odd dots. If all of the nozzles for a single color were
fired at simultaneously, the even and odd dots would be printed on
different dot-rows of the page such that the spatial difference
between any even/odd dot-pair is an exact number of dot lines. In
addition, the distance between a dot from one color and the
corresponding dot from the next color is also an exact number of
dot lines.
[0523] The exact distance between even and odd nozzle rows, and
between colors will vary between embodiments, so it is preferred
that these relationships be programmable with respect to SoPEC.
When 11 segments are joined together to create a 30 ppm printhead,
a single SoPEC will connect to them as shown in FIG. 51.
[0524] Notice that each phDataOutn lvds pair goes to two adjacent
printhead segments, and that each phClkn signal goes to 5 or 6
printhead segments. Each phRstn signal goes to alternate printhead
segments.
[0525] SoPEC drives phRst0 and phRst1 to put all the segments into
reset.
[0526] SoPEC then lets phRst1 come out of reset, which means that
all the segment 1, 3, 5, 7, and 9 are now alive and are capable of
receiving commands.
[0527] SoPEC can then communicate with segment 1 by sending
commands down phDataOut0, and program the segment 1 to be id 1. It
can communicate with segment 3 by sending commands down phDataOut1,
and program segment 3 to be id 1. This process is repeated until
all segments 1, 3, 5, 7, and 9 are assigned ids of 1. The id only
needs to be unique per segment addressed by a given phDataOutn
line.
[0528] SoPEC can then let phRst0 come out of reset, which means
that segments 0, 2, 4, 6, 8, and 10 are all alive and are capable
of receiving commands. The default id after reset is 0, so now each
of the segments is capable of receiving commands along the same
pDataOutn line.
[0529] SoPEC needs to be able to send commands to individual
printheads, and it does so by writing to particular registers at
particular addresses.
[0530] The exact relationship between id and register address etc.
is yet to be determined, but at the very least it will involve the
CPU being capable of telling the PHI to send a command byte
sequence down a particular phDataOutn line.
[0531] One possibility is that one register contains the id
(possibly 2 bits of id). Further, a command may consist of: [0532]
register write [0533] register address [0534] data
[0535] A 10-bit wide fifo can be used for commands in the PHI.
[0536] When 11 segments are joined together to create a 60 ppm
printhead, the 2 SoPECs will connect to them as shown in FIG.
52.
[0537] In the 60 ppm case only phClk0 and phRst0 are used (phClk1
and phRst1 are not required). However note that lineSync is
required instead. It is possible therefore to reuse phRst1 as a
lineSync signal for multi-SoPEC synchronisation. It is not possible
to reuse the pins from phClk1 as they are lvds. It should be
possible to disable the lvds pads of phClk1 on both SoPECs and
phDataOut5 on SoPEC B and therefore save a small amount of
power.
[0538] Various classes of printhead that can be used are now
described. With the exception of the PEC1 style slope printhead,
SoPEC is designed to be capable of working with each of these
printhead types at full 60 ppm printing speed.
[0539] The A-chip/A-chip printhead style consists of identical
printhead tiles (type A) assembled in such a way that rows of
nozzles between 2 adjacent chips have no vertical misalignment.
[0540] The most ideal format for this kind of printhead from a data
delivery point of view is a rectangular join between two adjacent
printheads, as shown in FIG. 53. However due to the requirement for
dots to be overlapping, a rectangular join results in a it results
in a vertical stripe of white down the join section since no nozzle
can be in this join region. A white stripe is not acceptable, and
therefore this join type is not acceptable.
[0541] FIG. 54 shows a sloping join similar to that described for
the bi-lithic printhead chip, and FIG. 55 is a zoom in of a single
color component, illustrating the way in which there is no visible
join from a printing point of view (i.e. the problem seen in FIG.
53 has been solved).
[0542] The A-chip/A-chip setup described above requires perfect
vertical alignment. Due to a variety of factors (including ink
sealing) it may not be possible to have perfect vertical alignment.
To create more space between the nozzles, A-chips can be joined
with a growing vertical offset, as shown in FIG. 56.
[0543] The growing offset comes from the vertical offset between
two adjacent tiles. This offset increases with each join. For
example, if the offset were 7 lines per join, then an 11 segment
printhead would have a total of 10 joins, and 70 lines.
[0544] To supply print data to the printhead for a growing offset
arrangement, the print data for the relevant lines must be present.
A simplistic solution of simply holding the entire line of data for
each additional line required leads to increased line store
requirements. For example, an 11 segment.times.1280-dot printhead
requires an additional 11.times.1280-dots.times.6-colors per line
i.e. 10.3125 Kbytes per line. 70 lines requires 722 Kbytes of
additional storage. Considering SoPEC contains only 2.5 MB total
storage, an additional 722 Kbytes just for the offset component is
not desirable. Smarter solutions require storage of smaller parts
of the line, but the net effect is the same: increased storage
requirements to cope with the growing vertical offset.
[0545] The problem of a growing offset described above is that a
number of additional lines of storage need to be kept, and this
number increases proportional to the number of joins i.e. the
longer the printhead the more lines of storage are required.
[0546] However, we can place each chip on a mild slope to achieve a
constant number of printlines regardless of the number of joins.
The arrangement is similar to that used in PEC1, where the
printheads are sloping. The difference here is that each printhead
is only mildly sloping, for example so that the total number of
lines gained over the length of the printhead is 7. The next
printhead can then be placed offset from the first, but this offset
would be from the same base. i.e. a printhead line of nozzles
starts addressing line n, but moves to different lines such that by
the end of the line of nozzles, the dots are 7 dotlines distant
from the startline. This means that the 7-line offset required by a
growing-offset printhead can be accommodated.
[0547] The arrangement is shown in FIG. 57.
[0548] If the offset were 7 rows, then a total of 72.2 KBytes are
required to hold the extra rows, which is a considerable saving
over the 722 Kbytes required above.
[0549] Note also, that in this example, the printhead segments are
vertically aligned (as in PEC1). It may be that the slope can only
be a particular amount, and that growing offset compensates for
additional differences--i.e. the segments could in theory be
misaligned vertically. In general SoPEC must be able to cope with
vertically misaligned printhead segments.
[0550] The question then arises as to how much slope must be
compensated for at 60 ppm speed. Basically--as much as can
comfortably handled without too much logic. However, amounts like 1
in 256 (i.e. 1 in 128 with respect to a half color), or 1 in 128
(i.e. 1 in 64 with respect to a half color) must be possible.
Greater slopes and weirder slopes (e.g. 1 in 129 with respect to a
half color) must be possible, but with a sacrifice of speed i.e.
SoPEC must be capable even if it is a slower print.
[0551] Note also that the nozzles are aligned, but the chip is
placed sloped. This means that when horizontal lines are attempted
to be printed and if all nozzles were fired at once, the effect
would be lots of sloped lines. However, if the nozzles are fired in
the correct order relative to the paper movement, the result is a
straight line for n dots, then another straight line for n dots 1
line up. The PEC1 style slope is the physical arrangement used by
printhead segments addressed by PEC1. Note that SoPEC is not
expected to work at 60 ppm speed with printheads connected in this
way. However it is expected to work and is shown here for
completeness, and if tests should prove that there is no working
alternative to the 21 mm tile, then SoPEC will require significant
reworking to accommodate this arrangement at 60 ppm.
[0552] In this scheme, the segments are joined together by being
placed on an angle such that the segments fit under each other, as
shown in FIG. 58. The exact angle will depend on the width of the
Memjet segment and the amount of overlap desired, but the vertical
height is expected to be in the order of 1 mm, which equates to 64
dot lines at 1600 dpi.
[0553] FIG. 59 shows more detail of a single segment in a
multi-segment configuration, considering only a single row of
nozzles for a single color plane. Each of the segments can be
considered to produce dots for multiple sets of lines. The leftmost
d nozzles (d depends on the angle that the segment is placed at)
produce dots for line n, the next d nozzles produce dots for line
n-1, and so on.
[0554] A-chip/A-chip with inter line compensation is effectively
the same as described above except that the nozzles are physically
arranged inside the printhead to compensate for the nozzle firing
order given the desire to spread the power across the printhead.
This means that one nozzle and its neighbor can be vertically
separated on the printhead by 1 printline. i.e. the nozzles don't
line up across the printhead. This means a jagged effect on printed
"horizontal lines" is avoided, while achieving the goal of
averaging the power.
[0555] The arrangement of printheads is the same as that shown in
FIG. 57. However the actual nozzles are slightly differently
arranged, as illustrated via magnification in FIG. 60.
[0556] Another possibility is to have two kinds of printing chips:
an A-type and a B-type. The two types of chips have different
shapes, but can be joined together to form long printheads. A
parallelogram is formed when the A-type and B-type are joined.
[0557] The two types are joined together as shown in FIG. 61.
[0558] Note that this is not a growing offset. The segments of a
multiple-segment printhead have alternating fixed vertical offset
from a common point, as shown in FIG. 62.
[0559] If the vertical offset from a type-A to a type-B printhead
were n lines, the entire printhead regardless of length would have
a total of n lines additionally required in the line store. This is
certainly a better proposition than a growing offset).
[0560] However there are many issues associated with an
A-chip/B-chip printhead. Firstly, there are two different chips
i.e. an A-chip, and a B-chip. This means 2 masks, 2 developments,
verification, and different handling, sources etc. It also means
that the shape of the joins are different for each printhead
segment, and this can also imply different numbers of nozzles in
each printhead. Generally this is not a good option.
[0561] The general linking concept illustrated in the A-chip/B-chip
can be incorporated into a single printhead chip that contains the
A-B join within the single chip type.
[0562] This kind of joining mechanism is referred to as the A-B
chip since it is a single chip with A and B characteristics. The
two types are joined together as shown in FIG. 63.
[0563] This has the advantage of the single chip for manipulation
purposes.
[0564] SoPEC must compensate for the vertical misalignment within
the printhead. The amount of misalignment is the amount of
additional line storage required.
[0565] Note that this kind of printhead can effectively be
considered similar to the mildly sloping printhead described above
except that the step at the discontinuity is likely to be many
lines vertically (on the order of 7 or so) rather than the 1 line
that a gentle slope would generate.
[0566] The A-B chip with printhead compensation kind of printhead
is where we push the A-B chip discontinuity as far along the
printhead segment as possible--right to the edge. This maximises
the A part of the chip, and minimizes the B part of the chip. If
the B part is small enough, then the compensation for vertical
misalignment can be incorporated on the printhead, and therefore
the printhead appears to SoPEC as if it was a single typeA chip.
This only makes sense if the B part is minimized since printhead
real-estate is more expensive at 0.35 microns rather than on SoPEC
at 0.18 microns.
[0567] The arrangement is shown in FIG. 64.
[0568] Note that since the compensation is accomplished on the
printhead, the direction of paper movement is fixed with respect to
the printhead. This is because the printhead is keeping a history
of the data to apply at a later time and is only required to keep
the small amount of data from the B part of the printhead rather
than the A part.
[0569] Within reason, some of the various linking methods can be
combined. For example, we may have a mild slope of 5 over the
printhead, plus an on-chip compensation for a further 2 lines for a
total of 7 lines between type A chips. The mild slope of 5 allows
for a 1 in 128 per half color (a reasonable bandwidth increase),
and the remaining 2 lines are compensated for in the printheads so
do not impact bandwidth at all.
[0570] However we can assume that some combinations make less
sense. For example, we do not expect to see an A-B chip with a mild
slope.
[0571] A linking printhead is constructed from linking printhead
ICs, placed on a substrate containing ink supply holes. An A4
pagewidth printer used 11 linking printhead ICs. Each printhead is
placed on the substrate with reference to positioning fidicuals on
the substrate.
[0572] FIG. 65 shows the arrangement of the printhead ICs (also
known as segments) on a printhead. The join between two ICs is
shown in detail. The left-most nozzles on each row are dropped by
10 line-pitches, to allow continuous printing across the join. FIG.
65 also introduces some naming and co-ordinate conventions used
throughout this document.
[0573] FIG. 65 shows the anticipated first generation linking
printhead nozzle arrangements, with 10 nozzle rows supporting five
colours. The SoPEC compensation mechanisms are general enough to
cover other nozzle arrangements.
[0574] Printheads ICs may be misplaced relative to their ideal
position. This misplacement may include any combination of: [0575]
x offset [0576] y offset [0577] yaw (rotation around z) [0578]
pitch (rotation around y) [0579] roll (rotation around z)
[0580] In some cases, the best visual results are achieved by
considering relative misplacement between adjacent ICs, rather than
absolute misplacement from the substrate. There are some practical
limits to misplacement, in that a gross misplacement will stop the
ink from flowing through the substrate to the ink channels on the
chip.
[0581] Correcting for misplacement obviously requires the
misplacement to be measured. In general this may be achieved
directly by inspection of the printhead after assembly, or
indirectly by scanning or examining a printed test pattern.
[0582] SoPEC can compensate for misplacement of linking chips in
the X-direction, but only snapped to the nearest dot. That is, a
misplacement error of less than 0.5 dot-pitches or 7.9375 microns
is not compensated for, a misplacement more that 0.5 dot-pitches
but less than 1.5 dot-pitches is treated as a misplacement of 1
dot-pitch, etc.
[0583] Uncompensated X misplacement can result in three effects:
[0584] printed dots shifted from their correct position for the
entire misplaced segment [0585] missing dots in the overlap region
between segments. [0586] duplicated dots in the overlap region
between segments.
[0587] SoPEC can correct for each of these three effects.
[0588] In preparing line data to be printed, SoPEC buffers in
memory the dot data for a number of lines of the image to be
printed. Compensation for misplacement generally involves changing
the pattern in which this dot data is passed to the printhead
ICs.
[0589] SoPEC uses separate buffers for the even and odd dots of
each colour on each line, since they are printed by different
printhead rows. So SoPEC's view of a line at this stage is as (up
to) 12 rows of dots, rather than (up to) 6 colours. Nominally, the
even dots for a line are printed by the lower of the two rows for
that colour on the printhead, and the odd dots are printed by the
upper row (see FIG. 65). For the current linking printhead IC,
there are 640 nozzles in row. Each row buffer for the full
printhead would contain 640.times.11 dots per line to be printed,
plus some padding if required.
[0590] In preparing the image, SoPEC can be programmed in the DWU
module to precompensate for the fact that each row on the printhead
IC is shifted left with respect to the row above. In this way the
leftmost dot printed by each row for a colour is the same offset
from the start of a row buffer. In fact the programming can support
arbitrary shapes for the printhead IC.
[0591] SoPEC has independent registers in the LLU module for each
segment that determine which dot of the prepared image is sent to
the left-most nozzle of that segment. Up to 12 segments are
supported. With no misplacement, SoPEC could be programmed to pass
dots 0 to 639 in a row to segment 0, dots 640 to 1279 in a row to
segment 1, etc.
[0592] If segment 1 was misplaced by 2 dot-pitches to the right,
SoPEC could be adjusted to pass to dots 641 to 1280 of each row to
segment 1 (remembering that each row of data consists entirely of
either odd dots or even dots from a line, and that dot 1 on a row
is printed two dot positions away from dot 0). This means the dots
are printed in the correct position overall. This adjustment is
based on the absolute placement of each printhead IC. Dot 640 is
not printed at all, since there is no nozzle in that position on
the printhead.
[0593] A misplacement of an odd number of dot-pitches is more
problematic, because it means that the odd dots from the line now
need to be printed by the lower row of a colour pair, and the even
dots by the upper row of a colour pair on the printhead segment.
Further, swapping the odd and even buffers interferes with the
precompensation. This results in the position of the first dot to
be sent to a segment being different for odd and even rows of the
segment. SoPEC addresses this by having independent registers in
the LLU to specify the first dot for the odd and even rows of each
segment, i.e. 2.times.12 registers. A further register bit
determines whether dot data for odd and even rows should be swapped
on a segment by segment basis.
[0594] FIG. 66 shows the detailed alignment of dots at the join
between two printhead ICs, for various cases of misplacement, for a
single colour.
[0595] The effects at the join depend on the relative misplacement
of the two segments. In the ideal case with no misplacement, the
last 3 nozzles of upper row of the segment N interleave with the
first three nozzles of the lower row of segment N+1, giving a
single nozzle (and so a single printed dot) at each dot-pitch.
[0596] When segment N+1 is misplaced to the right relative to
segment N (a positive relative offset in X), there are some dot
positions without a nozzle, i.e. missing dots. For positive offsets
of an odd number of dot-pitches, there may also be some dot
positions with two nozzles, i.e. duplicated dots. Negative relative
offsets in X of segment N+1 with respect to segment N are less
likely, since they would usually result in a collision of the
printhead ICs, however they are possible in combination with an
offset in Y. A negative offset will always cause duplicated dots,
and will cause missing dots in some cases. Note that the placement
and tolerances can be deliberately skewed to the right in the
manufacturing step to avoid negative offsets.
[0597] Where two nozzles occupy the same dot position, the
corrections described above will result in SoPEC reading the same
dot data from the row buffer for both nozzles. To avoid printing
this data twice SoPEC has two registers per segment in the LLU that
specify a number (up to 3) of dots to suppress at the start of each
row, one register applying to even dot rows, one to odd dot
rows.
[0598] SoPEC compensates for missing dots by add the missing nozzle
position to its dead nozzle map. This tells the dead nozzle
compensation logic in the DNC module to distribute the data from
that position into the surrounding nozzles, before preparing the
row buffers to be printed.
[0599] SoPEC can compensate for misplacement of printhead ICs in
the Y-direction, but only snapped to the nearest 0.1 of a line.
Assuming a line-pitch of 15.875 microns, if an IC is misplaced in Y
by 0 microns, SoPEC can print perfectly in Y. If an IC is misplaced
by 1.5875 microns in Y, then we can print perfectly. If an IC is
misplaced in Y by 3.175 microns, we can print perfectly. But if an
IC is misplaced by 3 microns, this is recorded as a misplacement of
3.175 microns (snapping to the nearest 0.1 of a line), and
resulting in a Y error of 0.175 microns (most likely an
imperceptible error).
[0600] Uncompensated Y misplacement results in all the dots for the
misplaced segment being printed in the wrong position on the
page.
[0601] SoPEC's compensation for Y misplacement uses two mechanism,
one to address whole line-pitch misplacement, and another to
address fractional line-pitch misplacement. These mechanisms can be
applied together, to compensate for arbitrary misplacements to the
nearest 0.1 of a line.
[0602] The buffers used to hold dot data to be printed for each row
contain dot data for multiple lines of the image to be printed. Due
to the physical separation of nozzle rows on a printhead IC, at any
time different rows are printing data from different lines of the
image.
[0603] For a printhead on which all ICs are ideally placed, row 0
of each segment is printing data from the line N of the image, row
1 of each segment is printing data from row N-M of the image etc.
where N is the separation of rows 0 and 1 on the printhead.
Separate SoPEC registers in the LLU for each row specify the
designed row separations on the printhead, so that SoPEC keeps
track of the "current" image line being printed by each row.
[0604] If one segment is misplaced by one whole line-pitch, SoPEC
can compensate by adjusting the line of the image being sent to
each row of that segment. This is achieved by adding an extra
offset on the row buffer address used for that segment, for each
row buffer. This offset causes SoPEC to provide the dot data to
each row of that segment from one line further ahead in the image
than the dot data provided to the same row on the other segments.
For example, when the correctly placed segments are printing line N
of an image with row 0, line N-M of the image with row 1, etc, then
the misplaced segment is printing line N+1 of the image with row 0,
line N-M+1 of the image with row 1, etc.
[0605] SoPEC has one register per segment to specify this whole
line-pitch offset. The offset can be multiple line-pitches,
compensating for multiple lines of misplacement. Note that the
offset can only be in the forward direction, corresponding to a
negative Y offset. This means the initial setup of SoPEC must be
based on the highest (most positive) Y-axis segment placement, and
the offsets for other segments calculated from this baseline.
Compensating for Y displacement requires extra lines of dot data
buffering in SoPEC, equal to the maximum relative Y offset (in
line-pitches) between any two segments on the printhead. For each
misplaced segment, each line of misplacement requires approximately
640.times.10 or 6400 extra bits of memory.
[0606] Compensation for fractional line-pitch displacement of a
segment is achieved by a combination of SoPEC and printhead IC fire
logic.
[0607] The nozzle rows in the printhead are positioned by design
with vertical spacings in line-pitches that have a integer and
fractional component. The fractional components are expressed
relative to row zero, and are always some multiple of 0.1 of a
line-pitch. The rows are fired sequentially in a given order, and
the fractional component of the row spacing matches the distance
the paper will move between one row firing and the next. FIG. 67
shows the row position and firing order on the current
implementation of the printhead IC. Looking at the first two rows,
the paper moves by 0.5 of a line-pitch between the row 0 (fired
first) and row 1 (fired sixth). is supplied with dot data from a
line 3 lines before the data supplied to row 0. This data ends up
on the paper exactly 3 line-pitches apart, as required.
[0608] If one printhead IC is vertically misplaced by a non-integer
number of line-pitches, row 0 of that segment no longer aligns to
row 0 of other segments. However, to the nearest 0.1 of a line,
there is one row on the misplaced segment that is an integer number
of line-pitches away from row 0 of the ideally placed segments. If
this row is fired at the same time as row 0 of the other segments,
and it is supplied with dot data from the correct line, then its
dots will line up with the dots from row 0 of the other segments,
to within a 0.1 of a line-pitch. Subsequent rows on the misplaced
printhead can then be fired in their usual order, wrapping back to
row 0 after row 9. This firing order results in each row firing at
the same time as the rows on the other printheads closest to an
integer number of line-pitches away.
[0609] FIG. 68 shows an example, in which the misplaced segment is
offset by 0.3 of a line-pitch. In this case, row 5 of the misplaced
segment is exactly 24.0 line-pitches from row 0 of the ideal
segment. Therefore row 5 is fired first on the misplaced segment,
followed by row 7, 9, 0 etc. as shown. Each row is fired at the
same time as the a row on the ideal segment that is an integer
number of lines away. This selection of the start row of the firing
sequence is controlled by a register in each printhead IC.
[0610] SoPEC's role in the compensation for fractional line-pitch
misplacement is to supply the correct dot data for each row.
Looking at FIG. 68, we can see that to print correct, row 5 on the
misplaced printhead needs dot data from a line 24 lines earlier in
the image than the data supplied to row 0. On the ideal printhead,
row 5 needs dot data from a line 23 lines earlier in the image than
the data supplied to row 0. In general, when a non-default start
row is used for a segment, some rows for that segment need their
data to be offset by one line, relative to the data they would
receive for a default start row. SoPEC has a register in LLU for
each row of each segment, that specifies whether to apply a one
line offset when fetching data for that row of that segment.
[0611] The Roll (rotation around X) kind of erroneous rotational
displacement means that all the nozzles will end up pointing
further up the page in Y or further down the page in Y. The effect
is the same as a Y misplacement, except there is a different Y
effect for each media thickness (since the amount of misplacement
depends on the distance the ink has to travel).
[0612] In some cases, it may be that the media thickness makes no
effective visual difference to the outcome, and this form of
misplacement can simply be incorporated into the Y misplacement
compensation. If the media thickness does make a difference which
can be characterised, then the Y misplacement programming can be
adjusted for each print, based on the media thickness. It will be
appreciated that correction for roll is particularly of interest
where more than one printhead module is used to form a printhead,
since it is the discontinuities between strips printed by adjacent
modules that are most objectionable in this context.
[0613] In the pitch (rotation around Y) rotation, one end of the IC
is further into the substrate than the other end. This means that
the printing on the page will be dots further apart at the end that
is further away from the media (i.e. less optical density), and
dots will be closer together at the end that is closest to the
media (more optical density) with a linear fade of the effect from
one extreme to the other. Whether this produces any kind of visual
artifact is unknown, but it is not compensated for in SoPEC.
[0614] The yaw (rotation around Z) kind of erroneous rotational
displacement means that the nozzles at one end of a IC will print
further down the page in Y than the other end of the IC. There may
also be a slight increase in optical density depending on the
rotation amount.
[0615] SoPEC can compensate for this by providing first order
continuity, although not second order continuity in the preferred
embodiment. First order continuity (in which the Y position of
adjacent line ends is matched) is achieved using the Y offset
compensation mechanism, but considering relative rather than
absolute misplacement. Second order continuity (in which the slope
of the lines in adjacent print modules is at least partially
equalised) can be effected by applying a Y offset compensation on a
per pixel basis. Whilst one skilled in the art will have little
difficulty deriving the timing difference that enables such
compensation, SoPEC does not compensate for it and so it is not
described here in detail.
[0616] FIG. 69 shows an example where printhead IC number 4 is be
placed with yaw, is shown in FIG. 69, while all other ICs on the
printhead are perfectly placed. The effect of yaw is that the left
end of segment 4 of the printhead has an apparent Y offset of -1
line-pitch relative to segment 3, while the right end of segment 4
has an apparent Y offset of 1 line-pitch relative to segment 5.
[0617] To provide first-order continuity in this example, the
registers on SoPEC would be programmed such that segments 0 to 3
have a Y offset of 0, segment 4 has a Y offset of -1, and segments
5 and above have Y offset of -2. Note that the Y offsets accumulate
in this example--even though segment 5 is perfect aligned to
segment 3, they have different Y offsets programmed.
[0618] It will be appreciated that some compensation is better than
none, and it is not necessary in all cases to perfectly correct for
roll and/or yaw. Partial compensation may be adequate depending
upon the particular application. As with roll, yaw correction is
particularly applicable to multi-module printheads, but can also be
applied in single module printheads.
[0619] The printhead will be designed for 5 colors. At present the
intended use is: [0620] cyan [0621] magenta [0622] yellow [0623]
black [0624] infra-red
[0625] However the design methodology must be capable of targeting
a number other than 5 should the actual number of colors change. If
it does change, it would be to 6 (with fixative being added) or to
4 (with infra-red being dropped).
[0626] The printhead chip does not assume any particular ordering
of the 5 colour channels.
[0627] The printhead will contain 1280 nozzles of each color--640
nozzles on one row firing even dots, and 640 nozzles on another row
firing odd dots. This means 11 linking printheads are required to
assemble an A4/Letter printhead.
[0628] However the design methodology must be capable of targeting
a number other than 1280 should the actual number of nozzles per
color change. Any different length may need to be a multiple of 32
or 64 to allow for ink channel routing.
[0629] The printhead will target true 1600 dpi printing. This means
ink drops must land on the page separated by a distance of 15.875
microns.
[0630] The 15.875 micron inter-dot distance coupled with mems
requirements mean that the horizontal distance between two adjacent
nozzles on a single row (e.g. firing even dots) will be 31.75
microns.
[0631] All 640 dots in an odd or even colour row are exactly
aligned vertically. Rows are fired sequentially, so a complete row
is fired in small fraction (nominally one tenth) of a line time,
with individual nozzle firing distributed within this row time. As
a result dots can end up on the paper with a vertical misplacement
of up to one tenth of the dot pitch. This is considered
acceptable.
[0632] The vertical distance between rows is adjusted based on the
row firing order. Firing can start with any row, and then follows a
fixed rotation. FIG. 70 shows the default row firing order from 1
to 10, starting at the top even row. Rows are separated by an exact
number of dot lines, plus a fraction of a dot line corresponding to
the distance the paper will move between row firing times. This
allows exact dot-on-dot printing for each colour. The starting row
can be varied to correct for vertical misalignment between chips,
to the nearest 0.1 pixels. SoPEC appropriate delays each row's data
to allow for the spacing and firing order
[0633] An additional constraint is that the odd and even rows for
given colour must be placed close enough together to allow them to
share an ink channel. This results in the vertical spacing shown in
FIG. 70, where L represents one dot pitch.
[0634] Multiple identical printhead chips must be capable of being
linked together to form an effectively horizontal assembled
printhead.
[0635] Although there are several possible internal arrangements,
construction and assembly tolerance issues have made an internal
arrangement of a dropped triangle (ie a set of rows) of nozzles
within a series of rows of nozzles, as shown in FIG. 71. These
printheads can be linked together as shown in FIG. 72.
[0636] Compensation for the triangle is preferably performed in the
printhead, but if the storage requirements are too large, the
triangle compensation can occur in SoPEC. However, if the
compensation is performed in SoPEC, it is required in the present
embodiment that there be an even number of nozzles on each side of
the triangle.
[0637] It will be appreciated that the triangle disposed adjacent
one end of the chip provides the minimum on-printhead storage
requirements. However, where storage requirements are less
critical, other shapes can be used. For example, the dropped rows
can take the form of a trapezoid.
[0638] The join between adjacent heads has a 45.degree. angle to
the upper and lower chip edges. The joining edge will not be
straight, but will have a sawtooth or similar profile. The nominal
spacing between tiles is 10 microns (measured perpendicular to the
edge). SoPEC can be used to compensate for both horizontal and
vertical misalignments of the print heads, at some cost to memory
and/or print quality.
[0639] Note also that paper movement is fixed for this particular
design. A print rate of 60 A4/Letter pages per minute is possible.
The printhead will assume the following: [0640] page length=297 mm
(A4 is longest page length) [0641] an inter-page gap of 60 mm or
less (current best estimate is more like 15+/-5 mm
[0642] This implies a line rate of 22,500 lines per second. Note
that if the page gap is not to be considered in page rate
calculations, then a 20 KHz line rate is sufficient.
[0643] Assuming the page gap is required, the printhead must be
capable of receiving the data for an entire line during the line
time. i.e. 5 colors1280 dots22,500 lines=144 MHz or better (173 MHz
for 6 colours).
[0644] The SRM043 is a CMOS and MEMS integrated chip. The MEMS
structures/nozzles can eject ink which has passed through the
substrate of the CMOS via small etched holes.
[0645] The SRM043 has nozzles arranged to create a accurately
placed 1600 dots per inch printout. The SRM043 has 5 colours, 1280
nozzles per colour.
[0646] The SRM043 is designed to link to a similar SRM043 with
perfect alignment so the printed image has no artifacts across the
join between the two chips.
[0647] SRM043 contains 10 rows of nozzles, arranged as upper and
lower row pairs of 5 different inks. The paired rows share a common
ink channel at the back of the die. The nozzles in one of the
paired rows are horizontally spaced 2 dot pitches apart, and are
offset relative to each other. 1600 dpi has a dot pitch of DP15.875
m. The MEMS print nozzle unit cell is 2DP wide by 5DP high (31.75
m.times.79.375 m). To achieve 1600 dpi per colour, 2 horizontal
rows of (1280/2) nozzles are placed with a horizontal offset of 5DP
(2.5 cells). Vertical offset is 3.5DP between the two rows of the
same colour and 10.1DP between rows of different colour. This slope
continues between colours and results in a print area which is a
trapezoid as shown in FIG. 73.
[0648] Within a row, the nozzles are perfectly aligned
vertically.
[0649] For ink sealing reasons a large area of silicon beyond the
end nozzles in each row is required on the base of the die, near
where the chip links to the next chip. To do this the first
4*Row#+4-2*(Row# mod 2) nozzles from each row are vertical shifted
down DP.
[0650] Data for the nozzles in the triangle must be delayed by 10
line times to match the triangle vertical offset. The appropriate
number of data bits at the start of each row are put into a FIFO.
Data from the FIFO's output is used instead. The rest of the data
for the row bypasses the FIFO. Because the MEMS are enabled with a
PMOSFET driver from Vpos it is necessary to ensure that this driver
is disabled at and after power up. This means that Vdd must be
supplied with RstL asserted (0 Volts). At least 3 clk cycles must
be applied before deasserting RstL.
[0651] SRM043 consists of a core of 10 rows of 640 MEMS constructed
ink ejection nozzles. Around each of these nozzles is a CMOS unit
cell.
[0652] The basic operation of the SRM043 is to [0653] receive dot
data for all colours for a single line [0654] fire all nozzles
according to that dot data
[0655] To minimise peak power, nozzles are not all fired
simultaneously, but are spread as evenly as possible over a line
time. The firing sequence and nozzle placement are designed taking
into account paper movement during a line, so that dots can be
optimally placed on the page. Registers allow optimal placement to
be achieved for a range of different MEMs firing pulse widths,
printing speeds and inter-chip placement errors.
[0656] The MEMS device can be modelled as a resistor, that is
heated by a pulse applied to the gate of a large PMOS FET.
[0657] The profile (firing) pulse has a programmable width which is
unique to each ink colour. The magnitude of the pulse is fixed by
the external Vpos supply less any voltage drop across the driver
FET.
[0658] The unit cell contains a flip-flop forming a single stage of
a shift register extending the length of each row. These shift
registers, one per row, are filled using a register write command
in the data stream. Each row may be individually addressed, or a
row increment command can be used to step through the rows.
[0659] When a FIRE command is received in the data stream, the data
in all the shift register flip-flops is transferred to a dot-latch
in each of the unit cells, and a fire cycle is started to eject ink
from every nozzle that has a 1 in its dot-latch.
[0660] The FIRE command will reset the row addressing to the last
row. A DATA_NEXT command preceding the first row data will then
fill the first row. While the firing/ejection is taking place, the
data for the next line may be loaded into the row shift
registers.
[0661] Due to the mechanism used to handle the falling triangle
block of nozzles the following restrictions apply: [0662] The rows
must be loaded in the same order between FIRE commands. Any order
may be used, but it must be the same each time. [0663] Data must be
provided for each row, sufficient to fill the triangle segment.
[0664] A fire cycle sequences through all of the nozzles on the
chip, firing all of those with a 1 in their dot-latch. The sequence
is one row at a time, each row taking 10% of the total fire cycle.
Within a row, a programmable value called the column Span is used
to control the firing. Each <span>'th nozzle in the row is
fired simultaneously, then their immediate left neighbours,
repeating <span> times until all nozzles in that row have
fired. This is then repeated for each subsequent row, according the
row firing order described below. Hence the maximum number of
nozzles firing at any one time is 640 divided by <span>.
[0665] In the default case, row 0 of the chip is fired first,
according to the span pattern. These nozzles will all fired in the
first 10% of the line time. Next all nozzles in row 2 will fire in
the same pattern, similarly then rows 4, 6 then 8. Immediately
following, half way through the line time, row 1 will start firing,
followed by rows 3, 5, 7 then 9.
[0666] FIG. 78 shows this for the case of Span=2.
[0667] The 1/10 line time together with the 10.1DP vertical colour
pitch appear on paper as a 10DP line separation. The odd and even
same-colour rows physically spaced 3.5DP apart vertically fired
half a line time apart results on paper as a 3DP separation.
[0668] A modification of the firing order shown in FIG. 78 can be
used to assist in the event of vertical misalignment of the
printhead when physically mounted into a cartridge. This is termed
micro positioning in this document.
[0669] FIG. 79 shows in general how the fire pattern is modified to
compensate for mounting misalignment of one printhead with respect
to its linking partner. The base construction of the printhead
separates the row pairs by slightly more than an integer times the
dot Pitch to allow for distributing the fire pattern over the line
period. This architecture can be exploited to allow micro
positioning.
[0670] Consider for example the printhead on the right being placed
0.3 dots lower than the reference printhead to the left. The
reference printhead if fired with the standard pattern.
[0671] The width of the pulse that turns a heater on to eject an
ink drop is called the profile. The profile is a function of the
MEMs characteristics and the ink characteristics. Different
profiles might be used for different colours.
[0672] Optimal dot placement requires each line to take 10% of the
line time. to fire. So, while a row for a colour with a shorter
profile could in theory be fired faster than a colour with a longer
profile, this is not desirable for dot placement.
[0673] To address this, the fire command includes a parameter
called the fireperiod. This is the time allocated to fire a single
nozzle, irrespective of its profile. For best dot placement, the
fireperiod should be chosen to be greater than the longest profile.
If a profile is programmed to be longer than a fireperiod, then
that nozzle pulse will be extended to match the profile. This
extends the line time, it does not affect subsequent profiles. This
will degrade dot placement accuracy on paper.
[0674] The fireperiod and profiles are measured in wclks. A wclk is
a programmable number of 288 Mhz clock periods. The value written
to fireperiod and profile registers should be one less than the
desired delay in wclks. These registers are all 8 bits wide, so
periods from 1 to 256 wclks can be achieved. The Wclk prescaler
should be programmed such that the longest profile is between 128
and 255 wclks long. This gives best line time resolution.
[0675] The ideal value for column span and fireperiod can be chosen
based on the maximum profile and the linetime. The linetime is
fixed by the desired printing speed, while the maximum profile
depends on ink and MEMs characteristics as described
previously.
[0676] To ensure than all nozzles are fired within a line time, the
following relationship must be obeyed: #
rows*columnspan*fireperiod<linetime
[0677] To reduce the peak Vpos current, the column span should be
programmed to be the largest value that obeys the above
relationship. This means making fireperiod as small as possible,
consistent with the requirement that fireperiod be longer than the
maximum profile, for optimal dot placement.
[0678] As an example, with a 1 uS maximum profile width, 10 rows,
and 44 us desired row time a span of 4 yields 4*10*1=40 uS minimum
time. A span of 5 would require 50 uS which is too long. Having
chosen the column span, the fireperiod should be adjusted upward
from its minimum so that nozzle firing occupies all of the
available linetime. In the above example, fireperiod would be be
set to 44 us/(4*10)=1.1 uS. This will produce a 10% gap between
individual profiles, but ensures that dots are accurately placed on
the page. Using a fireperiod longer or shorter than the scaled line
time will result in inaccurately placed ink dots.
[0679] The fireperiod to be used is updated as a parameter to every
FIRE command. This is to allow for variation in the linetime, due
to changes in paper speed. This is important because a correctly
calculated fireperiod is essential for optimal dot placement.
[0680] If a FIRE command is received before a fire cycle is
complete, the error bit NO_EARLY_ERR is set and the next fire cycle
is started immediately. The final column(s) of the previous cycle
will not have been fully fired. This can only occur if the new FIRE
command is given early than expected, based on the previous
fireperiod.
[0681] It is possible to use SoPEC to send dot data to a printhead
that is using less than its full complement of rows. For example,
it is possible that the fixative, IR and black channels will be
omitted in a low end, low cost printer. Rather than design a new
printhead having only three channels, it is possible to select
which channels are active in a printhead with a larger number of
channels (such as the presently preferred channel version). It may
be desirable to use a printhead which has one or more defective
nozzles in up to three rows as a printhead (or printhead module) in
a three color printer.
[0682] It would be disadvantageous to have to load empty data into
each empty channel, so it is preferable to allow one or more rows
to be disabled in the printhead.
[0683] The printhead already has a register that allows each row to
be individually enabled or disabled (register ENABLE at address 0).
Currently all this does is suppress firing for a non-enabled row.
To avoid SoPEC needing to send blank data for the unused rows, the
functionality of these bits is extended to:
1. skip over disabled rows when DATA_NEXT register is written;
[0684] 2. force dummy bits into the TDC FIFO for a disabled rows,
corresponding to the number of nozzles in the dropped triangle
section for that row. These dummy bits are written immediately
following the first row write to the fifo following a fire
command.
[0685] Using this arrangement, it is possible to operate a 6 color
printhead as a 1 to 6 color printhead, depending upon which mode is
set. The mode can be set by the printer controller (SoPEC); once
set, SoPEC need only send dot data for the active channels of the
printhead.
[0686] It will be appreciated by those skilled in the art that the
foregoing represents only a preferred embodiment of the present
invention. Those skilled in the relevant field will immediately
appreciate that the invention can be embodied in many other
forms.
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