U.S. patent number RE47,928 [Application Number 15/586,455] was granted by the patent office on 2020-04-07 for media detection apparatus and method.
This patent grant is currently assigned to DATAMAX-O'NEIL CORPORATION. The grantee listed for this patent is Datamax-O'Neil Corporation. Invention is credited to Jose Fernando Sanchez Gutierrez, Ronald Schwallie.
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United States Patent |
RE47,928 |
Sanchez Gutierrez , et
al. |
April 7, 2020 |
Media detection apparatus and method
Abstract
An apparatus and method for automatically calibrating a media
sensor configured to detect advancing print media in a printing
device. In some embodiments, the apparatus selects a first light
intensity level and a second light intensity level greater than the
first light intensity level. A light source unit, such as a light
emitting diode or laser diode is activated to emit light at the
second light intensity level. The light passes though print media,
for example, a roll of self-adhesive labels, that is advanced along
a print path of the printing device. The amount of light
transmitted through the print media is measured as the print media
advances. If the measured light .[.increases.].
.Iadd.decreases.Iaddend., the light source unit is reactivated to
emit light at the first light intensity level. In some embodiments,
the apparatus identifies whether print media has changed or an
out-of-stock condition exists.
Inventors: |
Sanchez Gutierrez; Jose
Fernando (Orlando, FL), Schwallie; Ronald (Lake Mary,
FL) |
Applicant: |
Name |
City |
State |
Country |
Type |
Datamax-O'Neil Corporation |
Orlando |
FL |
US |
|
|
Assignee: |
DATAMAX-O'NEIL CORPORATION
(Altamonte Springs, FL)
|
Family
ID: |
48669444 |
Appl.
No.: |
15/586,455 |
Filed: |
May 4, 2017 |
PCT
Filed: |
December 19, 2012 |
PCT No.: |
PCT/US2012/070605 |
371(c)(1),(2),(4) Date: |
June 23, 2014 |
PCT
Pub. No.: |
WO2013/096439 |
PCT
Pub. Date: |
June 27, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
61579258 |
Dec 22, 2011 |
|
|
|
Reissue of: |
14368113 |
Dec 19, 2012 |
9024988 |
May 5, 2015 |
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B41J
3/4075 (20130101); B41J 11/0095 (20130101); B41J
11/0095 (20130101); B41J 3/4075 (20130101); B41J
2/32 (20130101); B41J 2/32 (20130101) |
Current International
Class: |
B41J
3/407 (20060101); B41J 11/00 (20060101); B41J
2/32 (20060101) |
Field of
Search: |
;347/218 ;400/708
;250/559.01,559.1 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Nguyen; Minh
Attorney, Agent or Firm: Alston & Bird, LLP
Claims
What is claimed is:
1. A method of automatically calibrating a media sensor configured
to detect advancing print media, the method comprising: selecting a
first light intensity level and a second light intensity level
greater than the first light intensity level; setting a light
source unit to emit light at the second light intensity level;
measuring an amount of the emitted light that is transmitted
through the print media; advancing the print media; and; setting
the light source unit to emit light at the first light intensity
level in response to a determination that the light transmitted
through the print media is .[.increasing.].
.Iadd.decreasing.Iaddend..
2. The method in accordance with claim 1, further comprising
recording a position of the print media.
3. The method in accordance with claim 2, wherein recording a
position of the print media includes recording a position at which
that the light transmitted through the print media increases or
decreases.
4. The method in accordance with claim 1, further comprising
recording a measured amount of light transmitted through the print
media.
5. The method in accordance with claim 1, further comprising:
determining whether a print media status has changed since a
previous operation; determining whether an out-of-stock condition
exists in response to determination that print media status has
changed; and signaling a fault condition in response to a
determination that an out-of-stock condition exists.
6. The method in accordance with claim 5, wherein determining
whether a print media status has changed since a previous operation
includes comparing a current measured amount of light transmitted
through the print media with a previously measured amount of light
transmitted through the print media.
7. The method in accordance with claim 1, wherein determining
whether an out-of-stock condition exists includes comparing a
measured amount of light transmitted through the print media to a
predetermined out-of-stock value.
.[.8. A label printer configured for automatic media calibration,
the printer comprising: a media drive configured to advance label
media from a media supply to a print head; a setting unit in
operable communication with the media drive; a light source unit in
operable communication with the setting unit; a light detector unit
in operable communication with the setting unit and configured to
detect light emitted from the light source unit and transmitted at
least in part through label media; wherein the setting unit is
configured to: select a first light intensity level and a second
light intensity level greater than the first light intensity level;
cause the light source unit to emit light at the second light
intensity level; measure the amount of the emitted light
transmitted through the print media into the light detector unit;
cause the media drive to advance the print media; and set the light
source unit to emit light at the first light intensity level in
response to a determination that the light transmitted through the
print media is decreasing..].
.[.9. The label printer in accordance with claim 8, further
comprising a print head in operable communication with the setting
unit and configured to imprint visible indicia upon a media
label..].
.[.10. The label printer in accordance with claim 8, wherein the
setting unit is further configured to record a position of the
print media..].
.[.11. The label printer in accordance with claim 10, wherein a
position of the print media is recorded by recording a position at
which that the light transmitted through the print media increases
or decreases..].
.[.12. The label printer in accordance with claim 8, wherein the
setting unit is further configured to record a measured amount of
light transmitted through the print media..].
.[.13. The label printer in accordance with claim 8, wherein the
setting unit is further configured to: determine whether a print
media status has changed since a previous operation; determine
whether an out-of-stock condition exists in response to
determination that the print media status has changed; and signal a
fault condition in response to a determination that an out-of-stock
condition exists..].
.[.14. The label printer in accordance with claim 13, wherein the
determination whether a print media status has changed since a
previous operation includes comparing a current measured amount of
light transmitted through the print media with a previously
measured amount of light transmitted through the print
media..].
.[.15. The label printer in accordance with claim 8, wherein the
determination of whether an out-of-stock condition exists includes
comparing a measured amount of light transmitted through the print
media to a predetermined out-of-stock value..].
.[.16. The label printer in accordance with claim 8, further
comprising a communications interface operably coupled to the
setting unit and configured to communicate via a protocol selected
from the group consisting of a wired communication protocol or a
wireless communication protocol..].
.[.17. The label printer in accordance with claim 8, wherein the
media drive includes a stepper motor..].
.Iadd.18. A method of automatically calibrating a media sensor
configured to detect advancing print media, the method comprising:
selecting a first light intensity level for a light source unit
corresponding to gap or liner portions of a print media, the first
light intensity level selected to allow a light detecting unit to
detect a first predetermined value of light when transmitted
through the gap or liner portions of a print media; selecting a
second light intensity level for the light source unit
corresponding to label portions of the print media, the second
light intensity level selected to allow the light detecting unit to
detect a second predetermined value of light when transmitted
through the label portions of the print media, the second light
intensity level greater than the first light intensity level;
setting the light source unit to emit light at the second light
intensity level, based at least in part on an assumption that
initially a label portion of the print media will be located
between the light source unit and the light detecting unit;
advancing the print media and detecting a transition in light
intensity from one of the first and second predetermined values of
light to a detected value of light transmitted through the print
media; and ascertaining that initially a label portion of the print
media was located between the light source unit and the light
detecting unit if the transition from the predetermined value to
the detected value reflects an increase in the light transmitted
through the print media, and/or ascertaining that that, rather than
a label portion, initially a gap or a liner portion of the print
media was located between the light source unit and the light
detecting unit if the transition from the first predetermined value
corresponding to the second light intensity level to the detected
value reflects a decrease in the light transmitted through the
print media..Iaddend.
.Iadd.19. The method of claim 18, further comprising: setting the
light source unit to emit light at the first light intensity level
if the transition from the first predetermined value to the
detected value reflects a decrease in the light transmitted through
the print media, the decrease indicating that, rather than a label
portion, initially a gap or a liner portion of the print media was
located between the light source unit and the light detecting
unit..Iaddend.
.Iadd.20. The method of claim 18, further comprising: recording a
position of the print media corresponding to the transition from
the first predetermined value to the detected value, the position
representing a label edge; performing a first print command or feed
command; advancing the print media until light detected by the
light detecting unit corresponds to the first predetermined value
of light transmitted through the gap or liner portions of the print
media..Iaddend.
.Iadd.21. The method of claim 20, further comprising recording a
measured amount of light detected by the light detecting unit at
the conclusion of the first print command or feed
command..Iaddend.
.Iadd.22. The method of claim 21, further comprising: ascertaining
whether the print media has been changed prior to performing a
second print command or feed command, at least in part by comparing
a measured amount of light detected by the light detecting unit
upon receiving the second print command or feed command to the
measured amount of light detected by the light detecting unit at
the conclusion of the first print command or feed
command..Iaddend.
.Iadd.23. The method of claim 22, further comprising: upon
ascertaining that the print media has been changed, prior to
performing the second print command or feed command: setting the
light source unit to emit light at the second light intensity
level, based at least in part on an assumption that initially a
label portion of the print media will be located between the light
source unit and the light detecting unit; advancing the print media
and detecting a transition in light intensity from the second
predetermined value corresponding to the second light intensity
level to a detected value of light transmitted through the print
media; and ascertaining that initially a label portion of the print
media was located between the light source unit and the light
detecting unit if the transition from the second predetermined
value to the detected value reflects an increase in the light
transmitted through the print media, and/or ascertaining that that,
rather than a label portion, initially a gap or a liner portion of
the print media was located between the light source unit and the
light detecting unit if the transition from the first predetermined
value to the detected value reflects a decrease in the light
transmitted through the print media..Iaddend.
.Iadd.24. A method of automatically calibrating a media sensor
configured to detect advancing print media, the method comprising:
selecting a first light intensity level for a light source unit
corresponding to gap or liner portions of a print media, the first
light intensity level selected to allow a light detecting unit to
detect a first predetermined value of light when transmitted
through the gap or liner portions of a print media; selecting a
second light intensity level for the light source unit
corresponding to label portions of the print media, the second
light intensity level selected to allow the light detecting unit to
detect a second predetermined value of light when transmitted
through the label portions of the print media, the second light
intensity level greater than the first light intensity level;
setting the light source unit to emit light at the second light
intensity level, based at least in part on an assumption that
initially a label portion of the print media will be located
between the light source unit and the light detecting unit;
advancing the print media and detecting a transition in light
intensity from one of the first and second predetermined values of
light to a detected value of light transmitted through the print
media; recording a position of the print media corresponding to the
transition from the first predetermined value to the detected
value, the position representing a label edge; performing a first
print command or feed command; advancing the print media until
light detected by the light detecting unit corresponds to the first
predetermined value of light transmitted through the gap or liner
portions of the print media; and ascertaining that initially a
label portion of the print media was located between the light
source unit and the light detecting unit if the transition from the
predetermined value to the detected value reflects an increase in
the light transmitted through the print media, and/or ascertaining
that that, rather than a label portion, initially a gap or a liner
portion of the print media was located between the light source
unit and the light detecting unit if the transition from the first
predetermined value corresponding to the second light intensity
level to the detected value reflects a decrease in the light
transmitted through the print media..Iaddend.
Description
.Iadd.CROSS-REFERENCE TO RELATED APPLICATIONS.Iaddend.
.Iadd.This application is a broadening reissue application of U.S.
Pat. No. 9,024,988, which claims the benefit of U.S. application
Ser. No. 14/368,113, filed Jun. 23, 2014 and issued as U.S. Pat.
No. 9,024,988 on May 5, 2015, which claims priority to PCT
Application No. PCT/US2012/070605, filed Dec. 19, 2012, which
claims priority to U.S. provisional Application No. 61/579,258,
filed Dec. 22, 2011, each of which are hereby incorporated by
reference herein in their entirety..Iaddend.
BACKGROUND
1. Technical Field
The present disclosure generally relates to label printers, and,
more particularly, to an improved apparatus and method for
automatically sensing and setting label length in a label
printer.
2. Background of Related Art
Labels are everywhere in our daily life and have many uses, for
example, for the identification and tracking of products in the
distribution chain, identification of laboratory samples, and for
document and records identification. Almost every product, such as
fruits, manufactured foods, electrical or mechanical equipment,
books, consumer goods, etc., includes some form of label. Such
labels may include graphic images, human-readable alphanumeric
text, and machine-readable barcode. Many types of label media
exist, and many techniques for printing labels are used. For
example, thermal transfer techniques are widely used in modern
industry.
Generally, two kinds of thermal label media are commonly used. One
is a tag stock (no adhesive) type. In this type, the media itself
includes multiple pages attached end-to-end and wound on into a
roll. This tag stock type uses an index mark, index notch, or an
index hole to delineate labels from each other. This delineation
feature may be used to set a starting position for printing whereby
a label printer indexes the printed image from the starting
position as defined, directly or indirectly, by the delineation
feature of the media.
Another popular type of media is a label type which has two layers:
a backing (or liner) and a self-adhesive label attached to the
backing. The self-adhesive labels are detached or peeled from the
backing after printing, whereupon the label may be attached to the
desired item.
Each type of media may use a particular technique for separating
the labels from the roll as they advance out of the printer. For
this purpose, the tag stock type provides several methods. One of
them is perforations on boundaries of each label or tag. The
perforation method provides boundaries for each label and makes it
easy for a user to cleanly tear off a label form the roll. Other
methods include a manual (e.g., serrated edge) or automatic cutting
mechanism (e.g., guillotine), a notch, hole, or mark for each label
at a starting position for printing.
Typically, a label printer must be manually calibrated to set a
label starting position when a new supply of label media is loaded
into the printer. Inaccurately setting the starting position by the
user can cause printing problems such as poor registration, double
feeding, and so forth, and as a result, waste labels and time.
Thus, accurately setting a starting position for a label printer
has substantial impact on the process of printing labels.
SUMMARY
Disclosed is a method of automatically calibrating a media sensor
configured to detect advancing print media. In some embodiments in
accordance with the present disclosure, the method includes
operating a light-emitting unit .Iadd.emitting .Iaddend.at least
two light intensity levels: a first light intensity corresponding
.[.relating.]. to the gap between labels, and a second light
intensity that is greater than the first light intensity level
relating to the label. The first and second light levels are
selected such that a sufficient delta exists between the two levels
to enable the detection of a transition between paper to gap, or
gap to paper, as media advances through the print path. .[.A.].
.Iadd.In some embodiments a .Iaddend.light source unit is activated
to emit light at the second light intensity level, .Iadd.and in
some embodiments the method includes .Iaddend.measuring an amount
of the emitted light that is transmitted through the print media,
advancing the print media, and setting the light source unit to
emit light at the first light intensity level in response to a
determination that the light transmitted through the print media is
.[.increasing.]. .Iadd.decreasing.Iaddend..
Also disclosed is a method of automatically calibrating a media
sensor configured to detect advancing print media. In some
embodiments in accordance with the present disclosure, the method
includes selecting .[.at.]. a first light intensity level and a
second light intensity level that is greater than the first light
intensity level. .[.A.]. .Iadd.In some embodiments a .Iaddend.light
source unit is activated to emit light at the second light
intensity level, .Iadd.and in some embodiments the method includes
.Iaddend.measuring an amount of the emitted light that is
transmitted through the print media, advancing the print media, and
setting the light source unit to emit light at the first light
intensity level in response to a determination that the light
transmitted through the print media is .[.increasing.].
.Iadd.decreasing.Iaddend..
In some embodiments, a position of the print media is recorded,
and, in some embodiments, a position at which that the light
transmitted through the print media increases or decreases is
recorded.
In some embodiments, a measured amount of light transmitted through
the print media is recorded.
In some embodiments, the disclosed method further includes
determining whether a print media status has changed since a
previous operation, determining whether an out-of-stock condition
exists in response to determination that print media status has
changed, signaling a fault condition in response to a determination
that an out-of-stock condition exists. In some embodiments,
determining whether a print media status has changed since a
previous operation includes comparing a current measured amount of
light transmitted through the print media with a previously
measured amount of light transmitted through the print media.
In some embodiments, determining whether an out-of-stock condition
exists includes comparing a measured amount of light transmitted
through the print media to a predetermined out-of-stock value.
In another aspect, some embodiments of a label printer configured
for automatic media calibration in accordance with the present
disclosure include a media drive configured to advance label media
from a media supply to a print head, a setting unit in operable
communication with the media drive, a light source unit in operable
communication with the setting unit, and a light detector unit in
operable communication with the setting unit and configured to
detect light emitted from the light source unit and transmitted at
least in part through label media. The setting unit is configured
to select a first light intensity level and a second light
intensity level greater than the first light intensity level and to
cause the light source unit to emit light at the second light
intensity level. The setting unit is configured to measure the
amount of the emitted light transmitted through the print media
into the light detector unit, to cause the media drive to advance
the print media, and to set the light source unit to emit light at
the first light intensity level in response to a determination that
the light transmitted through the print media is decreasing.
In some aspects, the setting unit is configured to select two
intensity levels: a first "gap" light intensity level corresponding
to a gap level, and a second "paper" light intensity level
corresponding to paper level greater than the gap light intensity
level, and to cause the light source unit to emit light at the
paper light intensity level.
In some embodiments, a label printer in accordance with the present
disclosure includes a print head in operable communication with the
setting unit that is configured to imprint visible indicia upon a
media label.
In some embodiments, the setting unit of a label printer in
accordance with the present disclosure is configured to record a
position of the print media. In some embodiments, the position of
the print media is recorded by recording a position at which that
the light transmitted through the print media increases or
decreases. In some embodiments, the setting unit is further
configured to record a measured amount of light transmitted through
the print media.
In some embodiments, a setting unit in accordance with the present
disclosure is configured to determine whether a print media status
has changed since a previous operation, to determine whether an
out-of-stock condition exists in response to determination that the
print media status has changed, and to signal a fault condition in
response to a determination that an out-of-stock condition exists.
In some embodiments, the determination whether a print media status
has changed since a previous operation includes comparing a current
measured amount of light transmitted through the print media with a
previously measured amount of light transmitted through the print
media. In some embodiments, the determination of whether an
out-of-stock condition exists includes comparing a measured amount
of light transmitted through the print media to a predetermined
out-of-stock value.
In some embodiments, a label printer in accordance with the present
disclosure includes a communications interface operably coupled to
the setting unit and configured to communicate via a protocol
selected from the group consisting of a wired communication
protocol or a wireless communication protocol. In some embodiments,
a label printer in accordance with the present disclosure includes
a media drive having a stepper motor.
The present disclosure also describes a method and an apparatus for
automatically setting the starting position of the media for
printing. In some embodiments, a label printer in accordance with
the present disclosure includes a setting unit, a feeding unit, a
light source unit .[.unit.]., and a light detecting unit. The
setting unit sets a label starting position for the label printer
when one or more conditions are met, as will be described in detail
herein. The feeding unit feeds the media through the printer, e.g.,
from a supply of labels (typically a roll or fanfold supply),
through a print path including a print head, and outward of the
printer through an opening or slot provided in the printer housing.
The feeding unit may include one or more drive motors configured to
feed media through the printer. The light source unit emits light
which passes through the label media, and the light detecting unit
detects light transmitted through the label media. The detected
light transitions from one range of light intensity to another
range of light intensity as the media moves through the emitted
light beam. The light source unit and the light detecting unit are
aligned and placed opposite one another, and the media passes
through the light beam such that the light detecting unit receives
the varying levels of transmitted light detected after passing
through the media. The light detecting unit can include a
photovoltaic sensor, a photodiode, a phototransistor, or any
suitable sensor that can detect light. In some embodiments, a
photodiode is used for the light detecting unit, however, it is to
be understood any suitable light detector unit may be employed.
In some embodiments, a reflective arrangement may be employed
wherein the light source unit and light detector unit are
positioned on the same side of the print media. Light source unit
is configured to illuminate a region of the label media within the
field of view of the light detector unit such that gap and paper
light levels transitions are detected as the media advances through
the field of view of the light detector unit.
Generally, the light detecting unit is configured to detect two
differing ranges of light intensity .Iadd.transmitted through two
different portions of the print media.Iaddend.. .[.A first range is
a.]. .Iadd.One .Iaddend.range of light intensity .Iadd.corresponds
to light transmitted through the print media when .Iaddend.the
label .Iadd.portion of the print media .Iaddend.is .[.placed in.].
.Iadd.positioned .Iaddend.between the light source unit and the
light detecting unit. .[.A second range is a.]. .Iadd.Another
.Iaddend.range of light intensity .Iadd.corresponds to light
transmitted through the print media .Iaddend.when the liner
.Iadd.portion .Iaddend.of the media .Iadd.(e.g., no label) or a
gap.Iaddend., perforations, .Iadd.or .Iaddend.an index hole
.Iadd.between label portions .Iaddend.of the media, .[.or a gap
between the label media (e.g., no layer) is placed in.]. .Iadd.is
positioned .Iaddend.between the light source unit and the light
detecting unit. By this arrangement, the .[.first range of.]. light
intensity detected .Iadd.when the label portion of the media is
positioned in between the light source unit and the light detecting
unit .Iaddend.will be less than the .[.second range if.]. light
intensity .Iadd.detected when the liner portion of the media (e.g.,
no label) or a gap, perforations, or an intex hole between label
portions of the media, is positioned in between the light source
unit and the light detecting unit.Iaddend., because the transmitted
light may be partially or totally blocked by the label
.Iadd.portion of the .Iaddend.media. Conversely the .[.second range
of.]. light intensity .Iadd.detected when the liner portion of the
media (e.g., no label) or a gap, perforations, or an index hole
between label portions of the media, is positioned in between the
light source unit and the light detecting unit .Iaddend.is greater
than the .[.first range.]. .Iadd.light intensity detected when the
label portion of the media is positioned in between the light
source unit and the light detecting unit, .Iaddend.since the
.Iadd.liner portion, .Iaddend.gap, notch, or space between labels
permits more light to pass therethrough. After accounting for the
intensity of the light emitted by the light source unit, and the
sensitivity of the light detector unit, the ranges of detected
light intensity are determined by the thickness or light
transmissivity of media or labels.
In one aspect, the described method and apparatus will attempt
automatic recalibration when it is determined that a new supply of
media has been loaded into the printer. Advantageously, the
disclosed method can adapt to the new media regardless of whether
the new supply of the same type of media as was used immediately
prior, or, a different type of media has been loaded. For example,
if the new media demonstrates values outside the range of those
seen with respect to the previously-loaded batch of labels (e.g.,
is an outlier compared to the range of overall light transmissivity
values of previous labels), then calibration of the detecting unit
is configured to automatically adjust the two ranges of light
intensity with respect to the new label media's light
transmissivity.
In another aspect, the light detecting unit sends a signal to the
setting unit when it detects a range transition from one range to
another range of light intensity of the light emitted .Iadd.by the
light source unit and transmitted .Iaddend.through the media, and,
when the setting unit receives the signal two times, the setting
unit sets the starting position of the media to be printed. When
the setting unit sets the starting position for printing, the
auto-calibration process is complete and the label printer can
proceed to print labels without wasting many labels for adjustment,
and without user interaction.
In the drawings, a flow chart is provided which illustrates
auto-calibration for the label printer. Initially, after a label is
printed, the light detecting unit detects the light transmitted
though the label media, and transmits the value to the setting
unit. The setting unit stores this light intensity value, which
represents a transmissivity of the label media. The light intensity
value is dependent upon the type of media in use, and the position
of the media relative to the light beam. A motor associated with a
feeding unit is stopped while the printer is waiting for a print or
feed event. When the print or feed event occurs, the label printer
checks whether the media was changed during the time since the
motor previously stopped. Determination of media change is done by
checking light intensity value. When the label printer receives a
print event or a feed event, the light detecting unit detects light
intensity through the media and checks whether the detected value
is same as the stored value. If a change is detected between the
two values, then it is determined that new media have been loaded
into the label printer; or, if no change is detected, the label
printer assumes that the loaded media to be the same as which was
previously placed under the light source unit.
When it is determined that the media has changed, the label printer
also checks whether the media is out of stock. If no more media
remains in the label printer, then the label printer stops printing
and displays a message indicating no more media is available. When
there is media left to be printed, the label printer calibrates the
light detecting unit to detect a gap or a liner of the media.
In some embodiments, predetermined values of light intensity for a
gap .Iadd.or liner part of the media .Iaddend.and .Iadd.for
.Iaddend.a .[.liner.]. .Iadd.label .Iaddend.part .[.for.]. .Iadd.of
.Iaddend.the media are compared to measured values of light. In
order to calibrate the light detecting unit, at first, the light
source unit increases or decreases light intensity so that the
light detecting unit can detect a predetermined value of light
intensity for the gap or .[.the.]. liner .Iadd.part of the media,
and/or a predetermined value of light intensity for the label part
of the print media.Iaddend..
For convenience, it is assumed that a .[.liner.]. .Iadd.label
.Iaddend.part is placed under the light source unit in the
beginning of the auto-calibration process. Thus, the light source
unit increases or decreases the light intensity so that the
detected value reaches a certain predetermined value designated for
the .[.liner.]. .Iadd.label .Iaddend.part. This invention, however,
is not limited to this assumption, and can be extended to include
other embodiments that assume a .Iadd.liner or .Iaddend.gap part is
placed under the light source unit in the beginning of .Iadd.the
.Iaddend.auto-calibration process, or that assume the light source
unit emits light only with a predetermined level of light intensity
and the light detecting unit detects a transition of light
intensity between non-predetermined ranges of light intensity
through the media.
The feeding unit now feeds the media by starting the motor until a
range transition of light intensity through the media is
detected.
When a range transition is detected, the label printer checks
whether the transition is downward or upward. If it is a downward
transition from the predetermined value for the paper/.[.liner.].
.Iadd.label .Iaddend.part to a detected value at the time of the
transition, the label printer updates the predetermined value for
the .Iadd.liner or .Iaddend.gap with the predetermined value for
the paper/.[.liner.]. .Iadd.label .Iaddend.part and the
predetermined value for the .[.liner.]. .Iadd.label part
.Iaddend.with the detected value. When .[.a downward.]. .Iadd.an
upward .Iaddend.transition is detected, the calibration is not
necessary and .Iadd.the label printer .Iaddend.starts printing
labels on the media.
More specifically, when an upward transition is detected by the
light detecting unit, more light goes through the media to the
light detecting unit, which .[.implies.]. .Iadd.indicates
.Iaddend.that a .Iadd.liner or .Iaddend.gap part .[.is under.].
.Iadd.has moved between .Iaddend.the light source unit .[.now.].
.Iadd.and the light detecting unit as the media advanced.Iaddend..
In this way, the assumption that the paper/.[.liner.]. .Iadd.label
.Iaddend.part is placed under the light source unit in the
beginning .Iadd.of the auto-calibration process .Iaddend.has proved
to be correct and no need exists to update the predetermined value
for the liner .Iadd.or gap .Iaddend.part.[., e.g., update the light
level to the gap level.]. .Iadd.with the predetermined value for
the paper/label part.Iaddend..
On the other hand, when a downward transition is detected, less
light is transmitted through the media to the light detecting unit,
which indicates that .[.liner.]. .Iadd.a label.Iaddend./paper .[.is
now positioned.]. .Iadd.part has moved .Iaddend.between the light
source unit and light .[.detector.]. .Iadd.detecting unit as the
media advanced.Iaddend.. In other words, .[.a liner part or label
part is under the light source unit now while previously.]. there
was .Iadd.a liner part, a gap, .Iaddend.an index hole, notch, or
perforation .Iadd.between the light source unit and the light
detecting unit .Iaddend.in the beginning of the auto-calibration
process instead of the .[.liner (or label).]. .Iadd.label
.Iaddend.part. In this event, the assumption made at the beginning
.[.is.]. .Iadd.of the auto-calibration process was
.Iaddend.incorrect and the predetermined value for the .[.liner.].
.Iadd.label/paper .Iaddend.part should be updated. The detected
value at the transition becomes the predetermined value for the
.[.liner.]. .Iadd.label/paper .Iaddend.part.
The setting unit sets the location where a second transition occurs
as the starting position for printing. If a downward transition
occurs first, then an upward transition will follow when a gap part
is fed under the light source unit. If an upward transition occurs
first, then a downward transition will follow when a .[.liner.].
.Iadd.label .Iaddend.part right after the gap part is fed under the
light source. Thus, the second transition occurs at boundaries of
the gap part, namely, starting and ending of the gap between
labels. Since a .[.the.]. gap portion is not used for label
printing, auto-calibration for setting a starting position for
label printing is done when detecting the second transition. After
printing a label and pausing the motor, the value of light that the
light detecting unit detects at the time printing is completed is
recorded. In this manner, a stored or recorded value can be
compared with a detected value when the label printer restarts the
auto-calibration process.
In another aspect, the light detecting unit provides an upward
transition signal and a downward transition signal. If the setting
unit receives one pattern of signals whereby an upward transition
signal is received first and a downward transition signal second,
then the setting unit sets the starting position for printing at
the point at which it receives the second signal, e.g., the
downward transition signal. This represents the location where the
end of the gap portion or the start of the .[.liner.]. .Iadd.label
.Iaddend.portion is located. If the setting unit receives another
pattern of signals, e.g., a downward transition signal first and an
upward transition signal second, then the setting unit waits for a
third signal, another downward transition signal, and sets the
starting position for printing when it receives the .Iadd.third
signal, i.e., the .Iaddend.second downward transition signal. This
represents the position where the end of the gap part or the start
of the .[.liner.]. .Iadd.label .Iaddend.part is located. In this
way, the label printer sets the starting position for printing with
precision. Embodiments in accordance with this disclosure, however,
are not limited to this kind of label media and can be extended to
other media whose starting position for printing is a place other
than the end of gap part.
In some embodiments, it does not matter whether the media is a
label type or tag stock type. If it is a label type, labels are
attached on the media so that a label part has two layers and a
boundary part is only one layer, the liner. When the label is under
the light source unit at the beginning .[.the label.]., and the
feeding unit feeds media, the light detecting unit detects an
upward transition of light intensity when the boundary region
passes through the light beam because the boundary part only has
one layer (e.g., the liner) and thus the emitted light would pass
through the boundary more readily than at the beginning. In the
same sense, if the media is tag stock, perforations are along
boundaries of the label, .[.an index mark,.]. or an index hole or
slot is located on or near the boundary of each label. Thus, when
the label is under the light source unit at its beginning, and the
feeding unit feeds the media, the light detecting unit detects an
upward transition of light intensity when the boundary part, the
perforations along the boundaries, .[.and index mark,.]. or the
index hole .Iadd.or slot.Iaddend., is fed under the light source
unit because most of the emitted light would pass through directly
to the light detecting unit. Therefore, embodiments of the present
disclosure may be applied to both types of labels in a similar
manner.
By continuously monitoring the light detecting unit levels, the
intensity of the light source unit (e.g., LED current or the
transistor gain) can be adjusted to assure that there is adequate
differences in the levels to accurately detect range transitions
and the start of a new label or tag. Detecting the levels at the
end of media motion and start of motion the printer can determine
if additional calibration is required.
In another aspect, a sensor apparatus for a label printer is
disclosed. The disclosed sensor apparatus includes a feeding unit
configured to feed media of labels, a setting unit configured to
set a starting position of each label of the media for the label
printer, a light source unit configured to emit light through the
media, and a light detecting unit configured to detect a range
transition of light intensity through the media between a first
range and a second range of light intensity of the emitted light,
and send a signal to the setting unit when the range transition is
detected, wherein the first range is lower than the second range,
and the setting unit sets the starting position of each label of
the media for the label printer when the setting unit receives a
second signal from the light detecting unit.
In yet another aspect, a method of automatic setting for a label
printer is disclosed. The disclosed method include feeding media of
labels, emitting light on the media, detecting a range transition
of light intensity through the media between a first range and a
second range of light intensity of the emitted light, sending a
signal when the range transition is detected, receiving the signal,
and setting a starting position of the media for the label printer
when receiving the signal receives a second signal.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features, and advantages of the
present disclosure will become more apparent in light of the
following detailed description when taken in conjunction with the
accompanying drawings in which:
FIG. 1 shows an embodiment of a compact printer in accordance with
the present disclosure having a top cover in a closed position;
FIG. 2 shows the FIG. 1 embodiment of a compact printer having a
top cover in an open position;
FIG. 2A shows the FIG. 1 embodiment of a compact printer having a
top cover in an open position and media positioned along a print
path;
FIG. 3 is a schematic diagram of an embodiment of a media detection
system in accordance with the present disclosure; and
FIG. 4 is a flowchart illustrating a method of media detection in
accordance with the present disclosure.
DETAILED DESCRIPTION
Particular embodiments of the present disclosure are described
hereinbelow with reference to the accompanying drawings; however,
it is to be understood that the disclosed embodiments are merely
examples of the disclosure, which may be embodied in various forms.
Well-known and/or repetitive functions and constructions are not
described in detail to avoid obscuring the present disclosure in
unnecessary or redundant detail. Therefore, specific structural and
functional details disclosed herein are not to be interpreted as
limiting, but merely as a basis for the claims and as a
representative basis for teaching one skilled in the art to
variously employ the present disclosure in virtually any
appropriately detailed structure. In addition, as used herein,
terms referencing orientation, e.g., "top", "bottom", "up", "down",
"left", "right", "clockwise", "counterclockwise", and the like, are
used for illustrative purposes with reference to the figures and
features shown therein. It is to be understood that embodiments in
accordance with the present disclosure may be practiced in any
orientation without limitation. In this description, as well as in
the drawings, like-referenced numbers represent elements which may
perform the same, similar, or equivalent functions.
FIGS. 1, 2, and 2A present an example embodiment of a printer 10 in
accordance with the present disclosure. The printer 10 includes a
bottom housing 18 and a selectively positionable top cover 11 that
may be positioned in a closed position as shown in FIG. 1 and an
open position as shown in FIG. 2. Top cover 11 and bottom housing
18 are pivotably joined by a hinge 19. Top cover 11 includes a user
interface panel 12, one or more user input devices 14, and one or
more indicators 13. User interface panel 12 many be any suitable
form of display panel, including without limitation an LCD screen.
User input device 14 may be any suitable form of input device,
e.g., a snap dome or membrane pushbutton switch. Indicator 13 may
be any suitable indicator, such as without limitation a
light-emitting diode (LED). Indicator 13 may illuminate to indicate
the status an operational parameter, e.g., power, ready, media
empty, media jam, self test, and the like. Printer 10 includes a
power switch 15. A pair of latches 16 are disposed on either side
of top cover 11 to retain top cover 11 in a closed position, and
may be disengaged using finger pressure to facilitate opening of
top cover 11. A media slot 17 is defined in bottom housing 18 and
provides a point of egress for media, which may be advantageous
with self adhesive labels whereby the labels peel away from the
substrate upon exiting the printer.
Top cover 11 includes a print frame assembly 20 (see FIG. 2)
pivotably mounted therein. Print frame assembly 20 includes a
ribbon supply 22 and a ribbon take up spool 21 that are arranged to
supply transfer ribbon (not explicitly shown) across a print head
assembly 38. A pair of media support members 24 extend from a print
bed 26 and are adjustable across a lateral axis 32 of the printer
10 to accommodate a print media supply 25 of various widths. Print
media 25 includes a plurality of labels 23, which may be
self-adhesive style labels, releasably disposed on a backing
material 27. Each label 23 is separated from the adjacent label 23
by an inter-label gap 28 at which the backing material 27 is
exposed. A media drive 39 is configured to advance labels 23 from
media supply 25, to a print head assembly 38, and through media
slot 17. During use, labels 23 feed from print media supply 25
along the print bed 26 along a longitudinal axis 31 of the printer
10. A light detector unit 37 is positioned on print bed 26. In the
present embodiment, light detector unit 37 rides in a transverse
slot 36 defined in print bed 26 to enable selective positioning of
light detector unit 37 along the lateral axis 32, however, in other
embodiments light detector unit 37 may be positioned at a fixed
location. A light source unit 29 is positioned on print head
assembly 38. In the present embodiment, light source unit 29 rides
in a transverse slot 30 defined in print head assembly 38 to enable
selective positioning of light source unit 27 along the lateral
axis 32, however, in other embodiments light source unit 29 may be
positioned at a fixed location. Light detector unit 37 and light
source unit 29 are arranged such that, when top cover 11 is
positioned in a closed position, a light beam emitted from light
source unit 29 is aligned with light detector unit 37. In some
embodiments, light source unit 29 may provide a relatively narrow,
focused beam while in other embodiments, light source unit 29 may
provide a wide or ribbon-like beam spanning laterally across at
least a portion of the print media supply. In yet other
embodiments, light detector unit 37 may provide a relatively narrow
light sensing regions while in still other embodiments, light
detector unit 37 may provide a wide or ribbon-like light sensing
region spanning laterally across at least a portion of the print
media supply.
Turning now to FIG. 3, an embodiment of a printing system 100 in
accordance with the present disclosure includes a media supply 110
that includes label media 113 having a plurality of labels 111
disposed on a backing 112. The labels 111 are separated by a gap
114 at which the backing 112 is exposed. In the present embodiment
media supply 110 is shown as roll or web media, but it is to be
understood that other types of media supplies may be successfully
utilized by a printing system in accordance with the present
invention, such as without limitation, fanfold media. In some
embodiments, media supply 110 may include tag or card stock which
does not require backing 112, and in these embodiments no backing
is exposed at gap 114 and instead gap 114 is defined by a notch or
other similar feature that separates labels 111. Printing system
110 includes a media drive 120 that is configured to advance label
media 113 from media supply 110 to a print head assembly 150. In
the illustrated embodiment, media drive 120 includes a motor 121
having an output shaft operably coupled to a drive roller 122 that
is configured to mechanically engage media 113 to impart advancing
motion thereto. In some embodiments, drive roller 122 is
frictionally engaged with media 133. In some embodiments, drive
roller 122 may include a pin feed arrangement whereby one or more
mechanical features (not explicitly shown) project radially from
drive roller 122 to engage corresponding openings provided by media
113, e.g., along one or both edges of media 113. Media drive 120
may include a pinch roller 123 that is configured to assist or
enhance positive mechanical engagement between media 113 and drive
roller 122. While in the presently illustrated embodiment media
drive 120 is disposed upstream of print head assembly 150 (e.g.,
between media supply 110 and print head assembly 150 whereby media
drive 120 pulls media from media supply 110 and pushes media toward
print head assembly 150), in other embodiments media drive 120 may
be positioned on the downstream side of print head assembly 150
whereby media drive 120 pulls media through print head assembly 150
and from media supply 110.
Print head assembly 150 is configured to imprint visible indicia
upon media 113, and includes one or more print elements (not
explicitly shown) which may include, without limitation, a thermal
transfer element, an ink transfer element, a mechanical print
element (e.g., dot matrix, impact print elements, etc.) and the
like. In some embodiments, print head assembly 150 includes a
plurality of individually addressable thermal heating elements (not
explicitly shown). Printer 100 includes a media detection unit 132
that includes a light source unit 130 configured to direct a light
beam 131 though media 113 towards a light detecting unit 140. As
shown in the present embodiment, media detection unit 132 is
positioned downstream of and substantially adjacent to print head
assembly 150, while in other contemplated embodiments, media
detection unit 132 may be positioned upstream of print head
assembly 150 and/or may be positioned substantially apart from
print head assembly 150.
Print system 100 includes a setting unit 105, which includes a
number of features that interoperate with the aforedescribed
elements. Setting unit 105 includes a controller 160 that includes
in operative communication a processor 161 and a memory 162. Memory
162 may include volatile memory (e.g., RAM) and may include
non-volatile and/or non-transitory memory (e.g., ROM, EPROM,
EEPROM, flash memory, disk memory, and the like). Setting unit 105
includes a communications interface 170 in operable communication
with controller 160 that is configured to facilitate the
communication of operational data to and from print system 100 via
a communications ports 171. Communications interface 170 may be
configured to communicate via any one or a combination of wired or
wireless communication protocols, including without limitation USB,
IEEE 1394 "Firewire", serial (RS-232, RS-422, RS-485, and so
forth), parallel IEEE 1284 "Centronics", Ethernet, TCP/IP, 802.11
wireless ("WiFi"), Bluetooth, or any other communication protocol
now or in the future known. Communicated data may include, without
limitation, label data, formatting data, printer status, media
status, environmental data, font data, barcode data, quantity data,
handshaking, and so forth, communicated to and from a host machine,
application server, etc. Communicated data may include data
generated by a software program, e.g., a label generation
application or submodule. Print system 100 includes a user
interface panel 165 in operable communication with controller 160
that may include visual and audio indicators.
Setting unit 105 includes a number of interface modules adapted to
facilitate communication between controller 160 and other
components of printer 100. Light source interface 135 enables
communication between controller 160 and light source unit 130, and
may include circuitry configured to vary the intensity and/or color
of light emitted by light source unit 130 under the direction of an
algorithm. In some embodiments, such an algorithm may be executed
by processor 161. In some embodiments, light source interface 135
may include, without limitation, at least one of a constant current
source, a digital-to-analog (D/A) converter, or a pulse-width
modulator. In some embodiments, light source interface 135 may
include a sensing circuit configured to sense an operating
parameter of light source unit 130, e.g., operating current,
resistance, output level, etc. Light source interface 135 may
include a circuitry configured to provide power to light source
unit to effectuate operation thereof.
Setting unit 105 includes light detector interface 145 that enables
communication between controller 160 and light detector unit 140,
and may include circuitry configured to condition, read, sample,
convert, digitize and/or scale a signal received from light
detector unit 140 for use by controller 160. In some embodiments,
light detector interface 145 may include an analog-to-digital (A/D)
converter, a power circuit configured to provide power to light
detector unit 140. For example, light detector interface 145 may
include circuit elements configured to bias a phototransistor (not
explicitly shown) in the proper operating region to facilitate the
effective detection of light beam 131. During use, as labels 111
and/or gaps 114 pass between light source unit 130 and light
detector unit 140, light beam 131 is interrupted and/or modulated
and the varying light is detected by light detector unit 140.
Setting unit 105 includes a print head interface 155 that enables
communication between print head assembly 150 and controller 160.
Print head interface 155 may include one or more drivers that are
configured to provide power to the one or more print elements of
print head assembly 150, and additionally or alternatively may
include circuitry configured to communicate one or more operational
and/or identification parameters with print head 150. For example,
and without limitation, print head assembly 150 and/or print head
interface 155 may be configured to communicate an operating
temperature, an authentication code, a print command, and the
like.
Setting unit 105 includes a media drive interface 125 that is
configured to provide drive signals to media drive 120 and/or to
receive one or more sensor signals from media drive 120 for
conveyance to controller 160. For example, and without limitation,
in some embodiments where media drive 120 includes a stepper motor
121, media drive interface 125 may include a stepper motor driver
circuit configured to provide a full step drive signals, half step
drive signals, wave drive signals, and/or microstepping signals. In
some embodiments, embodiments where media drive 120 includes a
servo motor 121, media drive interface 125 may include a servo
driver circuit, and a feedback circuit configured to communicate
positional (e.g., rotational) information to controller 160. Other
forms of drive signals are contemplated to accommodate any suitable
media drive arrangement, e.g., linear steppers, brushless motors,
commutator motors, DC motors, AC motors, and so forth.
Considering now FIG. 4, a method 200 for automatically sensing and
setting label length in a label printer is illustrated. In step
205, the printer is idle and ready to perform an operation such as
a print event (e.g., a print command incorporating media feeding
substantially concurrently with printing indicia thereupon) or a
feed event (e.g., a form-feed command to advance print through the
printer). In step 210 a print event or a feed event occurs (e.g., a
print command or a feed command is received by the printer). Prior
to executing the command, in step 215 a determination is made as to
whether the print media has been changed since the last operation,
which indicates that media calibration is required. In some
embodiments, a light measurement MCURRENT is taken by light
detector unit 140 and compared to a measurement MPREV taken at the
conclusion of a prior print or feed event. If the two values are
equal (or, in some embodiments, within a predetermined tolerance),
it is determined that the print media has not changed. If, however,
the two values are unequal (or, in some embodiments, outside a
predetermined tolerance), or if no such previous measurement is
available, it is determined the print media has changed.
If, in step 215 it has been determined that the print media has
changed, then in step 220 a determination is made as to whether an
out-of-stock condition exists (e.g., end of roll or no media
installed). In some embodiments, a light measurement is taken by
light detector unit 140 and compared to a predetermined
out-of-stock value. In some embodiments, the predetermined
out-of-stock value is commensurate with a value corresponding to an
unobstructed light path 131 existing between light source unit 130
and light detector unit 140. If, in step 225 it is determined an
out-of-stock condition exists, then in step 225 a fault condition
is indicated. In some embodiments, a fault indication may include
presenting an alarm to the user indicating that a new supply of
label media needs to be loaded; such an alarm may include without
limitation, a visual indication and/or an audible indication. In
some embodiments, an out-of-stock status may be communicated via
communication interface 170.
If, however, no out-of-stock condition is detected in step 220,
e.g., a portion of label media 113 is positioned between light
source unit 130 and light detector unit 140, in step 230 a media
calibration is undertaken. Two preliminary light intensity levels
for light source unit 130 are chosen to accommodate the two
different portions of the label: a first, lower, light level L1
corresponding to the gap 114 and a second, higher light level L2
corresponding to the label 111. In some embodiments, the values of
L1 and L2 can be reversed (e.g., L1 is assigned the higher level
and L2 is assigned the lower level. The distinct values of L1 and
L2 enable light detector unit 140 to detect a transition between
gap 114 and label 111 as label media 113 advances through print
system 100.
Once the two levels L1 and L2 have been determined, in step 235
light source unit 130 is set at the higher (L2) level, and in step
240, label media 113 is advanced (e.g., to execute a print
operation or feed operation). By initially setting the light source
unit 130 level to L2 (e.g., higher), an assumption is made that the
light source unit 130 is calibrated to provide the expected light
transmission though the label 111 portion of label media 113,
therefore, a light .Iadd.transmission .Iaddend.level .Iadd.is
expected to .Iaddend.transition from .[.high to low is expected.].
.Iadd.a predetermined value to a higher detected value
.Iaddend.when a gap 114 is reached.
Once label media 113 is in motion, light detector unit 140 detects
the light beam 131 passing through label media 113. The output of
light detector unit 140 is monitored, preferably in a substantially
continuous manner in step 250, to determine whether the level of
detected light .[.rises from a low level to a higher level.].
.Iadd.increases from a predetermined value to a higher detected
value .Iaddend.(as expected per the assumption set forth above), or
.[.falls from a lower level to an even lower level.].
.Iadd.decreases from a predetermined value to a lowe detected value
.Iaddend.(in contravention of the assumption).
If, in step 255, it is determined that the level of detected light
.[.rises from a low level to a higher level.]. .Iadd.increases from
a predetermined value to a higher detected value.Iaddend., then the
assumption was correct. That is, initially, a .[.gap 114.].
.Iadd.label portion 111 .Iaddend.was positioned within light beam
131.Iadd., blocking some or all of light beam 131 and lowering the
level of light detected by light detector unit 140, .Iaddend.and
subsequently a .[.label 111.]. .Iadd.gap 114 .Iaddend.passed into
the beam, .[.occluding some of all of.]. .Iadd.allowing more light
from .Iaddend.light beam 131 .Iadd.to transmit through the gap 114
.Iaddend.and .[.lowering.]. .Iadd.increasing .Iaddend.the level of
light detected by light detector unit 140. In this case, the
current output level L2 of light source unit 130 is maintained, and
the process continues with step 265 as discussed below.
If, on the other hand, in step 255 it is determined that the level
of detected light decreases from a .[.low level to a lower level.].
.Iadd.predetermined value to a lower detected value.Iaddend., then
the assumption was incorrect in that, initially, a gap 114 was
positioned within light beam .Iadd.131 .Iaddend.and subsequently a
label 111 .Iadd.portion .Iaddend.passed into the beam.Iadd.,
.Iaddend.thus decreasing the level of light detected by light
detector unit 140. In this scenario, the position of the label 111
transition (edge) is recorded, step 260 is performed wherein output
level of light source unit 130 is changed to L1 (e.g.,
lowered).
The process continues with step 265 wherein the position of the
label 111 transition (edge) is recorded and the commanded operation
is performed (e.g., a print command, a feed command, etc.). After
the commanded operation is completed, the label media 113 is
advanced until the next gap 114 is positioned in the light beam 131
(e.g., positioned at the start of the next label 111). Then, in
step 270, a light measurement MPREV is taken at the conclusion of
the commanded operation for use during the next commanded
operation, as described above.
Advantageously, a printer according to the present disclosure
includes the capability to automatically adjust and adapt to a wide
variety of media supplies, particularly those of various lengths,
of various label stock and arrangements, and of various light
transmissivity.
While several embodiments of the disclosure have been described and
shown in the drawings, it is not intended that the disclosure be
limited thereto, as it is intended that the disclosure be as broad
in scope as the art will allow and that the specification be read
likewise. Therefore, the above description should not be construed
as limiting, but merely as examples of particular embodiments.
Those skilled in the art will envision other modifications within
the scope and spirit of the claims appended hereto.
* * * * *