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Procolored Printhead Safeguard System

Dreaming of fewer printhead issues? It’s no longer just a wish.

In early 2024, we launched our patented Siphon White Ink Circulation System to help reduce nozzle clogging by improving ink dynamics. Today, we are introducing another innovative technology: the Procolored Printhead Safeguard System.

Written by Procolored - Published on Sept 9, 2024

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Written by Procolored - Published on Sept 9, 2024

PASSAGE SUMMARY

1. Why Always Printhead Issues?
2. Common Anti-Scraping Devices
3. Meet Procolored Printhead Safeguard System
3.1 What is it ?
3.2 How does it work ?
3.3 Why it excels ?
4. Compatible Products

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1. Why Always Printhead Issues?

When browsing printer products online and reading through reviews, you might have noticed numerous complaints about printhead issues such as clogging or scraping. So why does the printhead often encounter these problems and disrupt printing plans?

Direct Ink Contact: The printhead contains microscopic nozzles that spray out ink droplets. Unfortunately, to prevent smudging and ensure high-quality printing, the ink is composed of special chemical formulations that dry quickly on both the printing medium and the nozzles, increasing the likelihood of printhead clogging.

Invasion of Foreign Objects: The printhead nozzle ranges from 20 to 50 microns—finer than a human hair. When it encounters foreign objects, even as small as dust to humans, it can easily become clogged or scraped, leading to inconsistent ink supply and poor print quality. In many cases, a curved printing medium like paper or film can be such a foreign object, causing potential printhead issues.

2. Common Anti-Scraping Devices

To avoid scraping from arched printing mediums or foreign objects, many printer brands have deployed anti-scraping devices on their products. The most commonly seen device on the current market is a snap-action mechanical structure.

Snap-action devices use a micro switch with a detection metal strip installed on the side of the printhead assembly. When the metal strip touches an arched printing film or other foreign objects, it triggers the microswitch to stop the printer. Due to its simple configuration and cost-effective materials, snap-action devices are generally inexpensive and widely used on printing machines.

However, despite its cost-effectiveness, its functionality falls short. Since printing mediums like paper or film can be quite lightweight, the detection strip often fails to effectively sense their curvature and does not stop printing in a timely manner. As a result, it only reduces the risk of printhead scraping by 20%. Additionally, because the device relies on contact-based sensing, it is prone to contamination from printed inks, leading to false triggers and requiring frequent maintenance.

3. Meet Procolored Printhead Safeguard System

To amend the shortcomings of the current anti-scraping devices, Procolored has collected feedback from our customers and experimented with several different methods, and now let’s meet the premium one - Procolored Printhead Safeguard System!

3.1 What is Procolored Printhead Safeguard System

Procolored Printhead Safeguard System utilizes diffused photoelectric detection technology to monitor the printing status without making physical contact. When the photoelectric sensor detects light reflected from an arched medium or foreign objects, the reflected light triggers the control system to immediately stop the printing action. This significantly reduces the risk of printhead scraping by over 90% and effectively extends the lifespan of the printhead.

3.2 Working principle of the system

To better understand the differences between the Procolored anti-scraping system and others, let’s delve into the diffused photoelectric detection technology mentioned above.The photoelectric detection system consists of two main components: an LED light emitter and a photosensitive receiver. It operates based on two key principles: diffuse reflection of light and triangulation theory.

Here’s how it works:

Set on the side of the printhead, the LED light emitter of the photoelectric detection unit emits a light source (typically infrared light of specific wavelengths and intensity, to minimize interference from external natural light).

The light is directed onto the printing area. When it encounters arched printing mediums like curved films or paper, or foreign objects, it reflects diffused light back. This reflected light is then focused onto the photoreceiver through the receiver lens. At this point, the emitter, the arched printing mediums or foreign objects, and the receiver collectively form a dynamic triangle.

The photosensitive element on the receiver converts the incoming light signal into electrical signals, which then enter the processing circuit within the receiver and are evaluated against a preset threshold (a default factory setting that is not adjustable). When the curvature or foreign objects are significant enough to disrupt successful printing, the electrical signals will exceed the threshold and trigger the protection action—the processing circuit opens, and the motor of the printhead assembly stops immediately.

At this point, the printer halts its operation with a double flashing alert, allowing the operator to intervene, fix the issue, and ensure the printing area is flat, clean, and properly aligned. The printhead assembly will then return to its home position after the printer is restarted, ready to resume further printing actions.

3.3 Why the Procolored system excels?

A Tidier Detection Process: Unlike most anti-scraping devices that rely on contact-based detection, the Procolored system uses a light detection method. This approach significantly reduces direct contact between the detection device and the detected objects, ensuring a tidier detection and printing process.

Less Maintenance Needed: Contact-based detection can potentially damage the detection device, as foreign objects can be carried back to the device's surface when sensed by the metal strip, negatively impacting detection quality. In contrast, the Procolored system uses light sensing, offering a high-tech detection method that requires less maintenance.

Higher Efficiency: Triggered by sensitive light and supported by a sophisticated detection device, the Procolored system offers effective detection with quick reactions, immediate notifications, and accurate feedback. It significantly reduces the risk of printhead scraping by over 90% and effectively extends the printhead’s longevity.

4. Compatible Products

So far the Procolored Printhead Safeguard System has passed the final inspection and will soon be employed on our DTF printers in the coming September, 2024. We sincerely look forward to launching this new technology to the public and redefining smart printing. Additionally, as always, we are open to any genuine feedback and are committed to providing ongoing support and updates to ensure the best possible user experience.

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