CN109823049B - Multi-target jet frequency control method and device for jet printing liquid drops - Google Patents
Multi-target jet frequency control method and device for jet printing liquid drops Download PDFInfo
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Abstract
The invention belongs to the relevant technical field of ink-jet printing, and discloses a multi-target jet frequency control method of jet printing liquid drops, which comprises the following steps: measuring three parameters of the ejection volume, the speed and the satellite liquid drop quantity of the liquid drops in real time in the trial printing process, and constructing a corresponding model for control to obtain the optimal jet printing frequency under the process window; through monitoring the real-time printing frequency and the nozzle height in the positive printing process, the feedforward-feedback online control of the droplet ejection frequency is realized, the voltage waveform is corrected, the ejection frequency error is in a required range, and the stable ejection of the nozzle is realized. The invention also discloses corresponding spray printing equipment. According to the invention, the printing frequency is maximized while the quality of the printed patterns is ensured, high-efficiency production is realized, the problem of change of the printing frequency caused by factors such as change of distance between the nozzle and the substrate, change of nozzle wettability and the like is avoided, and the stability of the quality of the printed patterns is further improved.
Description
Technical Field
The invention belongs to the technical field related to ink-jet printing, and particularly relates to a multi-target jet frequency control method and equipment for jet printing liquid drops.
Background
As a new flexible electronic manufacturing process, the ink-jet printing technology has attracted extensive attention of domestic and foreign research institutions and related manufacturers due to the characteristics of large scale, low cost and suitability for batch production. For example, a flexible electronic jet printing manufacturing device adopting an ink jet printing technology can directly print a corresponding pattern with a required ink volume at a specified position on a specific substrate by adopting data in a conventional graphic data format, so that a non-contact production process is realized, and the flexible electronic jet printing manufacturing device is widely applied to the research fields of organic light emitting display devices, thin film solar cells and the like at present, but is not yet applied to industrial production equipment in a large scale.
One of the important reasons that hinders industrial applications of inkjet printing technology is the contradiction between high printing frequency and good droplet morphology. For inkjet printing technology, production efficiency is directly related to the total volume of ink ejected per unit time by the jet printing apparatus, while the total volume of ink deposited is determined by the individual drop volume and the printing frequency. However, since the individual drop volume is limited by the print resolution, an important method to improve production efficiency is to increase the nozzle print frequency. However, too high a printing frequency affects the stability of the ejected droplet topography, thereby increasing the volume and velocity errors between droplets. Meanwhile, as the printing process is carried out, the stability of the printing frequency is influenced by the change of factors such as the distance between the nozzle and the substrate and the wettability of the nozzle. However, there is a coupling effect between the jet printing frequency and a plurality of jet printing factors, so that it is difficult to directly control the jet printing frequency by an analytical modeling method. Related proposals for droplet volume control have been made in part in prior patents, such as CN 103862863A.
However, further studies have shown that the techniques involved in the prior patents still suffer from the following disadvantages: on one hand, most of the methods print ink drops on media such as paper tapes and the like, and then the positions of the drop points of the ink drops and the shapes of formed patterns are measured to obtain and control the printing frequency and the printing quality; on the other hand, at present, the proper jet printing frequency needs to be obtained through repeated experiments, and experimental measurement needs to be carried out again after the ink material or the type of the spray head is changed, so that an accurate and convenient jet printing frequency control method is lacked. Accordingly, there is a need in the art to provide a more appropriate solution to meet the increasing process requirements.
Disclosure of Invention
Aiming at the defects or the improvement requirements of the prior art, the invention provides a multi-target jet frequency control method and equipment for jet printing liquid drops, wherein a jet liquid drop state evaluation model is constructed by selecting detection parameters such as the jet volume, the jet speed, the satellite liquid drop quantity and the like, and meanwhile, the jet frequency process of the liquid drops is optimized, so that the better jet printing frequency corresponding to a process window can be correspondingly obtained, the feedforward-feedback online control of the jet frequency of the liquid drops can be realized, the stable work of a nozzle is realized, and the method and the equipment are particularly suitable for flexible electronic industry production application occasions with extremely high requirements on both the printing precision and the production efficiency.
Accordingly, in accordance with one aspect of the present invention, there is provided a method for controlling the frequency of multiple target ejection of droplets, the method comprising the steps of:
(a) initial working parameter setting and inputting before printing
Presetting the initial jetting frequency of the jet printing equipment according to the requirements of printing process conditions, and inputting a corresponding jet printing voltage control instruction;
(b) ejection frequency optimization processing in trial printing stage
Trial printing using a jet printing apparatus and observing the actual volume M of the main droplet recorded in the processpActual initial velocity V of main dropletdAnd the actual number of satellite droplets ndMeanwhile, the following evaluation model of the state of the sprayed liquid drop is adopted to obtain an evaluation result; then, the evaluation result is compared with a preset evaluation target value, and the injection state error value F obtained by comparison is usedeAs a control variable, the maximum injection frequency f under the process conditions is correspondingly obtainedmax：
Wherein M ispRepresenting the actual volume of the main droplet, MrRepresenting a preset main drop reference volume; vdIndicating the actual initial velocity, V, of the main dropletrRepresenting a preset reference initial velocity of the main droplet; n isdRepresenting a preset satellite reference number, nrRepresenting the actual measured satellite number; k is a radical of1、k2、k3Respectively are preset control coefficients;
(c) online feed-forward control of injection frequency during formal printing phase
The actual distance h between the nozzle of the jet printing equipment and the substratepMeasuring and keeping a preset reference distance h0Comparing, and calculating to obtain the distance error delta h from the nozzle to the substrate; then, the distance error delta h is used as a control quantity to correct the corresponding jet printing voltage waveform, so that the jet frequency error is ensured to be within a required range in the whole formal printing period, and further the stable jet of the nozzle is realized;
(d) online feedback control of injection frequency in formal printing stage
Performing formal printing using the jet printing apparatus, and using a current sensor to jet an actual frequency f of liquid drops during the entire printing periodpCollecting and comparing it with the maximum injection frequency f obtained in step (a)maxComparing and calculating to obtain an injection frequency error delta f; and then, the ejection frequency error delta f is used as a control quantity to compensate the corresponding jet printing voltage waveform, so that the jet printing stability of the nozzle is further improved, and the whole jet printing process is completed.
As a further preference, in step (b), a visual camera and a strobe light source are preferably used to observe and record the main droplet actual volume MpActual initial velocity V of main dropletdAnd the actual number of satellite droplets nd(ii) a Further, it is preferable to perform closed-loop feedback control based on the control amount obtained by the ejected droplet state evaluation model and the current drive waveform parameter until the maximum ejection frequency f under the process condition is obtainedmax。
As a further preference, in step (b), the control coefficient k1、k2、k3Represents the degree of importance of the index represented to the evaluation function of the state of the ejected droplet, and the value is obtained through a plurality of tests, and is preferably set to k1＝3、k2＝2、k3＝0.02。
As a further preference, in the step (c), a laser distance meter is preferably adopted to measure the actual distance h between the nozzle of the jet printing device and the substratepCarrying out measurement; further, it is preferable to perform feedforward control based on the control amount and the voltage parameter, thereby compensating for an ejection frequency error due to a change in the distance between the nozzle and the substrate.
As a further preference, in step (d), the droplet ejection actual frequency fpThe acquisition mode of (2) is preferably designed as follows: firstly, a current sensor detects the tiny current generated by a voltage source in the process of jetting liquid drops by a nozzle, and then the detected current is filtered and subjected to noise reduction to obtain a time node of the occurrence of a current peak valueDetermining the droplet ejection time, and then passing through the nozzle for a time interval t between two successive current peak occurrencespFrom which the current actual injection frequency f is calculatedp。
According to another aspect of the invention, a corresponding jet printing device is also provided, and the device comprises a spray head module, a detection module and a voltage control module, and is characterized in that:
the spray head module comprises a spray nozzle, a pneumatic pump and a Z-axis linear motion module, wherein the spray nozzle is arranged on the Z-axis linear motion module and can realize the adjustment of the distance between the spray nozzle and the substrate; the pneumatic pump is connected with the nozzle through an air supply pipe and is used for controlling the air pressure of the ink cavity;
the detection module comprises a current detection system, a liquid drop observation system and a nozzle laser ranging system, wherein the current detection system detects a current peak value through the current sensor connected with the nozzle; the liquid drop observation system acquires a liquid drop flying image by using the visual camera and the frequency flash source, and calculates the actual volume and the actual initial speed of the liquid drop through image processing; the nozzle laser ranging system realizes real-time measurement of the distance from the nozzle to the substrate through the laser range finder arranged beside the nozzle;
the voltage control module comprises an upper computer, a jet printing control card and a current control circuit, wherein the upper computer transmits correspondingly updated waveform data to the jet printing control card according to jet frequency optimization control in a trial printing stage, jet frequency online feedforward control in a formal printing stage and jet frequency online feedback control in the formal printing stage, the jet printing control card generates a corresponding voltage control signal through instruction analysis and transmits the corresponding voltage control signal to the voltage control circuit, and finally, a voltage waveform required by nozzle ink jet is generated through the voltage control signal to jet corresponding liquid drops.
As a further preference, the ejection target of the above-described inkjet printing apparatus is preferably various types of flexible electrons.
Generally, compared with the prior art, the above technical solution conceived by the present invention mainly has the following technical advantages:
1. the method comprises the steps of measuring three parameters of the ejection volume, the ejection speed and the satellite droplet quantity of droplets in a trial printing process in real time by adopting a droplet ejection frequency optimization control method, and simultaneously constructing a proper droplet ejection state evaluation model to obtain the optimal ejection frequency under a process window; compared with the prior art, the printing frequency is maximized while the quality of the spray printing pattern is ensured, and high-efficiency production is realized;
2. in the formal printing process, the voltage waveform is corrected by monitoring the printing frequency and the height of the nozzle in real time and adopting a droplet ejection frequency feedforward-feedback online control method, so that the ejection frequency error is in a required range, and the stable ejection of the nozzle is realized. Therefore, the problem of change of spray printing frequency caused by factors such as change of distance between the nozzle and the substrate, change of nozzle wettability and the like is solved, and the stability of the quality of the printed pattern is further improved. Therefore, the method is particularly suitable for high-precision industrial and experimental application occasions such as flexible electronics, bioengineering and the like.
Drawings
FIG. 1 is a general process flow diagram of a method of multiple target injection frequency control constructed in accordance with the present invention;
FIG. 2 is a control block diagram for exemplarily illustrating an injection frequency optimization control method according to the present invention;
FIG. 3 is a control block diagram showing an on-line feed-forward control method of drop ejection frequency, according to a preferred embodiment of the present invention;
FIG. 4 is a control block diagram showing an on-line feedback control method of drop ejection frequency, according to another preferred embodiment of the present invention;
fig. 5 is a diagram for exemplary illustration of a hardware implementation of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
FIG. 1 is a general process flow diagram of a method of multiple target injection frequency control constructed in accordance with the present invention. As shown in fig. 1, the method mainly comprises the following operation steps, which will be specifically explained one by one.
First, the initial operating parameter setting and inputting step before printing.
In this step, the initial jetting frequency of the jet printing device can be preset according to the requirements of the printing process conditions, and a corresponding jet printing voltage control command is input.
Next, an ejection frequency optimization processing step in the trial printing stage is performed.
In this step, trial printing may be performed using the jet printing apparatus, and the actual volume M of the main droplets recorded in the process is observedpActual initial velocity V of main dropletdAnd the actual number of satellite droplets ndMeanwhile, the following evaluation model of the state of the sprayed liquid drop is adopted to obtain an evaluation result; then, the evaluation result is compared with a preset evaluation target value, and the injection state error value F obtained by comparison is usedeAs a control variable, the maximum injection frequency f under the process conditions is correspondingly obtainedmax：
Wherein M ispRepresenting the actual volume of the main droplet, MrRepresenting a preset main drop reference volume; vdIndicating the actual initial velocity, V, of the main dropletrRepresenting a preset reference initial velocity of the main droplet; n isdRepresenting a preset satellite reference number, nrRepresenting the actual measured satellite number; k is a radical of1、k2、k3Respectively, are preset control coefficients.
Next, an ejection frequency on-line feedforward control step in the main printing stage is performed.
In the step, the actual distance h between the nozzle of the jet printing device and the substrate is measuredpMeasuring and keeping a preset reference distance h0Comparing, and calculating to obtain the distance error delta h from the nozzle to the substrate; then, the distance error delta h is used as a control quantity to correct the corresponding jet printing voltage waveform, so that the jet frequency error is ensured to be within a required range in the whole formal printing period, and further the stable jet of the nozzle is realized;
and finally, performing online feedback control on the injection frequency in the main printing stage.
In this step, formal printing is performed using the inkjet printing apparatus, and the actual frequency f of droplet ejection is measured using a current sensor during the entire printing periodpCollecting and comparing it with the maximum injection frequency f obtained in step (a)maxComparing and calculating to obtain an injection frequency error delta f; and then, the ejection frequency error delta f is used as a control quantity to compensate the corresponding jet printing voltage waveform, so that the jet printing stability of the nozzle is further improved, and the whole jet printing process is completed.
The control principle of the droplet ejection frequency optimization control method employed according to the present invention will be described below with reference to fig. 2.
The optimal control method of the liquid drop spraying frequency is that the actual volume M of the liquid drop is observed by a camerapActual initial velocity VdAnd the actual satellite number ndAn evaluation index F is obtained by an evaluation function of the state of the ejected liquid dropletpAnd a target value FrComparing the resulting injection condition errors FeOptimizing according to the controlled quantity and the current drive waveform parameter for controlling quantity, continuously performing closed-loop feedback control until meeting the termination condition, and obtaining the maximum jet printing frequency f under the process conditionmax。
The method of on-line feed-forward control of the drop ejection frequency employed in accordance with the present invention will now be described with reference to fig. 3.
Specifically, the actual nozzle-to-substrate distance h may be measured with a nozzle laser ranging systempAnd a set distance h0Make a comparison, whatThe obtained distance error delta h between the nozzle and the substrate is a control quantity, so that the feedforward control of the jet printing frequency is realized, and the jet printing frequency error caused by the distance change between the nozzle and the substrate is compensated by adjusting a voltage parameter. The reason why this important step is affected and needs to be performed is that when a large-area substrate is subjected to jet printing, it is difficult to ensure that the horizontal surface of the substrate does not incline during the movement due to the limitations of machining precision, mounting precision and the like, and the inclination of the substrate causes the distance between the nozzle and the substrate to change, thereby affecting the frequency of droplet ejection in a part of the jet printing process.
An on-line feedback control method of the droplet ejection frequency employed in accordance with the present invention will be described with reference to fig. 4.
Specifically, the calculated droplet ejection actual frequency f may be measured by the current detection systempAnd maximum jet printing frequency fmaxAnd comparing, wherein the obtained droplet ejection frequency error delta f is used as a control quantity, then a proper closed-loop feedback control algorithm is used for realizing the feedback control of the jet printing frequency, and the influence of interference caused by jet printing condition change in the jet printing process on the jet printing frequency is further reduced by adjusting voltage parameters.
A hardware implementation according to the invention will be explained in more detail below with reference to fig. 5. The control device includes a nozzle module, a detection module, and a voltage control module, which will be explained in detail one by one.
The spray head module 210 comprises a spray nozzle 211, a pneumatic pump 212 and a Z-axis linear motion module 213, wherein the spray nozzle 211 is mounted on the Z-axis linear motion module 213 to adjust the distance between the spray nozzle and the substrate; the pneumatic pump 212 is connected to the nozzle 211 via an air supply pipe to control the air pressure in the ink chamber.
The detection module 220 comprises a current detection system 221, a droplet observation system 222 and a nozzle laser ranging system 223, wherein the current detection system 221 detects a current peak value through a current sensor connected with the nozzle 211; the liquid drop observation system 222 collects a liquid drop flight image by using a camera and a stroboscopic light source, and calculates the actual volume and the actual initial velocity of the liquid drop through image processing; the nozzle laser ranging system 223 realizes real-time measurement of the distance from the nozzle to the substrate by a laser range finder arranged beside the nozzle.
The current control module 230 comprises an upper computer 231, a jet printing control card 232 and a current control circuit 233, wherein the upper computer 231 transmits the updated waveform data of frequency optimization control in a trial printing stage, frequency online feedforward and feedback control in a formal printing stage to the jet printing control card 232, the jet printing control card 232 analyzes an instruction to generate a corresponding voltage control signal and transmits the corresponding voltage control signal to the voltage control signal 233, and the voltage control signal 233 generates a voltage waveform required by ink jetting of the nozzle 211 so as to jet corresponding liquid drops.
In summary, compared with the prior art, the control method according to the present invention performs optimization control in various aspects such as injection frequency optimization under a predetermined process window and injection frequency real-time closed-loop feedback control in the process of inkjet printing, and can obtain a more accurate control result. Firstly, on the basis of establishing an evaluation function of the droplet ejection state by a unified target method, three parameters of the droplet ejection volume, the droplet ejection speed and the satellite droplet number are measured in real time and controlled by a droplet ejection frequency optimization control method in a trial printing process, and the optimal ejection frequency under the process window is obtained. Secondly, the liquid drop jet frequency feedforward-feedback online control is realized by monitoring the real-time printing frequency and the height of the nozzle in the formal printing process, the voltage waveform is corrected, the jet printing frequency error is in a required range, and the stable jet printing of the nozzle is realized.
Many practical tests show that the method for controlling multiple stages in the printing process maximizes the ejection frequency, ensures the stability of the ejection frequency of liquid drops in the jet printing process, and realizes the optimization of efficiency and jet printing quality. Meanwhile, the invention avoids the problem of the change of the spray printing frequency caused by the factors such as the change of the distance between the nozzle and the substrate, the change of the wettability of the nozzle and the like, and further improves the stability of the quality of the printed pattern, thereby being particularly suitable for the application occasions of flexible electronic industrial production with extremely high requirements on the precision and the production efficiency.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (7)
1. A method for controlling the frequency of multiple target ejection of droplets of a print medium, the method comprising the steps of:
(a) initial working parameter setting and inputting before printing
Presetting the initial jetting frequency of the jet printing equipment according to the requirements of printing process conditions, and inputting a corresponding jet printing voltage control instruction;
(b) ejection frequency optimization processing in trial printing stage
Trial printing using a jet printing apparatus and observing the actual volume M of the main droplet recorded in the processpActual initial velocity V of main dropletdAnd the actual number of satellite droplets ndMeanwhile, the following evaluation model of the state of the sprayed liquid drop is adopted to obtain an evaluation result; then, the evaluation result is compared with a preset evaluation target value, and the injection state error value F obtained by comparison is usedeAs a control quantity, performing closed-loop feedback control based on the control quantity and the current drive waveform parameter until the maximum injection frequency f under the process condition is obtainedmax：
Wherein M ispRepresenting the actual volume of the main droplet, MrRepresenting a preset main drop reference volume; vdIndicating the actual initial velocity, V, of the main dropletrRepresenting a preset reference initial velocity of the main droplet; n isdRepresenting a preset satellite reference number, nrRepresenting the actual measured satellite number; k is a radical of1、k2、k3Respectively are preset control coefficients;
(c) online feed-forward control of injection frequency during formal printing phase
The actual distance h between the nozzle of the jet printing equipment and the substratepMeasuring and keeping a preset reference distance h0Comparing, and calculating to obtain the distance error delta h from the nozzle to the substrate; then, the distance error delta h is used as a control quantity to correct the corresponding jet printing voltage waveform, so that the jet frequency error is ensured to be within a required range in the whole formal printing period, and further the stable jet of the nozzle is realized;
(d) online feedback control of injection frequency in formal printing stage
Performing formal printing using the jet printing apparatus, and using a current sensor to jet an actual frequency f of liquid drops during the entire printing periodpCollecting and comparing it with the maximum injection frequency f obtained in step (b)maxComparing and calculating to obtain an injection frequency error delta f; and then, the ejection frequency error delta f is used as a control quantity to compensate the corresponding jet printing voltage waveform, so that the jet printing stability of the nozzle is further improved, and the whole jet printing process is completed.
2. The multi-target ejection frequency control method according to claim 1, wherein in the step (b), the actual volume M of the main droplets is observed and recorded using a visual camera and a strobe light sourcepActual initial velocity V of main dropletdAnd the actual number of satellite droplets nd。
3. The multiple target injection frequency control method according to claim 2, wherein in step (b), the control coefficient k is set to be equal to or greater than a predetermined value1、k2、k3Representing the importance degree of the represented index to the sprayed liquid drop state evaluation model, and the value is obtained through multiple experimental tests and is respectively set as k1＝3、k2＝2、k3＝0.02。
4. A plurality of claim 2 or 3The target ejection frequency control method is characterized in that, in the step (c), the actual distance h between the nozzle of the jet printing equipment and the substrate is measured by using a laser distance meterpCarrying out measurement; further, feedforward control is performed based on the control amount and the voltage parameter, thereby compensating for an ejection frequency error due to a change in the distance between the nozzle and the substrate.
5. The multiple target spray frequency control method as claimed in claim 4, wherein in step (d), the droplet spray actual frequency fpThe acquisition mode is designed as follows: firstly, detecting the tiny current generated by a voltage source in the process of ejecting liquid drops by a nozzle through a current sensor, then carrying out filtering and noise reduction on the detected current to obtain a time node of the occurrence of a current peak value so as to determine the liquid drop ejection time, and then determining the interval time t of the occurrence of two consecutive current peak values before and after the nozzle through the current sensorpFrom which the current actual injection frequency f is calculatedp。
6. A jet printing apparatus for performing the multi-target jet frequency control method as claimed in claim 2 or 3, the apparatus comprising a head module, a detection module, and a voltage control module, characterized in that:
the spray head module comprises a spray nozzle, a pneumatic pump and a Z-axis linear motion module, wherein the spray nozzle is arranged on the Z-axis linear motion module and can realize the adjustment of the distance between the spray nozzle and the substrate; the pneumatic pump is connected with the nozzle through an air supply pipe and is used for controlling the air pressure of the ink cavity;
the detection module comprises a current detection system, a liquid drop observation system and a nozzle laser ranging system, wherein the current detection system detects a current peak value through the current sensor connected with the nozzle; the liquid drop observation system acquires a liquid drop flying image by using the visual camera and the stroboscopic light source, and calculates the actual volume and the actual initial speed of the liquid drop through image processing; the nozzle laser ranging system realizes real-time measurement of the distance from the nozzle to the substrate through the laser range finder arranged beside the nozzle;
the voltage control module comprises an upper computer, a jet printing control card and a current control circuit, wherein the upper computer transmits correspondingly updated waveform data to the jet printing control card according to jet frequency optimization control in a trial printing stage, jet frequency online feedforward control in a formal printing stage and jet frequency online feedback control in the formal printing stage, the jet printing control card analyzes an instruction to generate a corresponding voltage control signal and simultaneously transmits the corresponding voltage control signal to the voltage control circuit, and finally, voltage waveforms required by nozzle ink jet are generated through the voltage control circuit to jet corresponding liquid drops.
7. The inkjet printing apparatus according to claim 6 wherein the ejection target of the inkjet printing apparatus is a flexible electron of various types.
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