KR101109332B1 - Image recording method - Google Patents

Abstract

[PROBLEMS] To provide an image recording method that uses a conventional apparatus configuration as it is, and is simple in configuration and capable of performing calibration of positions of a recording head and a camera.
[Resolution] A plurality of recording heads are wound in a roll to form a head calibration pattern for calibrating the position of the recording head with respect to a pair of long recording materials, and a camera calibration pattern for calibrating the position of the camera. A calibration pattern forming process and a head calibration pattern and a camera calibration pattern are photographed with a camera to measure the position error of each head and the position error of the camera. The recording position of the image by the recording head is corrected.

Description

Image recording method {IMAGE RECORDING METHOD}

The present invention relates to an image recording method for recording an image on a long recording material.

In recording an image, an image recording apparatus for recording an image on a sheet-like recording material is generally used. However, in the case of using a thin recording material having a thickness of, for example, 0.1 mm or less, such as a recording material for a flexible printed board called FPC (flexible printed circuit) or the like, When the recording material is placed on a table for recording an image or when an operator puts the recording material into an apparatus, there is a problem that wrinkles easily occur in the recording material.

For this reason, for example, an image recording apparatus has also been proposed in which a long recording material in the shape of a roll is used, and the long recording material is conveyed in the longitudinal direction while the image is recorded in the recording material using the recording head. For example, refer patent document 1).

In such an image recording apparatus, a configuration is adopted in which a plurality of alignment marks formed on the recording material are photographed by a plurality of cameras to adjust the recording position of the image.

In such an image recording apparatus, calibration of these positions is performed in order to make the recording position of the image by the recording head and the photographing position of the alignment mark by the camera accurate. This calibration is performed using a calibration scale which is arranged at the end of the apparatus.

However, when the image is recorded using a long recording material, which is a pair (rolled into a unit of counting thin and long) wound in a roll shape, since the calibration scale is covered by the recording material, the recording material is You cannot carry out a calibration operation unless you remove it from the device. For this reason, an image recording apparatus has also been proposed in which an apparatus is configured so that the recording material passes under the alignment correction member, and the alignment correction member can be photographed by moving the alignment correction member during calibration (see Patent Document 2). ).

Patent Document 1: Japanese Patent Application Laid-Open No. 2003-115449 Patent Document 2: Japanese Patent Application Laid-Open No. 2006-98726

However, in the image recording apparatus described in Patent Document 2, there is a problem in that the device configuration is extremely complicated.

The present invention has been made to solve the above problems, and an object thereof is to provide an image recording method capable of performing calibration of the positions of the recording head and the camera with a simple configuration using a conventional apparatus configuration as it is.

In the invention according to claim 1, recording is performed by reciprocating a long, long recording material in the Y direction and simultaneously moving a plurality of recording heads integrally in the X direction orthogonal to the Y direction. Image recording which records an image by dividing the entire surface of the material into a plurality of stripe-shaped areas, and simultaneously captures a plurality of alignment marks formed on the recording material with a plurality of cameras and corrects the recording position of the image by the plurality of recording heads. An image recording method for recording an image using an apparatus, wherein the plurality of recording heads are moved to a position for recording the first stripe-shaped area, and then the recording head is calibrated with the recording head for the recording material. Forming a first head calibration pattern to form a first head calibration pattern A second step of forming a second head calibration pattern for calibrating the position of the recording head with respect to the recording material by moving the plurality of recording heads to a position for recording the last stripe region; Measuring the deviation amount of the head calibration pattern forming step and the first head calibration pattern and the second head calibration pattern by photographing the adjacent ones with a camera, and the positional error of each head from the deviation amount. A head calibration process having a position error measuring step of measuring a; and moving one of the plurality of recording heads to the formation region of each alignment mark in the recording material, and then Multiple camera calibration patterns for calibrating position The camera position for measuring the camera calibration pattern and the camera's position error by measuring the camera calibration pattern and the camera's field of view deviation from the camera's field of view by imaging each camera calibration pattern with each camera. A plurality of alignment marks formed on the recording material using both the head position error obtained in the head calibration process and the camera position error obtained in the camera calibration process after performing both of the camera calibration pattern measuring process having the error measuring process. To correct a recording position of an image by the plurality of recording heads determined by photographing the plurality of cameras.

In the invention according to claim 2, in the invention according to claim 1, the qualitative positional error that occurs qualitatively in each head when each head moves to a position for recording the respective stripe-shaped regions is previously known. The measurement position is used to correct the recording position of the image by the recording head using this qualitative position error.

The invention as set forth in claim 3 is a recording material by reciprocating a set of long recording materials in the Y direction and intermittently moving a plurality of recording heads integrally in the X direction orthogonal to the Y direction. A recording position of an image by a plurality of recording heads formed on the plurality of recording materials by photographing a plurality of alignment marks formed on the recording material by dividing the front surface of the image into a plurality of stripe-shaped regions and simultaneously recording the plurality of alignment marks formed on the recording material. An image recording method for recording an image using an image recording apparatus for correcting the error, comprising: measuring qualitative positional errors generated qualitatively in each head when each head is moved to a position for recording the respective stripe-shaped regions; A head qualitative error measuring process and a position where the first stripe-shaped area is recorded on the plurality of recording heads. A first head calibration pattern forming step of forming a first head calibration pattern for calibrating the position of the recording head with respect to the recording material after the recording head is moved; And a second head calibration pattern forming step of forming a second head calibration pattern for calibrating the position of the recording head with respect to the recording material by moving the recording head to a recording position, and one of the plurality of recording heads. A camera calibration forming step of moving a plurality of camera calibration patterns for calibrating the position of the camera with respect to the recording material after moving the to the formation region of each alignment mark in the recording material, 1 head calibration pattern and the second head A head position error measuring step of measuring the amount of such deviation and measuring the positional error of each head from the amount of the deviation by photographing the adjacent ones with the camera among the calibration patterns, and the respective camera calibration patterns A camera position error measuring step of measuring an amount of deviation between the camera calibration pattern and the field of view of the camera by measuring the difference between the camera calibration pattern and the field of view of the camera, and measuring the position error of the camera from the amount of the deviation. Images by the plurality of recording heads determined by photographing a plurality of alignment marks formed on the recording material using a plurality of cameras using the qualitative position error of each head obtained in the step and the camera position error obtained in the head position error measuring step. It is characterized by correcting the recording position of.

According to the invention of claim 4, an image is obtained by intermittently moving a plurality of long elongated recording materials in the Y direction and intermittently moving a plurality of recording heads in the X direction orthogonal to the Y direction. An image recording method of recording an image using an image recording apparatus for recording a plurality of alignment marks formed on a recording material and simultaneously correcting a recording position of an image by the plurality of recording heads while recording. A calibration pattern forming step of forming a head calibration pattern for calibrating the position of the recording head with respect to the recording material by the plurality of recording heads, a camera calibration pattern for calibrating the position of the camera, the head calibration pattern and the camera Photographing calibration patterns with a camera And measuring the positional errors of the heads and the positional errors of the cameras, and taking a plurality of alignment marks formed on the recording material using the positional errors obtained in the measuring process and photographing the plurality of alignment marks. The recording position of the image by the plurality of recording heads is corrected.

According to the invention as claimed in claims 1 to 4, it is possible to carry out calibration of the position of the recording head and the camera while having a simple configuration. For this reason, the recording position of an image can be adjusted more accurately, and it becomes possible to record an image with high precision.

In particular, according to the inventions of claims 2 and 3, since the recording position of the image can be adjusted including the qualitative position error that occurs qualitatively in each head, it is possible to record the image more accurately. Done.

1 is a side schematic view of an image recording apparatus to which the present invention is applied.
2 is a schematic plan view of an image recording apparatus to which the present invention is applied.
3 is a schematic side view of the image recording unit 4. FIG.
4 is a schematic plan view of the image recording unit 4.
FIG. 5: is explanatory drawing which shows the Z-axis table 36 and the rotation table 37. FIG.
6 is a schematic diagram of the recording head 34.
7 is an explanatory diagram for explaining a head calibration operation.
8 is an explanatory diagram for explaining a head calibration operation.
9 is an explanatory diagram for explaining a head calibration operation.
10 is an explanatory diagram for explaining a head calibration operation.
Fig. 11 is a schematic diagram illustrating an operation of correcting qualitative position error.
12 is a schematic diagram showing an operation of determining the reference position of the recording head 34a.
Fig. 13 is a schematic diagram showing an operation of determining the reference position of the recording head 34a.
It is explanatory drawing for demonstrating a camera calibration process.
15 is an explanatory diagram for explaining a camera calibration step.
16 is an explanatory diagram for explaining a camera calibration process.
FIG. 17 is an explanatory diagram for explaining a camera calibration process. FIG.
18 is an explanatory diagram showing an image recording operation.
Fig. 19 is an explanatory diagram showing an image recording operation.
20 is a flowchart showing an image recording operation.
Fig. 21 is an explanatory diagram showing an image recording operation after the position of the alignment mark M is changed.
Fig. 22 is an explanatory diagram showing an image recording operation after the position change of the alignment mark M;
Fig. 23 is a flowchart showing an image recording operation after the position of the alignment mark M is changed.

EMBODIMENT OF THE INVENTION Hereinafter, embodiment of this invention is described based on drawing. Fig. 1 is a side schematic view of an image recording apparatus to which the present invention is applied, and Fig. 2 is a plan schematic view thereof.

The image recording apparatus records an image on a thin long-length recording material 1 for an FPC. The image recording apparatus includes an unwinding roller 11 for unrolling and unrolling the recording material 1, and a first dancer roller. A supply section 2 having a mechanism 12, an alignment mark forming mechanism 3 for forming alignment marks on both sides of the recording material 1, an image recording section 4, and a second dancer roller mechanism 13; And a recovery section 5 having a winding roller 14 for winding the recording material 1.

The said supply part 2 consists of the unwinding roller 11 which rotates by the drive of a motor which is not shown in figure, the guide roller 15, a set of fixed rollers 21 and 22, and a dancer roller 23. As shown in FIG. The first dancer roller mechanism 12 is formed. Similarly, the recovery part 15 includes a winding roller 14, a guide roller 16, a set of fixed rollers 24 and 25 and a dancer roller 26 that rotate by driving of a motor (not shown). It consists of the 2nd dancer roller mechanism 13 comprised by it. In addition, the alignment mark forming mechanism 3 includes an alignment mark forming portion 51 composed of a pair of upper and lower exposure portions 52 and 53.

Next, the structure of the said image recording part 4 is demonstrated. 3 is a side schematic view of the image recording section 4, and FIG. 4 is a plan schematic view thereof.

The recall recording section 4 is provided with an adsorption table 31 for holding and retaining the recording material 1 from its lower surface, and is disposed at both ends in the moving direction of the adsorption table 31, and the surface of the adsorption table 31 is provided. A pair of peeling rollers 32 for peeling the recording material 1 from each other, a pair of CCD cameras 33 for detecting the alignment marks M (see FIG. 2) formed on the recording material 1, and 4 Two recording heads 34a, 34b, 34c, and 34d (hereinafter, referred to as "recording head 34") and a pair of nip rollers.

On the surface of the adsorption table 31, a plurality of adsorption holes for adsorbing and holding the recording material 1 are drilled and provided. In addition, the suction table 31 includes a Z-axis table 36, a rotary table 37, and a support 41 between the movable motors 38 of the linear motor 40. Connected with For this reason, according to the stator 39 of the linear motor 40, the suction table 31 is shown from the edge part of the movement stroke by the unwinding roller 11 side shown by the solid line in FIG. Reciprocates in the Y direction to the movement stroke on the winding roller 14 side indicated by the imaginary line. And the above-mentioned pair of peeling rollers 32 are connected to the support stand 41, and it is set as the structure which reciprocates in a Y direction in synchronism with the movement of the suction table 31. As shown in FIG. In addition, this pair of peeling rollers 32 raises and lowers in the Z direction shown by FIG. 1 and FIG. 3 by the lifting mechanism not shown.

FIG. 5: is explanatory drawing which shows the Z-axis table 36 and the rotation table 37 mentioned above. 5A is a plan view of the turntable 37, FIG. 5B is a plan view of the Z-axis table 36, and FIG. 5C is a turntable 37 and a Z-axis table 36. FIG. Side view.

As shown in Figs. 5A and 5C, the rotary table 37 rotates the rotary part 43 by the driving of the motor 42 to unwind the suction table 31. It rotates at a small angle in a plane parallel to the surface of the recording material 1 about an axis perpendicular to the surface of the recording material 1 unwound from and wound by the winding roller 14. That is, the suction table 31 rotates in the (theta) direction shown in FIG. 4 by the drive of the motor 42. FIG.

5 (b) and 5 (c), the Z-axis table 36 unwinds the suction table 31 by sliding the base 45 by driving the motor 44. This is for lifting up and down in the direction perpendicular to the surface of the recording material 1 unwound from 11 and wound by the winding roller 14. That is, the suction table 31 moves up and down in the Z direction shown in FIG. 3 by driving the motor 44.

A pair of CCD cameras 33 for measuring the alignment mark M (see Fig. 2) formed on the recording material 1 is connected to a ball screw 86 that rotates by driving of the motor 85, respectively. For this reason, these CCD cameras 33 can change the imaging position according to the position of the alignment mark M. FIG.

The four recording heads 34a, 34b, 34c, and 34d described above are disposed and provided above the moving stroke of the suction table 31, and intersect with the moving direction of the recording material 1 (X shown in FIG. 4). Direction) and is guided by a pair of linear guides 88 extending in a movable manner. And between the linear guides 88, the linear motor 87 arrange | positioned in parallel with the linear guide 88 is arrange | positioned, and is provided. For this reason, the four recording heads 34a, 34b, 34c, and 34d reciprocate in the X direction by the drive of the linear motor 87.

Among the nip rollers 35 described above, the upper nip rollers 35 are elevated in the Z direction as shown in FIG. 3 by driving the air cylinder 89. For this reason, by driving the air cylinder 89, a pair of nip rollers 35 can take the clamping state which clamps the recording material 1, and the open state which releases the recording material 1. Done.

6 is a schematic diagram of the recording head 34 described above. In addition, the four recording heads 34a, 34b, 34c, and 34d have the same configuration.

The recording head 34 includes a light amount adjusting filter 64 for dimming the light from the light source 61, a rod integrator 65, an illumination system lens 66, and a DMD (Digital Micromirror) as a two-dimensional modulation element. Device (digital micromirror device) 69 and projection lenses 70 and 72 are provided. Here, the DMD 69 is a spatial modulator that modulates light by tilting a plurality of square micromirrors arranged and arranged in a matrix shape by an electrostatic field action.

A light beam emitted from a light source and guided by an optical fiber (not shown) includes a mirror 62, a lens 63, a light amount adjusting filter 64, a rod integrator 65, and an illumination system lens 66. And enters the DMD 69 through the mirrors 67 and 68. This light beam is spatially modulated by the DMD 69 and then irradiated onto the recording material 1 through the projection lens 70, the mirror 71, and the projection lens 72.

Next, the recording operation of the image by the above-described image recording apparatus will be described.

In this image recording apparatus, the alignment mark forming mechanism for the recording material 1 unwound from the unwinding roller 11 and wound by the unwinding roller 14 before the image is first recorded on the recording material 1. By (3), the alignment mark M is formed in the front side and the back surface side.

When the image is recorded, the image recording area of the recording material 1 is sucked and held by the suction table 31. At this time, the above-described pair of nip rollers 35 sandwiches the recording material 1, and the recording material is fixed. Then, the position of the alignment mark M in the recording material 1 is detected by a pair of CCD cameras 33.

Next, based on the detection value of the alignment mark M by this CCD camera 33, and the correction value mentioned later, the suction table 31 is removed from the unwinding roller 11 by the action of the rotation table 37 mentioned above. Positioning of the rotary table by rotating the micro-angle in a plane parallel to the surface of the recording material 1 about an axis perpendicular to the surface of the recording material 1 unwinded and wound by the winding roller 14. Is done.

That is, in the case of recording a pattern such as a printed wiring board on both surfaces of the recording material 1, it is necessary to position the patterns recorded on both surfaces of the recording material 1 with each other. For this reason, when the image is recorded on the front and back surfaces of the recording material 1, the suction table 31 is first moved by using the alignment marks M formed on both surfaces of the recording material by the alignment mark forming mechanism 3. In this way, the positioning of the recording material 1 is performed.

Next, the nip of the recording material 1 by the pair of nip rollers 35 is released. While the suction table 31 reciprocates in the Y direction shown in Figs. 2 and 3, four recording heads 34a, 34b, 34c, and 34d are moved in the X direction shown in Fig. 4 in synchronism with the reciprocating movement. Move intermittently. By repeating such an operation, image recording is performed by four recording heads 34a, 34b, 34c, and 34d for the entire area of the image recording area in the recording material 1.

That is, at the time of recording of this image, the front surface of the recording material 1 is plural stripes by moving the four recording heads 34a, 34b, 34c, 34d intermittently in the X direction with respect to the recording material moving in the Y direction. The image recording is performed by dividing into the shape area.

At this time, with the reciprocating movement of the suction table 31, the recording material 1 repeats only the moving stroke of the suction table 31. The movement of this recording material 1 is absorbed by the first and second dancer roller mechanisms 12 and 13. The lifting distance of the dancer rollers 23 and 26 at this time is one half of the movement stroke of the suction table 31.

When recording of the image is finished, the recording material 1 is unwound from the unwinding roller 11 in the direction indicated by the arrow A in FIG. 1, and simultaneously wound up by the unwinding roller 14. At this time, the alignment mark M corresponding to the next image recording area is read by a pair of CCD cameras 33 while the recording material 1 is adsorbed and held by the suction table 31. The recording material 1 is moved together with the suction table 31 until now. At this time, the unwinding roller 11 unwinds only the moving distance of the adsorption table 31, and the unwinding roller 14 winds up the recording material 1 by the moving distance of the adsorption table 31. As shown in FIG.

Next, the recording material 1 is sandwiched and fixed by a pair of nip rollers 35. Then, the suction holding of the recording material 1 by the suction table 31 is released. Next, the recording material 1 is peeled from the surface of the suction table 31 by raising a pair of peeling rollers 32 arranged and disposed at both ends in the moving direction of the suction table 31. In addition, instead of raising the peeling roller 32, the adsorption table 31 is lowered using the Z-axis table 36 mentioned above, and the recording material 1 is peeled off from the surface of the adsorption table 31. FIG. You may also

Then, the suction table 31 is moved to a position corresponding to the next image recording area in the recording material 1. At this time, the pair of peeling rollers 32 rotate while being in contact with the lower surface of the recording material 1. Then, the pair of peeling rollers 32 are lowered, and the recording material 1 is sucked and held by the suction table 31.

As described above, according to this image recording apparatus, the suction table 31 reciprocates in the state in which the long recording material 1 is adsorbed and held, and the recording head 34 records the image on the recording material 1. With this configuration, it is possible to accurately record an image without causing wrinkles or the like on the recording material 1.

In such an image recording apparatus, in order to make the recording position of the image by the four recording heads 34a, 34b, 34c, and 34d and the imaging position of the alignment mark M by the CCD camera 33 accurate, Calibration of the position is performed. Hereinafter, the calibration operation which is a feature part of this invention is demonstrated.

First, the principle of the head calibration process for calibrating the positions of the four recording heads 34a, 34b, 34c, and 34d will be described. 7-10 is explanatory drawing for demonstrating a head calibration process.

The image recording apparatus divides the entire surface of the recording material 1 into a plurality of stripe regions by intermittently moving the four recording heads 34a, 34b, 34c, and 34d while reciprocating the recording material 1. In this case, the image is recorded. However, when performing the head calibration operation, first, the four recording heads 34a, 34b, 34c, and 34d are moved to the position where the first stripe region is recorded. As shown in Fig. 7, a first head calibration pattern 73 is formed at an end portion of the recording area 75 by each recording head 34a, 34b, 34c, 34d. At this time, a calibration pattern is displayed on the DMD 69 of each recording head 34a, 34b, 34c, 34d, and pattern formation is performed by opening the shutter of the light source 61 for a predetermined time.

In addition, the four recording heads 34a, 34b, 34c, and 34d are moved to the position where the last stripe-shaped area is recorded. As shown in Fig. 8, the second head calibration pattern 74 is formed at the end of the recording area 75 by the recording heads 34a, 34b, 34c, and 34d. Also at this time, a calibration pattern is displayed on the DMD 69 of each recording head 34a, 34b, 34c, 34d, and pattern formation is performed by opening the shutter of the light source 61 for a predetermined time.

Next, as shown in FIG. 9, the CCD camera 33 image | photographs the thing which adjoins mutually among the 1st head calibration pattern 73 and the 2nd head calibration pattern 74. Next, as shown in FIG.

That is, as shown in Fig. 8, the second head calibration pattern 74 formed at the end of the recording area by the recording head 34a and the end of the recording area by the recording head 34b. The first head calibration pattern 73 formed at the adjacent portion is adjacent to the recording area by the second head calibration pattern 74 and the recording head 34c formed at the end of the recording area by the recording head 34b. The 1st head calibration pattern 73 formed in the edge part adjoins. For this reason, as shown in FIG. 9, the CCD camera 33 picks up the 1st head calibration pattern 73 and the 2nd head calibration pattern 74 which are arrange | positioned adjacent to each other.

At this time, the second head calibration pattern 74 formed by the recording head 34a and the second head calibration pattern formed by the recording head 34b and the first head calibration pattern 73 formed by the recording head 34b. The first head calibration pattern 73 formed by the 74 and the recording head 34c is picked up by one CCD camera 33, and the second head calibration pattern 74 formed by the recording head 34c. The first head calibration pattern 73 formed by the recording head 34d may be imaged by the other CCD camera 33.

Next, as shown in FIG. 10, from the distances in the X and Y directions of the first head calibration pattern 73 and the second head calibration pattern 74, each of the recording heads 34a, 34b, 34c, and 34d is separated. Measure the position error. At this time, the X head distance between the first head calibration pattern 73 and the second head calibration pattern 74 records the first head calibration pattern 73 and the second head calibration pattern 74 by the recording head 34. In this case, the predetermined distance X _i and the position error δ _X preset in the recording area are added. For this reason, subtracting Xi from the distance of the X head direction of the 1st head calibration pattern 73 and the 2nd head calibration pattern 74 turns into position error (delta) _X. On the other hand, the distance in the Y direction of the first head calibration pattern 73 and the second head calibration pattern 74 is the position error δ _Y in the Y direction.

The integrated value of the position errors δ _X and δ _Y is calculated for each of the other recording heads 34b, 34c, 34d on the basis of the recording head 34a, and stored as the position errors of the other recording heads 34b, 34c, 34d. The position error is used to correct the positions of the four recording heads 34a, 34b, 34c, and 34d together with the qualitative position error described below.

11 is a schematic diagram illustrating a correcting operation of qualitative position error.

When the four recording heads 34a, 34b, 34c, and 34d move in the X direction in order to record an image in each stripe area, the qualitative positional errors in the X and Y directions qualitatively occur in each head in advance. It is measured. As shown in Fig. 11, this qualitative position error is provided to the position correction memory 76 as the X direction correction value and the Y direction correction value at the position in the X direction for each of the recording heads 34a, 34b, 34c, and 34d. I remember. The position error measured in the above-described head calibration process is stored in the position correction memory 76 together with this qualitative position error.

12 and 13 are schematic views showing the operation of determining the reference position of the recording head 34a.

In the above-described head calibration process, positional errors of other recording heads 34a, 34b, 34c, and 34d are determined based on the recording head 34a. As shown in Fig. 12, the position of the recording head 34a serving as a reference is at the end of the apparatus in the state where the recording material 1 is not mounted, such as immediately after the start of the apparatus or when the recording material 1 is replaced. It is confirmed using the installed reference scale 77. That is, the position of the recording head 34a is confirmed by measuring the distance between the center mark 78 and the mark line 79 of the reference scale 77, and the reference position error is measured.

In addition, instead of confirming the position of the recording head 34a in the state where the recording material 1 is not mounted in this way, as shown in FIG. 13, the reference scale is extended to an area not covered by the recording material 1. The recording head 34a may be moved to the area so that the reference position error may be measured every time the head calibration operation is performed.

Next, the principle of the camera calibration process of calibrating the position of a pair of CCD camera 33 is demonstrated. 14-17 is explanatory drawing for demonstrating a camera calibration process.

When performing the camera calibration process, as shown in FIG. 14, the recording head 34a is moved to the formation area | region of one alignment mark in the recording material 1. As shown in FIG. Then, the recording head 34a forms a camera calibration pattern 81 for calibrating the position of one CCD camera 33 with respect to the recording material 1. At this time, the pattern for calibration is displayed on the DMD 69 of the recording head 34a, and pattern formation is performed by opening the shutter of the light source 61 for a predetermined time.

Next, as shown in FIG. 15, the recording head 34d is moved to the formation area of the other alignment mark in the recording material 1. Next, as shown in FIG. Then, the recording head 34d forms a camera calibration pattern 81 for calibrating the position of the other CCD camera 33 with respect to the recording material 1. At this time, the calibration pattern is displayed on the DMD 69 of the recording head 34d, and the pattern is formed by opening the shutter of the light source 61 for a predetermined time.

Next, as shown in FIG. 16, each camera calibration pattern 81 is imaged with a pair of CCD cameras 33, so that the camera calibration pattern 81 and the field of view of the CCD camera 33 are different. The shifted amount is measured, and the positional errors ε _X and ε _Y of the CCD camera 33 are measured from the shifted amount.

That is, as shown in FIG. 17, the pair of CCD cameras 33 is separated from the distance between the camera calibration pattern 81 and the mark line 82 representing the center of view of the CCD camera 33 in the X and Y directions. Measure the position error. This position error is stored in the position correction memory 76 and used for correcting the position of a pair of CCD cameras 33.

Next, an image recording operation for recording an image by executing the above-described head calibration process and camera calibration process will be described. 18 and 19 are explanatory diagrams showing an image recording operation, and FIG. 20 is a flowchart thereof.

When recording an image, first, as shown in Fig. 18A, the recording material 1 is adsorbed and held by the suction table 31 and positioned at an initial position (step S1).

Next, as shown in Fig. 18B, a pattern for head calibration is formed (step S2). In this case, the four recording heads 34a, 34b, 34c, and 34d are moved to the position where the first stripe-shaped area is recorded to form the first head calibration pattern 73, and then the four recording heads 34a, 34b, 34c and 34d are moved to the position where the last stripe-shaped area is recorded to form the second head calibration pattern 74.

Next, as shown in Fig. 18C, a pattern for camera calibration is formed (step S3). At this time, the recording head 34a is moved to the formation area of one alignment mark in the recording material 1 to form a camera calibration pattern 81 for calibrating the position of one CCD camera 33, The recording head 34d is moved to the formation area of the other alignment mark in the recording material 1 to form a camera calibration pattern 81 for calibrating the position of the other CCD camera 33.

Next, as shown in Fig. 18D, the calibration of the four recording heads 34a, 34b, 34c, and 34d is performed (step S4). At this time, the CCD camera 33 captures an image of the first head calibration pattern 73 and the second head calibration pattern 74 that are adjacent to each other, and the first head calibration pattern 73 and the second head calibration pattern 73 are adjacent to each other. The positional errors of the respective recording heads 34a, 34b, 34c, and 34d are measured from the distances in the X direction and the Y direction with the head calibration pattern 74. FIG. This position error is stored in the position correction memory 76 together with the qualitative position error.

Next, as shown in Fig. 19A, the calibration of the CCD camera 33 is executed (step S5). At this time, by imaging each camera calibration pattern 81 with a pair of CCD cameras 33, the amount of shift | deviation between the camera calibration pattern 81 and the visual field of the CCD camera 33 is measured, and the The positional error of the CCD camera 33 is measured from the shifted amount.

Next, as shown in Fig. 19B, the resorption holding of the recording material 1 is performed (step S6). At this time, the recording material 1 is held by the nip roller 35 and the suction table 31 releases the suction of the recording material 1. Then, the recording material 1 is peeled off from the suction table 31. Then, the adsorption table 31 is moved by the four recording heads 34a, 34b, 34c, and 34d so that the recording area of the image is in a predetermined position, and then the recording material ( 1) is maintained by adsorption.

Next, positioning of the recording material 1 is executed (step S7). At this time, as shown in Fig. 19C, the alignment mark M formed at one end of the recording material 1 is detected by one CCD camera 33. As shown in Figs. As shown in Fig. 19D, the alignment mark M formed at the other end of the recording material 1 is detected by the other CCD camera 33. As shown in Figs. Then, using the positional errors of the four recording heads 34a, 34b, 34c, and 34d previously stored in the positional correction memory 76, the qualitative positional errors, and the positional errors of the CCD camera 33, the recording material 1 is used. The information regarding the recording position of the image by the four recording heads 34a, 34b, 34c, and 34d determined based on the positions of the formed plurality of alignment marks M is corrected.

Thereafter, the image is recorded (step S8). In this case, first, the rotational error, the shift amount, and the expansion ratio of the recording material 1 are calculated based on the data of the corrected image recording position. Then, based on the rotational error of the recording material 1, the suction table 31 is rotated by a small angle. Further, the zoom magnification and the recording start position of each recording head 34a, 34b, 34c, 34d are determined based on the shift amount and the expansion ratio of the recording material 1. Thereafter, the recording material 1 is reciprocated in the Y direction, and each recording head 34a, 34b, 34c, 34d is intermittently moved in the X direction to perform image recording.

In such an image recording apparatus, when the position of the alignment mark M is changed due to a change in the size of an image recorded on the recording material 1, the camera calibration for calibrating the position of a pair of CCD cameras 33 again. The process is executed.

FIG.21 and FIG.22 is explanatory drawing which shows the image recording operation | movement after the position change of the alignment mark M, and FIG.23 is the flowchart.

Fig. 21A shows a state in which an image is recorded (step S11), and Fig. 21B shows a state in which image recording is completed (step S12). In addition, in FIG. 21 and FIG. 22, the shade display is provided to the area | region which the image recording was complete | finished.

When the image to be recorded is changed and the position of the alignment mark M is changed, as shown in Fig. 21C, first, the position at which the camera calibration pattern is formed is set to four recording heads 34a, 34b, 34c, and 34d. The recording material 1 is moved together with the adsorption table 31 so that it can be arranged below (step S13).

Next, as shown in FIG.21 (d), the camera calibration pattern 81 is formed (step S14). At this time, the recording material 1 is sandwiched by the nip roller 35 and the suction holding of the recording material 1 by the suction table 31 is released. Then, the recording material 1 is peeled off from the suction table 31. After that, the suction table 31 is moved so that the recording position of the pattern by any of the four recording heads 34a, 34b, 34c, and 34d becomes a predetermined position in the suction table 31, and then again. The adsorption table 31 adsorbs and holds the recording material 1. And the camera calibration pattern 81 is formed in the position.

Next, as shown in Fig. 22A, camera calibration 81 is executed (step S15). At this time, as described above, the CCD camera 33 moves to the position where the camera calibration pattern 81 can be photographed.

Next, the positioning of the recording material 1 is executed (step S16). At this time, as shown in Fig. 22 (b), the alignment mark M formed on one end of the recording material 1 is detected by one CCD camera 33. As shown in Fig. 22C, the alignment mark M formed at the other end of the recording material 1 is detected by the other CCD camera 33. Figs. Similarly to the above-described step S7, the positional errors, qualitative positional errors of the four recording heads 34a, 34b, 34c, and 34d stored in the positional correction memory 76 in advance and the positional errors of the CCD camera 33 are used. Then, the information regarding the recording position of the image by the four recording heads 34a, 34b, 34c, 34d determined based on the positions of the plurality of alignment marks M formed on the recording material 1 is corrected.

Thereafter, the image is recorded (step S17). At this time, similarly to step S8 described above, the rotational error, the shift amount, and the expansion ratio of the recording material 1 are calculated based on the data of the corrected image recording position. Then, the suction table 31 is rotated by a small angle based on the rotational error of the recording material 1. Further, the zoom magnification and the recording start position of each recording head 34a, 34b, 34c, 34d are determined based on the shift amount and the stretching ratio of the recording material 1. Thereafter, the recording material 1 is reciprocated in the Y direction, and each recording head 34a, 34b, 34c, 34d is intermittently moved in the X direction to perform image recording.

1 recording material
2 supply
3 Alignment mark forming mechanism
4 Image Record
5 collection parts
11 unwinding roller
12 1st dancer roller mechanism
13 2nd Dancer Roller Mechanism
14 winding roller
31 adsorption table
32 peeling roller
33 CCD Camera
34 recording head
35 nip rollers
36 Z axis table
37 turntables
38 mover
39 stator
40 linear motors
41 Support
51 Alignment Mark Formation
52 Exposure Section
53 Exposure section
61 light source
64 Light Filter
66 illumination system lens
69 DMD
70 projection lens
72 projection lens
73 First Head Calibration Pattern
74 2nd Head Calibration Pattern
76 position correction memory
77 Reference Scale
81 Camera Calibration Pattern
82 mark
M alignment mark

Claims (4)

By reciprocating the long and long recording material in the Y direction and intermittently moving the plurality of recording heads integrally in the X direction in a straight line with the Y direction, An image recording apparatus for dividing the front surface into a plurality of stripe-shaped regions to record an image, and simultaneously photographing a plurality of alignment marks formed on the recording material with a plurality of cameras to correct the recording position of the image by the plurality of recording heads As an image recording method for recording an image using
A first head calibration pattern which moves the plurality of recording heads to a position for recording the first stripe-shaped area, and then forms a first head calibration pattern for calibrating the position of the recording head with respect to the recording material by the recording head; And forming a second head calibration pattern for calibrating the position of the recording head with respect to the recording material by moving the plurality of recording heads to the position where the last stripe region is recorded. Measuring the deviation amount of the second head calibration pattern forming step and the first head calibration pattern and the second calibration pattern by photographing the adjacent ones with the camera, and the position of each head from the deviation amount. Head position error measurement process to measure the error Head calibration process to have,
After moving one of the plurality of recording heads to the formation area of each alignment mark in the recording material, a camera calibration for forming a plurality of camera calibration patterns for calibrating the position of the camera with respect to the recording material by the recording head. A camera position error measurement step of measuring a deviation amount between the camera calibration pattern and the field of view of the camera by imaging the pattern forming step and each camera calibration pattern with each camera, and measuring the positional error of the camera from the deviation amount. A camera calibration process comprising:
After performing both the head calibration process and the camera calibration process,
An image by the plurality of recording heads determined by photographing a plurality of alignment marks formed on the recording material by using a plurality of cameras using the positional error of the head obtained in the head calibration process and the positional error of the camera obtained in the camera calibration process. And correcting the recording position of the image. The method of claim 1,
The qualitative position error qualitatively generated at each head when each head moves to the position where the respective stripe-shaped regions are recorded is measured in advance, and the recording is performed using the qualitative position error. An image recording method for correcting a recording position of an image by a head. By moving the pair of long and long recording materials in the Y direction and intermittently moving the plurality of recording heads in the X direction which is directly parallel to the Y direction, the front surface of the recording material has a plurality of stripe shapes. At the same time as recording the image by dividing it into regions, recording the image by using an image recording apparatus which photographs a plurality of alignment marks formed on the recording material with a plurality of cameras and corrects the recording position of the image by the plurality of recording heads. As an image recording method
A head qualitative error measuring step of measuring qualitative position errors generated qualitatively in each head when each head is moved to a position for recording each stripe region;
A first head calibration for moving the plurality of recording heads to a position for recording the first stripe-shaped area, and then forming, by the recording head, a first head calibration pattern for calibrating the position of the recording head with respect to the recording material; Pattern forming process,
A second head calibration for moving the plurality of recording heads to a position for recording the last stripe-shaped area, and then forming a second head calibration pattern for calibrating the position of the recording head with respect to the recording material by the recording head; Pattern forming process,
A camera for moving one of the plurality of recording heads to the formation region of each alignment mark in the recording material, and then forming a plurality of camera calibration patterns for calibrating the position of the camera with respect to the recording material by the recording head. Calibration pattern forming process,
A head for measuring the amount of misalignment and measuring the positional error of each head from the misaligned amount by imaging with the camera an image of the first head calibration pattern and the second head calibration pattern adjacent to each other. Position error measurement process,
A camera position error measuring step of measuring an amount of deviation between the camera calibration pattern and a field of view of the camera by imaging each camera calibration pattern with each camera, and measuring a position error of the camera from the amount of the deviation;
The qualitative positional error of each head obtained in the head qualitative error measuring step, the positional error of each head obtained in the head positional error measuring step, and the positional error of the camera obtained in the camera positional error measuring step are used for recording data. And a recording position of an image by the plurality of recording heads determined by photographing the formed plurality of alignment marks with a plurality of cameras. An image is recorded at the same time as the pair of long and long recording materials are reciprocated in the Y direction, and the plurality of recording heads are integrally moved in the X direction perpendicular to the Y direction to simultaneously record images. An image recording method of recording an image using an image recording apparatus which photographs a plurality of alignment marks with a plurality of cameras and corrects a recording position of an image by the plurality of recording heads,
A calibration pattern forming step of forming a head calibration pattern for calibrating the position of the recording head and a camera calibration pattern for calibrating the position of the camera with respect to the recording material by the plurality of recording heads;
And measuring a position error of each head and a position error of said camera by imaging said head calibration pattern and said camera calibration pattern with a camera,
And a recording position of an image by the plurality of recording heads determined by photographing a plurality of alignment marks formed on the recording material using a plurality of cameras using the position error obtained in the measuring step.

Images