MX6000

Module:
Module:
Graphics
Graphics

1
 Graphics Module
Lesson Objectives:
Given: A student workbook, a Service Information CD, a MX6000
Graphics Module assembly, a MX6000 System, and a toolkit

Objective: Upon completion of this lesson, the student will be able to:
-- identify the module sensors and motors
-- identify other major mechanical components utilized
-- describe the function of the sensors, motors, and major
mechanical components
-- remove and replace designated components
-- test sensors and motors using appropriate diagnostic routines
-- perform specified module adjustments

Criteria: Production of a specified service test card after satisfying the

objectives listed above 2
Activity: Graphics Module (Major Functions)

The architecture of the Graphics Module

supports the following (3) functions….

Graphics
Module
Functions

Transport Raise & Lower Advance

the card the the ribbon
print head

The immediate following slides introduce these functions, identifying the

major components that carry out these tasks and defining their purpose3
Activity: -- Identify Major Components
Transport
the Card

Motors • transport servomotor The graphics module operates in two modes:

• card entry sensor print mode or pass-through mode. In pass-
Sensors • card exit sensor through mode, cards entering are transported
• stepper drive belt directly to the card exit sensor. In print mode
• card entry rollers/shafts the print roller along with five roller pairs are
drive gear/coupling gear used to transport cards through the graphics
• card exit rollers/shafts
Other module. The 1st intermediate roller pairs
drive gear/coupling gear
Major • intermediate rollers (6) consist of both upper and roller sets.
Components --shafts (4)
--drive gears (3) card 2nd print 1st card
exit intermediate roller intermediate entry
--coupling gears (3)
• spring-loaded bearings (4) rollers rollers rollers rollers
• print roller/shaft/drive gear
• idler gears (2)
• idler pulleys (3) s 2 s
• upper card guides (2)
• lower card guide
2 card

4
 Transport

Activity: -- Identify Major Components the Card

card transport assembly A The components that perform the task of transporting
the card through the module are contained on a common
assembly (card transport assembly). This assembly is
secured to the print head drive assembly with (4) screws
[see yellow arrows]. The print roller drive gear must first
be removed from the end of the print roller shaft in order
to remove the transport assembly.

print roller shaft

Locate components
---card transport assembly
---assembly mounting hardware
5
<overhead view> ---print roller shaft
 Transport

Activity: -- Identify Major Components the Card

Guide the Card

B The module lower card guide is one
continuous piece of metal that is
secured to the transport assembly base.
A section of the front card guide lip is
cutout in the print station area to
accommodate the thermal printhead
assembly as it is driven forward onto
the card for printing.

lower card guide Locate components

cutout
---lower card guide
6
---card guide cutout
 Transport
the Card
Activity: -- Identify Major Components
exit upper card guide cutout for card
entry sensor

cutout for card entrance upper card guide

exit sensor

C Guide the Card

Tops of cards are guided
through the module using a
pair of upper card guides.
transport The longer entrance upper
assembly guide has a cutout in it to
accommodate the mounting
of the card entry sensor.

Locate components
---exit upper card guide
---entrance upper card
7
guide
 Transport

Activity: -- Identify Major Components the Card

Locate components
spring
---entrance upper card
guide support
---exit upper card guide
exit upper card assembly
guide assembly ---door spring

Guide the Card

The upper card guides are attached to the upper card guide supports.
The entrance support is a 2-piece assembly with the vertical member
D securing to the module base with a pair of screws (see red arrows).
The horizontal member, to which the card guide attaches, secures to
the vertical member also with a pair of screws (red arrows). The
support at the exit incorporates a hinged door with an attached spring.
This allows for the easy removal of cards from the end of the module.
Two screws secure this assembly to the transport assembly base.
8
entrance support (yellow arrows)
 Transport
the Card
Activity: -- Identify Major Components
Card drive for the module is carried
Transport the Card E out strictly using a roller-drive
design. Together with the normal
spring-loaded entrance and exit roller pairs, upper
print roller bearings
card card entry and lower roller pairs prior to the
exit rollers print roller and a roller pair
rollers immediately following the print
roller help to transport the card
through the module. In each case,
all front rollers of the pairs
incorporate spring-loaded bearings
to allow the module to support a
wide range of card thicknesses.

Locate components

---card entry rollers

---1st inter-stage rollers
spring-loaded 1st inter-stage ---print roller
bearings 2nd inter-stage rollers
rollers ---2nd inter-stage rollers
(upper & lower)
---card exit rollers 9
---spring-loaded bearings (6)
 Transport

Activity: -- Identify Major Components the Card

Transport the Card

F
Drive for the print roller is
supplied by the transport
transport servo motor. The output gear
servo
of the servo meshes with a
motor
very large gear attached to the
end of the print roller shaft. This
large gear provides the fine
stepping of the card past the
head to allow the printing of
columns on the card at the
correct resolution.

print roller shaft

print roller Locate components
drive gear
---transport servo motor
---print roller drive10
gear
---print roller shaft
 Transport

Activity: -- Identify Major Components the Card

Transport the Card

G
coupling gears A serpentine timing belt on
the underside of the transport
assembly base distributes
drive power to the rest of the
roller pairs via the print roller
drive pulley secured to the
print roller shaft. Also aiding
the distribution are a pair of
idler idler pulleys and a pair of idler
print
gear gears.
roller
print
drive Locate components
roller
idler pulley timing belt
shaft
pulley ---timing belt
servo motor ---print roller shaft
output ---print roller drive pulley
---idler pulleys (2)
---idler gear
---transport roller
11
coupling gears (8)
 Transport

Activity: -- Identify Major Components the Card

manual card H
advance knob
Because all of the roller pairs
are in affect driven by the
print roller drive pulley (via
the serpentine belt), a knob
placed on the top end of the
print roller shaft serves as a
means of manually advancing
cards through the module.

Locate components
print roller print roller shaft
drive pulley ---manual card-advance
knob
12
 Transport

Activity: -- Identify Major Components the Card

Locate components I Monitor the Card

---card entry sensor Card traffic through the module is
---card exit sensor monitored by a pair of pass -
through sensors; one at the entrance
card exit (card entry sensor) and one at the
sensor exit (card exit sensor). Each of these
sensors is affixed to an upper card
guide, secured with two mounting
screws. The entry sensor checks for
card jam conditions and for lost card
conditions from the previous module.
It also is used to control the left-hand
card entry print margin on the card, with the
sensor trailing edge of the card serving as the
trigger. The exit sensor checks for jam
conditions, lost card conditions within
the module, and is used for “hand-
shaking” to coordinate card transfers
to the downstream module. 13
 Raise & Lower
Activity: -- Identify Major Components the
Print Head

Motors • leadscrew stepper As the card passes through the print station
Sensors • TPH position sensor (being advanced by the print roller), the thermal
print head assembly is brought forward against
• print head drive assembly the card to begin printing columns. The print
• TPH carriage head assembly is attached to and guided by a pair
• carriage guide shafts of guide shafts that can be drawn inward or
• guide shaft block/linear
driven outward utilizing the action of a leadscrew.
bearings (4)
• guide shaft springs
Other
• leadscrew
Major • leadscrew fixed plate card
Components • leadscrew driven plate B
thermal
• TPH position flag print print roller
• leadscrew drive belt head
• leadscrew drive pulley
• TPH assembly
• TPH carriage guide A
• TPH fan shafts
14
 Raise & Lower
the
Activity: -- Identify Major Components Print Head

print head drive assembly A The components that perform the task of
moving the print head inward and outward
are contained on a common assembly (print
head drive assembly).
This assembly is secured to the module
base-plate using (4) mounting screws.

2 (each side)

Locate components

---print head drive

assembly
---assembly mounting 15
hardware
 Raise & Lower
the
Activity: -- Identify Major Components Print Head

print head drive assembly The thermal print head assembly

TPH assembly B is secured to a carriage that is
positioned immediately beneath
it. The carriage in turn is attached
to a pair of guide shafts that get
driven inward or outward to
directly control the movement of
carriage guide shafts the print head. The guide shafts
pass through the guide shaft block
assembly (yellow dashed lines)
with their movement aided by (4)
internal linear bearings.

Locate components

TPH carriage ---thermal print head (TPH)

guide shaft block ---TPH carriage
16
---carriage guide shafts
---guide shaft block
 Raise & Lower
the
Activity: -- Identify Major Components Print Head

leadscrew The leadscrew is mounted to the

guide shafts (2) fixed plate C driven plate with (3) shoulder
screws, but the leadscrew threads
are threaded through the fixed
plate. The guide shafts themselves
pass through openings in the driven
plate and are then each terminated
leadscrew leadscrew stepper
with a large captive spring.

The yellow arrows indicate the

direction of pressure that is exerted
by the compressed springs onto the
guide shafts.

Locate components
---leadscrew
---leadscrew fixed plate
guide shaft leadscrew ---leadscrew driven plate
springs (2) driven plate ---leadscrew stepper
17
---guide shaft springs
 Raise & Lower
the
Activity: -- Identify Major Components Print Head

D
leadscrew stepper Drive for the leadscrew is
provided by the leadscrew
stepper motor. The stepper
leadscrew drive pulley output gear couples drive to
leadscrew the leadscrew drive pulley
via a drive belt.

As the drive pulley is exercised,

the leadscrew driven plate and
the guide shafts will move
inward or outward accordingly.

drive belt
Locate components
---leadscrew stepper
---drive belt
driven plate guide shaft (2) ---leadscrew drive18pulley
 Raise & Lower
the
Activity: -- Identify Major Components Print Head

fixed plate
A flag (TPH position flag) has been
E incorporated on the leadscrew driven
plate. Together with the ribbon load
position sensor which mounts to the
leadscrew fixed plate, these two
components work together to retract
driven plate
the print head a significant distance to
make it easier for the operator to load
print ribbon supplies.

TPH position flag

ribbon load Locate components

position
sensor ---TPH position sensor
---TPH position flag
---driven plate 19
 Raise & Lower
the
Activity: -- Identify Major Components Print Head

An additional sensor located atop a bracket at the rear of

F the mechanical assembly, also uses the TPH position flag
for locating the print head to a “home” position. Then
during the printing process this flag and sensor are used
for determining the amount of pressure that the
print head applies to the card.

bracket

TPH
Locate components position
flag
---TPH home sensor
---sensor bracket TPH
---TPH position flag home 20
sensor
 Raise & Lower
the
Activity: -- Identify Major Components Print Head

6,7 G
summary of step sequence:
1) stepper energized
2) leadscrew moves to rear
3) driven plate moves to rear
4) guide shafts move to rear
5) carriage moves to rear
6) print head moves to rear
4 7) print head contacts card
9 8) stepper continues to advance
5 print head a distance
2 determined by firmware
9) springs compressed by driven
plate
9 10) compressed springs cause
4 print head to exert pressure
3 on card (during printing)
21
 Raise & Lower
Activity: -- Identify Major Components the
Print Head

H The thermal print head assembly is

thermal print head
mounted onto the head holder utilizing
a (head mount) shaft that slides through
a pair of holes on the head assembly and
on the head holder. The head retention
clip then slides down the rear of the head
heatsink (wide fin channel) and interfaces
retention clip with a cutout in the head mount shaft.
The head holder is also used as part of t
he head skew adjustment process. This
design allows the head to pivot at its
center to help promote head contact with
the surface of the card to be printed.

skew adjustment Locate components

assembly / head holder head
mount
shaft ---thermal print head
---skew adjustment assembly
---head mount shaft22
---head retention clip
 Raise & Lower
the
Activity: -- Identify Major Components Print Head

The head holder (and thermal print

I head) then mounts onto the footprint
print assembly adjustment bracket via two screws
carriage which allows horizontal positioning
mounting of the head with respect to the print
screws roller, which absorbs the head load
during the printing process.
carriage This assembly then mounts onto the
mount
print head assembly carriage
screws
head utilizing another screw pair. The
holder Carriage then in turn is secured to the
drive system by the pair of drive shaft
screws.

Locate components
---head holder
---footprint adjustment
footprint assembly
drive adjustment ---print assembly carriage
shaft assembly ---carriage mount screws
23 (2)
screws ---carriage drive shaft screws
 Raise & Lower
Activity: -- Identify Major Components the
Print Head

TPH J To help with temperature control of the

actuator thermal print head, a fan assembly is
assembly mounted onto the print assembly carriage.
An airflow guide mounted to the carriage
immediately behind the fan redirects
the airflow upward across the TPH
heatsink to aid in cooling.

print assembly carriage

airflow
guide

Locate components
---print assembly carriage
cooling fan ---cooling fan 24
---airflow guide
Activity: -- Identify Major Components
Advance
the ribbon

•takeup stepper motor

Motors •supply stepper motor The function of advancing print ribbon during
•inner limit supply sensor
the printing process is executed by two major
•outer limit supply sensor assemblies: the ribbon supply assembly and the
Sensors •splice detection sensor ribbon take-up assembly. The tape take-up
•supply assembly stepper motor takes up the slack ribbon that is
•take-up assembly produced by the card moving past the print
•supply spindle/shaft/gear
•takeup spindle/shaft/gear
head with the ribbon pinched against the card
•takeup spindle clutch (pulling ribbon off of the supply spindle).
•supply dancer arm
•dancer arm spring/rod card
•manual tape advance knob
•supply pivot block TPH
Other
•supply pivot cylinder
Major
•print head holder
Components •ribbon guides (2)
•capstan roller/pivot block motor
•capstan pressure spring
•capstan drive belt
•capstan drive pulleys/gear
take-up supply 25
• RFID board /cover
 Advance

Activity: -- Identify Major Components the ribbon

The graphics module “advance the ribbon”

A function is executed by (2) major assemblies:
the ribbon supply assembly, and the ribbon
takeup assembly. Each of these assemblies
is secured to the module base using (4)
screws (yellow arrows).

two each side

Locate components
two each side
---ribbon supply assembly
---ribbon takeup assembly 26
take-up assembly ---mounting hardware supply assembly
 Advance

Activity: -- Identify Major Components the ribbon

The supply assembly contains a stepper motor for supplying print

supply assembly B ribbon, prior to the printing process beginning. As the ribbon is
advanced off of the supply spindle, slack is avoided since the
spindle spring-loaded dancer arm takes up the slack by moving outward
to the right. The stepper output gear meshes directly with the
dancer large supply spindle gear on the assembly underside.
arm

Locate
Components

---supply spindle
---supply spindle
gear
supply
stepper stepper ---supply stepper
motor output gear motor
---dancer arm
27
supply spindle gear
 Advance

Activity: -- Identify Major Components the ribbon

supply assembly The spring-loaded design of the dancer arm is accomplished

C by the components shown below. A rod that is secured to a
pivot block passes through the pivot cylinder, with a
compressed spring captivated in between. It is this spring
action that pushes on the cylinder (and therefore the dancer
arm), that causes the dancer arm to move outward. As the
dancer arm moves outward, the pivot cylinder and pivot
dancer arm
block will be forced to rotate by the changing angle of the
spring rod.

spring rod pivot cylinder

Locate components

---dancer arm
---dancer arm spring & rod captive spring
---pivot cylinder 28
---pivot block pivot block
 Advance

Activity: -- Identify Major Components the ribbon

D
A pair of sensors mounted to the
supply station base work with a
outer limit flag incorporated on the dancer
sensor arm to control the operation of
the supply function. Before the
printing process, the supply motor
is turned on to load the dancer arm
with enough ribbon to print the
next card. The motor is turned off
when the outer limit sensor is
dancer flag
covered by the flag.

Locate components
---dancer flag
inner limit ---inner limit29sensor
sensor ---outer limit sensor
 Advance

Activity: -- Identify Major Components the ribbon

During the printing process, the supply

E motor will be off and the take-up motor
will be on. The outer limit sensor is
expected to go uncovered as the printing
outer limit begins and if it doesn’t, a “ribbon break”
sensor condition is suspected generating an
error. During a normal print and strip
operation, the dancer arm will
approach but not cover the inner
limit sensor. Preparation for the next
card will again energize the supply
motor causing the arm to move to
dancer flag the right, so with normal operation,
the inner sensor never gets covered.
If by chance the sensor does get covered,
it will turn on the supply motor to
provide more ribbon.

Locate components
---dancer flag
inner limit ---inner limit30sensor
sensor ---outer limit sensor
 Advance

Activity: -- Identify Major Components the ribbon

Prior to Printing During Printing

With the take-up motor off, the supply motor is turned on During the printing process, the take-up motor is on
providing print ribbon to the dancer arm assembly that taking up the exhausted ribbon and the supply motor
takes up the slack by swinging to the right. When the is off holding tension as the dancer arm is pulled to
dancer full sensor gets covered, the supply motor is turned the left.
off since enough ribbon to print the next card is in place.

dancer
arm

dancer full
s sensor s

off on on off

31
takeup supply takeup supply
 Advance

Activity: -- Identify Major Components the ribbon

F Mounted to the corner of the antenna board (in the vicinity of the
ribbon idler guide) is a pass-through type sensor. This sensor
monitors the ribbon supply for detection of a ribbon splice or an
“end of tape” condition. When a splice is detected, there is enough
ribbon in place to print the next card but then a fixed amount of
ribbon gets advanced to move the splice past the print head.

Locate components
---splice / “end of
32 tape”
detection sensor
 Advance
Activity: -- Identify Major Components the ribbon

The supplies ID feature is incorporated in the graphics module. Each supply core
G contains an RFID tag attached to the bottom. When installed on the spindle, the tag
resides directly above the RFID antenna board , which is mounted within a housing
for protection.
The RF tag and the tag reader board each have an RFID
(antenna)
antenna to transmit and receive data, allowing for
tag
communication between these components.
Information about the supply item is maintained
within the supply core.

I/O connection

RFID Locate components

tag reader
board ---RFID tag reader board
---RFID tag 33
---I/O connection
 Advance

Activity: -- Identify Major Components the ribbon

H Additional guiding of the ribbon

takes place on each side of the
print head assembly. On the entry
side, a guide is provided that is
supported by the upper and lower
head card card guides. On the exit side, a
holder guide guide is provided that is actually
assembly assemblies mounted as part of the head holder
assembly.
exit entry
ribbon ribbon guide
guide

Locate components

---ribbon guides (2)

---print head holder assembly
---upper card guide assembly
34
---lower card guide assembly
 Activity: -- Identify Major Components
Advance
the ribbon

I Take-up Assembly
As spent ribbon leaves the TPH ribbon guide, it
is routed directly to the take-up spindle where it
is wound on the spindle in a clockwise
direction. A plate mounted under the spindle Locate components
helps to prevent telescoping of take-up ribbon. ---take-up spindle
take-up ---anti-telescoping
spindle plate

card

TPH

anti-telescoping
plate motor

take-up supply 35
take-up assembly
 Advance

Activity: -- Identify Major Components the ribbon

J Drive for the take-up function is carried out by a stepper motor. On the Locate components
underside of the assembly, the stepper output gear meshes with the
take-up spindle drive gear. This large gear overdrives the spindle with ---take-up stepper motor
respect to actual printing speed, but the clutch on the spindle shaft allows ---spindle drive gear
for slippage to prevent ribbons breaks from over-tension. ---stepper output gear
---take-up clutch
take-up
stepper
motor

stepper
output
gear
spindle
drive gear

clutch
36
 Advance

Activity: -- Identify Major Components the ribbon

K A capstan roller, mounted to a block assembly that

capstan roller pivots about a pivot shaft, utilizes a heavy duty spring
to pull the assembly toward the spindle, applying a
pressure against the ribbon during ribbon take-up.
This capstan pressure against the take-up ribbon
ensures a tight wind of the spent ribbon.
pivot
shaft
capstan
roller block

pressure spring

Locate components
---capstan roller
---capstan roller block
---roller block pivot shaft 37
---pressure spring
 Advance

Activity: -- Identify Major Components the ribbon

manual advance knob L Drive components for the capstan roller are
shown below. Actual drive originates at the
take-up stepper motor and is transferred to the
capstan drive gear via the large spindle gear.
A timing belt is then used to couple drive
power from the capstan drive pulley over to
the driven pulley. The driven pulley is secured
to the shaft of the take-up capstan roller. The
green knurled knob at the top of the capstan
roller serves as a manual advance knob for
capstan manually advancing ribbon past the thermal
capstan drive pulley printhead.
driven
pulley

Locate components
---capstan driven pulley
drive ---capstan roller drive belt
belt ---capstan drive pulley
---capstan drive38
gear
capstan drive gear ---manual advance knob
 MX6000

Module:
Module:
Color
Color
Differences
Differences

39
 Activity: Color Module Differences
D2T2 Color Modules are identical to Graphics Modules in regards to hardware, except for a few simple changes.

During the actual printing process, the print head is advanced forward under pressure against the card, with the
print roller supplying the drive for moving the card. As the vertical columns are printed on the card, in many
instances printing will still be occurring when the leading card edge penetrates the nip of the exit inter-stage roller
pair, or the trailing card edge leaves the grip of the entrance inter-stage roller pair. In both situations, a slight
hesitation or jumping of the card will occur, resulting in an undesired feint vertical line printed on the card

To alleviate this print quality issue, the front inter-stage rollers will be retracted a distance of 0.040” during the
printing process, while the card is being advanced by the print roller.

print roller

exit entrance
inter-stage inter-stage
rollers rollers
40
Activity: Color Module Differences
How can I easily distinguish between the two?

< roller retraction

From… ….To components >

Graphics Module D2T2 Color Module

41
 Activity: Color Module Differences
drive belt
cam pulleys
Retraction
retraction
Interface
stepper
The drive for the retraction cam
interface is supplied by the shaft
retraction stepper motor. A eccentric cam
timing belt couples drive to a
pair of drive shafts. The shaft on
the card entry side contains two
cams since it interfaces with a
pair of spring-loaded upper and cam
lower roller sets, whereas the position
shaft on the card exit side only sensor
has a single cam. In each case, Retraction
these cams when rotated, actually Interface
push on three retraction push
plates that are directly tied to the
Components
shafts of the front rollers of the retraction • retraction stepper
push plate
pairs, that are spring-loaded. As • stepper drive belt
the push plates move forward, • eccentric cams (3)
the front rollers are lifted off of • cam shafts (2)
the rear drive rollers. • cam pulleys (2)
• retraction push
plates (3)
42 sensor
• cam position
 Activity: Color Module Differences
slotted Because the cam mounting hole is offset from
opening center, the dimensions X and Y shown below
are not equal. When dimension X is against
the push plate, the roller is at its normal
“forward” position. When the cam is moved
so the Y position is against the push plate,
then the front transport roller is lifted off of
the drive roller by 0.040”.

fixed eccentric cam

to shaft

A shoulder screw that passes

through the push plate, threads
into a hole provided in the vertical vertical
support. The opening provided in support
the push plate for the shoulder
screw is elongated, allowing for X Y
movement by the push-plate.

43
 Activity: Color Module Differences
The rear rollers of the
roller pairs supply the
drive for the card trans-
porting whereas the front
rollers are spring-loaded
idler rollers. Since card
slippage is not acceptable,
all rear rollers utilize a
setscrew to secure the
roller to the shaft, instead
of a dowel pin that is used
on the front roller.

The rear gears of the pairs

supply the drive for the card
transporting whereas the front
gears couple this drive power
to the front shafts /rollers. rear
Since card slippage is not
acceptable, all rear gears
utilize a roll-pin (which needs front
to be press-fit into the hole)
instead of a dowel pin to secure
the gear to the shaft, eliminating
the small amount of play
between the components. 44
 Activity: Color Module Differences
A pass-through type sensor is utilized within the design to monitor the position of the eccentric cam. A
screw is threaded through the shaft that the cam is mounted to, and this screw serves as a flagging
device for the camming operation. When the flag covers the sensor,
the cam drive motor is turned off with the cam low spot eccentric cam
interfaced with the pusher plate. This is considered the
home position. When the inter-stage rollers need to be
lifted away from the card track, the motor will be enabled
turning the cam 180 degrees. At this time the cam high
spot is interfaced with the pusher plate, causing the inter-
stage roller pairs to be separated by 0.040”, thereby
removing the load from the card being printed.

inter-stage cam flag

eccentric transport
cam rollers

flag

cam
180 swing
o 0.040” separation position 45
sensor
 Activity: Color Module Differences
The color modules incorporate a 2 nd card registration sensor that
mounts to the underside of the upper card guide plate, immediately
downstream of the color print roller. This reflective type sensor is
used to register images that are to be printed on the last two inches
of the card . Dependent on the number of images to be printed,
along with their specific location on the card, it is possible that two
sensors work to accurately place the images on the card with one card track
of them triggering on the card’s trailing edge and one triggering on
the card’s leading edge.

upper card guide

output door

2nd
card registration
sensor

print roller

46
End

47