Application of BEDOOK Sensor in Digital Printing Machine

Today, let’s dive into a topic that hits close to home for every one of us working in the digital printing machine sector: BEDOOK Sensor in Digital Printing Machine.

Based on BEDOOK’s global market analysis of digital printing machines, the industry now faces a clear challenge: core components like printheads and conveyor belts deliver excellent performance but come with high costs.

For printheads, top global brands such as Japan’s KyOCERA (KJ4B series for textile printing), EPSON (ideal for high-precision needs), RICOH (suited for industrial production), and KONICA MINOLTA (for mass production) perform exceptionally well, yet their purchase and maintenance expenses are substantial.

When it comes to conveyor belts, leading options like Switzerland’s Habasit (focused on stability and chemical resistance, widely used by industry clients), Switzerland’s Rapplon (cost-effective imported choice, represented by Hantang in China), and China’s Shanghai Yongli (short lead times) also bring significant cost pressures.

As the “critical support” for unlocking the performance of these high-cost core components, traditional sensors often fall short—they’re inaccurate in positioning, slow in response, and poor in compatibility. This not only limits machine efficiency but also risks damaging high-value printheads and conveyor belts, pushing up operational costs for businesses.

Today, we’ll break down six key sensor-related issues in digital printing machines, analyze their real-world impacts, and show how the BEDOOK Sensor in Digital Printing Machine offers targeted solutions.

1. Printhead Linear Guide Limiting Issue

(1) Problem Phenomenon

From what we’ve learned in BEDOOK’s global market analysis, the printhead is the core component of a digital printing machine—its performance directly determines printing quality, speed, and costs. Different application scenarios require different numbers of printheads: 4-8 for garment customization, 16-24 for home textile mass production, 32 for industrial use, and a staggering 336-384 for Single-pass high-speed models. Global mainstream printheads like KyOCERA KJ4B, EPSON high-precision printheads, and RICOH industrial printheads demand extremely high positioning accuracy from linear guides.

However, traditional sensors struggle with inaccurate positioning and unstable signal output, which often leads to printhead collisions or deviations. At best, this causes reduced printing precision and lower product yield; at worst, it damages expensive printheads, resulting in repair losses and downtime. What’s more, traditional sensors can hardly adapt to the guide rail structures of different digital printing machine brands—such as Italy’s MS and the U.S.’s Kornit Digital, both ranked among the top 10 global printing machine brands in 2025—forcing businesses to replace sensors frequently and increasing adaptation costs.

(2) BEDOOK’s Solution

To tackle this pain point, BEDOOK uses the BB-Q1805-P11P3 inductive proximity sensor. This model offers far higher positioning accuracy than traditional sensors, perfectly matching the operational needs of mainstream global printheads like KyOCERA KJ4B, EPSON, and RICOH. Even in high-speed scenarios with Single-pass high-speed machines, it ensures real-time and precise linear guide limiting, avoiding printhead collision risks.

Compared to competitors like Autonics PSE17-5DN2, it delivers a more stable signal output and can be compatible with the guide rail structures of global brands such as Italy’s MS and the U.S.’s Kornit Digital. This eliminates the need for frequent sensor replacements, significantly reducing adaptation and maintenance costs while minimizing the risk of printhead damage—all thanks to the BEDOOK Sensor in the Digital Printing Machine.

2. Printhead Built-in Fabric Collision Issue

(1) Problem Phenomenon

Digital printing machines are widely used in the garment, home textile, and sports equipment industries, handling multi-material fabrics like cotton, polyester, and chemical fibers. For Single-pass high-speed models, the fast fabric conveying speed drastically increases collision risks. Traditional sensors respond slowly, failing to detect fabric shifts or bulges in time—this often leads to fabric collisions with printheads. Minor collisions cause printhead clogs and disrupt printing continuity; major ones damage printheads and raise maintenance costs.

We’ve also noticed that while competitors like Keyence PR-M51N1 can meet detection needs, their high costs put significant pressure on small and medium-sized enterprises (SMEs)—a group that makes up a large portion of the industry.

(2) BEDOOK’s Solution

BEDOOK addresses this issue with the FQ21-LJ5D-P51P2 and FQ21-LJ5N-P31P2 photoelectric sensors. Both support real-time close-range detection: when fabrics shift or bulge, they immediately trigger printhead shutdown protection.

Even in high-speed conveying scenarios with Single-pass machines, they respond quickly to avoid batch printhead damage. Their detection performance is not affected by fabric material, color, or texture, perfectly matching the collision protection needs of mainstream printheads like KyOCERA and EPSON.

Compared to Keyence PR-M51N1, this solution maintains stability while cutting sensor procurement costs—making it much more suitable for SMEs’ cost-control needs. This is how the BEDOOK Sensor in the Digital Printing Machine balances performance and affordability.

3. Fabric Bulge Detection Issue

(1) Problem Phenomenon

Digital printing machines handle fabrics of varying thicknesses—think thick home textile fabrics, thin garment fabrics, and elastic sports equipment fabrics. Uneven feeding or inherent thickness variations in fabrics often cause bulges.

Traditional sensors have low sensitivity to subtle bulges (such as 0.1mm-level), leading to frequent missed detections. Bulging fabrics result in uneven printing and ink leakage, harming product appearance; if they come into contact with printheads, they can also scratch high-cost printheads.

Additionally, mainstream conveyor belts like Habasit and Rapplon operate at a stable pace, but traditional sensors cannot sync with their conveying rhythm—further worsening detection errors and increasing equipment wear risks.

(2) BEDOOK’s Solution

BEDOOK uses the FQ31-L5D-P51P2-1 and FQ31-L5N-P11P2-1 photoelectric sensors to solve this problem. These sensors have high sensitivity to subtle changes in fabric thickness, accurately detecting 0.1mm-level bulges to avoid missed detections and printhead scratches. Their detection rhythm can sync with the conveying pace of mainstream conveyor belts like Habasit (strong chemical resistance) and Rapplon (cost-effective), dynamically adapting to the detection needs of fabrics of different thicknesses.

Compared to Omron ESZ-T61, they offer better adaptability—no separate debugging is needed for different digital printing machine brands, such as China’s Honghua Digital and Japan’s MIMAKI. This reduces businesses’ adaptation difficulty and costs, highlighting the versatility of the BEDOOK Sensor in Digital Printing Machines.

4. Ink Cartridge Level Detection Issue

(1) Problem Phenomenon

As the core component for ink storage, ink cartridges rely heavily on accurate level detection. Traditional sensors have two major flaws: contact detection easily contaminates ink, causing consumable waste; non-contact detection has poor compatibility with ink cartridge materials from different countries/regions (such as eco-friendly plastics in Europe and the U.S., and conventional resins in Asia), leading to unstable level detection.

When ink runs low, no timely alert is triggered, resulting in printing interruptions and finished product scrapping— a significant loss for businesses engaged in large-scale production.

(2) BEDOOK’s Solution

BEDOOK adopts the CN-Q2010N-P21P2 capacitive proximity sensor to address this pain point. With a non-contact design, it detects ink levels without touching the ink, fundamentally avoiding ink contamination and waste—aligning with global digital printing machines’ ink usage needs.

It also boasts strong compatibility, adapting to ink cartridges made of different materials (eco-friendly plastics, conventional resins, etc.). No matter which type of ink cartridge a business uses, it ensures a stable level of detection and triggers timely alerts when ink is low, preventing scrapping due to ink interruptions.

Compared to Pepperl+Fuchs CBN15-F64-E2, it’s easier to install—no complex debugging is required to adapt to the ink cartridge structures of global brands like the U.S.’s HP and Italy’s Durst. This lowers debugging costs and time for multinational enterprises, proving why the BEDOOK Sensor in Digital Printing Machine is a reliable choice for global users.

5. Roller Position and Fabric Roll Diameter Detection Issue

(1) Problem Phenomenon

Digital printing machine rollers need to adapt to fabrics of different widths and materials—such as narrow fabrics for garments (1-1.5 meters wide), wide fabrics for home textiles (2-3 meters wide), and extra-wide fabrics for advertising. The positional accuracy of rollers and the accuracy of fabric roll diameter calculations directly affect feeding stability.

Traditional sensors have large errors in roller position detection and cannot accurately calculate dynamically changing fabric roll diameters, often leading to uneven feeding tension and printing misalignment. Minor issues require rework, increasing labor costs; major ones cause fabric scrapping, raising raw material losses.

Particularly for Single-pass high-speed models, fabric roll diameters change dynamically at a fast pace, and traditional sensors respond too slowly to meet real-time detection needs—seriously limiting the performance of high-end machines from brands like Italy’s MS and the U.S.’s Kornit Digital.

(2) BEDOOK’s Solution

BEDOOK selects the UM18-T10V2-C31S12-X ultrasonic diffuse reflection sensor to meet this challenge. This solution offers dual detection functions: it accurately positions rollers and calculates fabric roll diameters in real time, adapting to fabrics of different specifications (narrow, wide, extra-wide).

For Single-pass models, it responds quickly, ensuring feeding rhythm syncs with printing rhythm without affecting high-speed production efficiency. Additionally, it has strong anti-interference capabilities, maintaining stable operation in different global production environments (high temperature, high humidity, etc.).

Compared to Pepperl+Fuchs UB1000-18GM75-U-V15, it has better environmental adaptability, reducing detection errors and equipment failure rates caused by environmental factors. This is another example of how the BEDOOK Sensor in the Digital Printing Machine addresses industry-specific challenges.

6. Printhead Linear Guide (Small Slot Type) Limiting Issue

(1) Problem Phenomenon

Small digital printing machines (such as 4-8-head models for garment customization) mostly use cost-sensitive printheads like EPSON encrypted heads and RICOH G4. These machines have compact structures, requiring small slot-type sensors to adapt to guide rail limiting.

However, traditional small slot-type sensors (like Omron EE-SX series) are too large to fit the narrow guide rail space of small machines—this makes installation difficult and limits positioning accuracy, easily causing printhead collisions and damage.

Moreover, traditional sensors can hardly adapt to the guide rail structures of small machines from domestic brands like China’s FEDAR and Xiamen Hanyin, forcing businesses to invest in customized modifications and increasing adaptation costs.

(2) BEDOOK’s Solution

BEDOOK launches the FG15N series small slot-type photoelectric sensors for small machine needs. With a compact structure, this series perfectly fits the narrow guide rail space of 4-8-head models for garment customization, solving the size issue of traditional sensors.

It also offers high limiting accuracy, precisely controlling the movement trajectory of cost-sensitive printheads like EPSON encrypted heads and RICOH G4 to avoid printhead collisions with guide rails.

Additionally, the FG15N series has strong compatibility—it can adapt to the guide rail structures of small digital printing machines from global brands like China’s FEDAR, Xiamen Hanyin, and Japan’s MIMAKI, eliminating the need for customized modifications. With high cost-effectiveness, it meets the cost-control needs of small printing enterprises. This tailored solution further demonstrates the practical value of the BEDOOK Sensor in the Digital Printing Machine.

Conclusion

To wrap up, based on BEDOOK’s global market analysis of digital printing machines, the industry’s core pain point lies in the “poor adaptability between high-cost core components (printheads, conveyor belts) and traditional sensors.”

This manifests in six key issues: inaccurate printhead guide limiting, ineffective fabric collision/bulge detection, unstable ink cartridge level monitoring, deviations in roller and roll diameter detection, and poor adaptation of small slot-type guides. All these issues easily reduce equipment efficiency, damage high-value components, and increase costs.

Against this backdrop, the BEDOOK Sensor in Digital Printing Machine stands out: through specialized sensors like the BB-Q1805-P11P3, FQ21-LJ5 series, FQ31-L5 series, CN-Q2010N-P21P2, UM18-T10V2-C31S12-X, and FG15N series, we address these pain points from four dimensions—accuracy improvement, response acceleration, compatibility optimization, and cost control. These sensors not only adapt to global mainstream core components (KyOCERA, EPSON, Habasit) but also work with different machine brands (Italy’s MS, the U.S.’s Kornit Digital, China’s Honghua Digital).

By effectively solving the flaws of traditional sensors, BEDOOK Sensor in Digital Printing Machine provides reliable support for digital printing machine enterprises to reduce operational costs and improve production efficiency—truly a game-changer for our industry.