This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2005-243182, filed Aug. 24, 2005, the entire contents of which are incorporated herein by reference.
1. Field of the Invention
The present invention relates to a belt driving mechanism, and in particular, to a belt driving mechanism for a flat belt conveyor system incorporated into an apparatus such as an electro-photographic apparatus, a printer, a printing machine, a bill inspection machine, or a mail sorter.
2. Description of the Related Art
The belt conveyor system is known as a technique for conveying various objects such as sheets, for example, print paper, bills, and tickets using a sheet-like belt having no concavities or convexities. In the field of copiers, a printing method is adopted which transfers a toner image drawn on a transfer belt, from the transfer belt to paper. In this field, the flat belt conveyor system is also used as a mechanism that conveys the transfer belt. The flat belt conveyor system is composed of a plurality of rollers including driving rollers driven by a motor or the like and a flat belt wrapped around the rollers. Rotating at least one of the driving rollers allows the flat belt to be conveyed to drive the entire mechanism.
A problem with the flat belt conveyor system is that the belt may be displaced laterally with respect to a belt driving direction. For example, in the formation of a color image, the lateral displacement can not register various colors when images of the colors are superimposed on one another. It is important for the flat belt conveyor system to accurately control the position of the belt.
A factor causing the lateral displacement of the belt is the tilt of the rollers. When the belt is conveyed with the axes of a driving roller and a driven roller not parallel to each other, the rotating direction of the rollers may be tilted from an intended belt advancing direction. A lateral force thus acts on the belt, which is consequently displaced laterally. Even an inclination equivalent to a design error may laterally shift the belt. A mechanism is thus required which avoids displacing the belt or corrects the belt position.
The following methods have been proposed to prevent the belt from being laterally displaced: providing ribs such that the opposite edges of the belt are caught on the rollers, forming the opposite ends of the rollers into flanges, or shaping the belt like the letter T or the like, that is, so that it has concaves and convexes and driving the belt using rollers having concaves and convexes that are fitted together.
The flat belt can also be run stably by using a crown roller the middle of which is slightly swollen like a drum. To prevent the flat belt from being laterally displaced without using the crown-face roller, a tension roller or the like may be placed and forcibly tilted in response to the lateral displacement of the belt.
Another method for preventing lateral displacement is to fix the running position of the belt using a pole or a guide. This method causes the belt to be always rubbed during driving, thus disadvantageously shortening the life of the belt or apparatus.
Jpn. Pat. Appln. KOKAI Publication No. 7-157129 proposes a method of correcting the belt position using a brake. This proposal uses the brake to exert a braking force on a part of the belt to vary the tension on the belt surface, thus suppressing the lateral displacement.
The above belt driving mechanism is incorporated into an image forming apparatus disclosed in Jpn. Pat. Appln. KOKAI Publication No. 2004-45700, a bill inspection machine disclosed in Jpn. Pat. Appln. KOKAI Publication No. 2005-96896, a mail sorter disclosed in Jpn. Pat. Appln. KOKAI Publication No. 2004-338854, and the like. The belt driving mechanism is an important component of these apparatuses.
As described above, the belt can be prevented from being laterally displaced by the method of providing ribs such that the opposite edges of the belt are caught on the rollers, forming the opposite ends of the rollers into flanges, or shaping the belt so that it has concaves and convexes, for example, like the letter T and driving the belt using rollers having concaves and convexes that are fitted together. However, these methods forcibly suppress the force displacing the belt laterally to exert an unnatural force on the belt to disadvantageously shorten the life of the belt. Further, if the concaves and convexes of the belt increase its thickness, a stronger force is required to bend the belt. A heavy burden is thus imposed on the conveyor system to also disadvantageously shorten the life of the apparatus. Thus, it is desirable to use a flat belt with a minimum number of concaves and convexes.
With the method of using the crown-face roller, the belt is slightly bent along the middle of the roller during conveyance. Thus, disadvantageously, the crown roller cannot be used in, for example, an apparatus such as a intermediate transfer belt in an image forming apparatus in which bending of the belt may distort the image.
The method of forcibly tilting the tension roller or the like increases the number of parts required and thus the size of the conveyor system. This is disadvantageous in terms of cost and space.
The method proposed by Jpn. Pat. Appln. KOKAI Publication No. 7-157129 uses the brake to exert a braking force on a part of the belt to vary the tension on the belt surface. The lifetime of the belt is shortened because the belt is always rubbed during driving by the method.
The above problematic belt driving mechanism is applied to the image forming apparatus disclosed in Jpn. Pat. Appln. KOKAI Publication No. 2004-45700, the bill inspection machine disclosed in Jpn. Pat. Appln. KOKAI Publication No. 2005-96896, the mail sorter disclosed in Jpn. Pat. Appln. KOKAI Publication No. 2004-338854, and the like. However, the belt driving mechanism has posed various problems in the above apparatuses; processing accuracy may lower as a result of the lateral displacement of the belt and the lifetime of the apparatus may be shortened.
An object of the present invention is to provide a mechanism of correcting a lateral displacement of a belt that may occur in flat belt conveyor system, using a simple method imposing a reduced burden on the mechanism.
According to an aspect of the present invention, there is provided a belt driving mechanism comprising:
a driving roller having first and second opposite ends, a first roller axis passing through the first and second opposite ends and a first middle point between the first and second opposite ends, the driving roller being rotated;
a driven roller having third and fourth opposite ends and a second roller axis passing through the third and fourth opposite ends and a second middle point between the third and fourth opposite ends, the second roller axis being placed at a certain angle of torsion to a plane containing the first and second opposite ends and the second middle point;
an endless belt wrapped around the driving roller and driven roller to run between the driving roller and the driven roller, the driven roller being rotated by the endless belt in accordance with the rotation of the driving roller;
a brake configured to apply a braking force to the driven roller to restrict the rotation of the driven roller while keeping the driving roller rotating to run the endless belt, so that the endless belt is slipped on the driven roller; and
a control unit configured to control the brake.
According to another aspect of the present invention, there is provided a method of controlling a position of an endless belt in a belt driving mechanism comprising:
a driving roller having first and second opposite ends, a first roller axis passing through the first and second opposite ends and a first middle point between the first and second opposite ends, the driving roller being rotated;
a driven roller having third and fourth opposite ends and a second roller axis passing through the third and fourth opposite ends and a second middle point between the third and fourth opposite ends, the second roller axis being placed at a certain angle of torsion to a plane containing the first and second opposite ends and the second middle point; and
an endless belt wrapped around the driving roller and driven roller to run between the driving roller and the driven roller, the driven roller being rotated by the endless belt in accordance with the rotation of the driving roller;
the method comprising:
applying a braking force to the driven roller and adjusting the braking force to restrict the rotation of the driven roller while keeping the driving roller rotating to run the endless belt, so that the endless belt is slipped on the driven roller.
There will be described a belt driving mechanism in accordance with an embodiment of the present invention with referring to the accompany drawings.
As an example of an apparatus which is provided with the belt driving mechanism in accordance with the embodiment of the present invention, description will be given of an image forming apparatus such as the one shown in Jpn. Pat. Appln. KOKAI Publication No. 2004-45700. Description will also be given of the formation of a toner image, which is a job performed by the image forming apparatus.
In the image forming apparatus shown in
A developing device 7a is disposed at a position where, as a result of rotation of the photosensitive drum 1a, it lies opposite the area of the photosensitive drum 1a on which the electrostatic latent image has been formed by the exposure device 5a and then uses a certain housed developer to develop the electrostatic latent image into a toner image. A belt 13 is disposed at a position where, as a result of rotation of the photosensitive drum 1a, it contacts the area of the photosensitive drum 1a in which the electrostatic latent image has been developed into the toner image by the developing device 7a; paper P is conveyed on the belt 13. The conveyor belt 3 is rotated by a driven roller 2 and a driving roller 1 to convey the paper P from upstream to downstream. Here, the upstream and downstream sides are defined on the basis of the direction in which the conveyor belt 3 conveys the paper P.
The conveyor belt 3 attracts the paper P charged by an attracting device 19 with an electrostatic force. The driving roller 1 and driven roller 2, which are in contact with the conveyor belt 3, are electrically grounded to maintain a stable electrostatic force between the conveyor belt 3 and the paper P. Rotating the driving roller 1 in the direction of arrow i concurrently rotates the driven roller 2 in the direction of arrow j. The conveyor belt 3 is rotated at a velocity equal to the peripheral velocity of the photosensitive drum 1.
A transfer device 9a is disposed opposite a surface of the conveyor belt 3 which is located opposite the surface lying opposite the photosensitive drum 1a and paper P; the transfer device 9a transfers the toner image from the photosensitive drum 1a to the paper P. A positive voltage is applied to the transfer device 9a to attract and transfer the toner image formed on the photosensitive drum 1a to the paper P by an electrostatic force.
A static eliminating device 11a is disposed at a position where, as a result of rotation of the photosensitive drum 1a, it lies opposite the area of the photosensitive drum 1a on which the toner image transferred to the paper P was formed, to uniformly eliminate static electricity from the surface of the photosensitive drum 1a. The static eliminating device 11a is composed of a light emitting element consisting of a LED or the like and uniformly irradiating the photosensitive drum 1a with light beams. A first process unit 100a is composed of the photosensitive drum 1a, the charging device 3a, the exposure device 5a, the developing device 7a, the transfer device 9a, and the static eliminating device 11a.
A second process unit 100b is configured similarly to the first process unit. The second process unit 100b is disposed at a position where it further transfers a toner image to the paper P to which the above toner image has already been transferred by the first process unit 100a and which is conveyed on the conveyor belt 3. A third process unit 100c is disposed at a position where it further transfers a toner image to the paper P to which the above toner image has already been transferred by the second process unit 100b and which is conveyed on the conveyor belt 3. A fourth process unit 100d is disposed at a position where it further transfers a toner image to the paper P to which the above toner image has already been transferred by the third process unit 100c and which is conveyed on the conveyor belt 3. Reference numeral 3 denotes a paper stocker that supplies paper to the conveyor belt 3.
The second, third, and fourth process units 100b, 100c, and 100d are configured similarly to the first process unit 100a. Accordingly, the parts or components constituting the process units 100b, 100c, and 100d are denoted by the same reference numerals as those for the first process unit 100a, that is, 1, 3, 5, 7, 9, 11, etc. Additional symbols “b”, “c”, and “d” corresponding to the process units are added to these reference numerals. These parts or components will thus not be described.
The developing device 7a in the first process unit 100a accommodates a yellow developer. A developing device 7b in the second process unit 100b accommodates a magenta developer. A developing device 7c in the third process unit 100c accommodates a cyan developer. A developing device 7d in the fourth process unit 100d accommodates a black developer.
A fixing device 23 is provided at a position to which the paper P on which the toner image has been formed by the four process units 100a, 100b, 100c, and 100d is conveyed on the conveyor belt 3; the fixing device 23 fixes the toner image to the paper P. Now, operations of the image forming apparatus 1 will be described with reference to
In the first process unit 100a, the photosensitive drum 1a starts rotating in the direction of arrow k. The charging device 3a then uniformly charges the surface of the photosensitive drum 1a (S1). The photosensitive drum 1a rotates, and the charged area of its surface lies opposite the exposure device 5a. The exposure device 5a then exposes the surface of the photosensitive drum 1a to form an electrostatic latent image on the basis of yellow image data generated by the image processing device 104 (S2). The photosensitive drum 1a rotates, and the area of its surface on which the electrostatic latent image has been drawn lies opposite the developing device 7a. The developing device 7a then uses yellow toner sufficiently negatively charged in itself to develop the electrostatic lateral image drawn on the surface of the photosensitive drum 1a into a toner image (S3). The transfer device 9a is subsequently operated at a predetermined time to transfer the toner image formed on the surface of the photosensitive drum 1a to the paper P passing between the transfer device 9a and the photosensitive drum 1a (S4). The static eliminating device 11a eliminates static electricity from the surface of the photosensitive drum 1a on which toner remains rather than being transferred to the paper P (S5).
In the above image forming apparatus, the paper P is conveyed by conveyor system 10 including the conveyor belt 3, driven roller 2, and driving roller 1. The toner image is transferred to the paper P during the conveyance. The role of the belt driving mechanism constituting the conveyor system 10 is important for such a conveying and transferring job. With reference to
It should be noted that, in the description below, the job is not limited to a conveying and transferring job utilizing the belt driving mechanism in the above image forming apparatus but also means a job of conveying media utilizing a belt driving mechanism in another apparatus, for example, the bill inspection machine disclosed in Jpn. Pat. Appln. KOKAI Publication No. 2005-96896 or the mail sorter disclosed in Jpn. Pat. Appln. KOKAI Publication No. 2004-338854.
The conveyor system 10 is composed of the driving roller 1, which is rotated by exerting a driving force on it, the driven roller 2, to which a rotating force from the driving roller 1 is transmitted, and the endless belt 3, passed between the driving roller 1 and the driven roller 2 and run on the driving roller 1 and driven roller 2 by the driving roller 1 to rotate the driven roller 2. The driving roller 1 is connected to a motor 4 directly or via a connecting mechanism such as a timing belt and is driven by the motor 4. The driven roller 2 is connected to a brake 5 that applies a braking force to the driven roller 2. The motor 4 and the brake 5 are controlled by the operation control unit 103.
The driving roller 1 is driven by rotation of the motor. The driving roller 1 is rotated to convey the endless belt 3, and the endless belt 3 is passed between the driving roller 1 and the driven roller 2, around the driving roller 1 and the driven roller 2. The conveyance of the endless belt 3 causes the driven roller 2 to be concurrently rotated. Thus, the motor 4 drives the conveyor system 10, and the operation control unit 103 controllably rotates the motor 4 and controls the brake 5 using required timings as described later.
The belt driving mechanism shown in
When the endless belt 3 thus slips on the driven roller 2, the endless belt 3 is placed so as to minimize the length of the path circulating between the driving roller 1 and the driven roller 2; the endless belt 3 thus runs stably. Thus, as shown in
The first reference plane as the reference plane 11 contains the axis AX-1 of the driving roller 1 but not the axis AX-2 of the driven roller 2 as shown in
The angle of torsion between the axis AX-1 of the driving roller 1 and the axis AX-2 of the driven roller 2, which are in the torsional relationship, is set at 5° or smaller, preferably between 0.01° and 1°. The angle of torsion corresponds to the angle between the axis AX-2 of the driven roller 2 and the first reference plane as the reference plane 11. The torsional relationship can be established by inclining the axis AX-2 of the driven roller 2 from the first reference plane as the reference plane 11. The angle of torsion similarly corresponds to the angle between the axis AX-1 of the driving roller 1 and the second reference plane as the reference plane 11. The torsional relationship can be established by inclining the axis AX-1 of the driving roller 1 from the second reference plane as the reference plane 11. In the design of the belt driving mechanism consisting of the driving roller 1, the driven roller 2, and the endless belt 3, the driving roller 1 and the driven roller 2 are appropriately arranged so as to set such an angle of torsion. The driven roller is preferably provided with a structure that adjusts the inclination or installed position of the driven roller so as to fine the position of the rollers after the belt mechanism has been assembled.
If the axis AX-1 of the driving roller 1 and the axis AX-2 of the driven roller 2 are in the torsional relationship, the minimum distance between the axes AX-1 and AX-2 is determined. However, normally, the minimum distance Lmin between the axes AX-1 and AX-2 is preferably set between the center point 1C of the driving roller 1 on the axis AX-1 and the center point 2C of the driven roller 2 on the axis AX-2.
The frictional force between the endless belt 3 and the driving roller 1 or driven roller 2 is set by appropriately selecting a material for the roller surface and adjusting the contact angles between the rollers and belt. The preferable roller surface material for the driving roller 1 is such that the coefficient of friction μ1 of the driving roller 1 is larger than that μ2 of the driven roller 2. The preferable roller surface material for the driven roller 2 is such that the coefficient of friction μ2 of the driven roller 2 is smaller than that μ1 of the driving roller 1. For example, the surface of the driving roller 1 is composed of urethane rubber, which provides a relatively large coefficient of friction μ1. The surface of the driven roller is composed of acetal resin, which provides a relatively small coefficient of friction μ2.
The contact angles α, θ1, and θ2 between the rollers and the belt are preferably adjusted on the basis of the diameters and arrangement of the rollers. In the conveyor system shown in
Specifically, the contact angles α, θ1, and θ2 shown in
The brake 5 may be any of a drum brake, an electromagnetic brake, and a disk brake provided that it can exert a sufficient braking force on a particular driven roller.
With reference to a flowchart 1, description will be given of a control method of correcting the belt position in the conveyor system comprising the belt driving mechanism shown in
The operation period of the brake may be set at a predetermined value by, for example, pre-measuring the time required to correct the belt position. The driven roller 2, braked by the brake 5, may have its rotation completely stopped or may continue to rotate while being braked by a braking force, that is, may continue limited rotation.
Now, with reference to
In the belt driving mechanism shown in
With reference to the flowchart shown in
In the above process, before the start of the job, the operation control unit 103 determines the presence of a brake operation depending on the running distance. The operation control unit 103 can thus ensure that, during the execution of the job, the belt 3 is run within a predetermined tolerable margin in spite of a displacement of the belt. Here, the running distance means the distance the belt 3 runs continuously without being subjected to a braking force.
The following method enables the more accurate sensing and control of the position to which the endless belt 3 is displaced laterally with respect to the running direction: the lateral position of the belt is sensed by, for example, detecting the edge of the belt, and is then used as a trigger signal for allowing the operation control unit 103 to apply a braking force to the driven roller 2. The sensor detecting the lateral displacement may be any of various sensors, for example, a contact sensor, an optical sensor, and a magnetic sensor.
The area sensor is not limited to the optical position sensor 8 but may be another type of sensor.
In step S33, if the position of the endless belt 3 exceeds the threshold, the process shown in steps S37 to S39 is executed. As shown in step S37, the operation control unit 103 exerts a braking force on the driven roller 2. As shown in step S38, the operation control unit 103 then senses the position of the endless belt 3 on the basis of the sensor signal. As shown in step S39, the operation control unit 103 determines whether or not the laterally displaced position of the endless belt 3 has been corrected. If the laterally displaced position has not been corrected, the process returns to step S37 to continuously apply the braking force. If the operation control unit 103 senses that the lateral displacement of the belt has been corrected, the process shifts to step S40. The driven roller 2 then starts to rotate with the brake 5 released and thus no braking force applied to the driven roller 2.
To precisely determine that the belt position has been corrected, the above method continuously senses and corrects the position of the belt 3 while exerting a braking force on the driven roller 2, in steps S37 to S39.
When the process shifts to step S40, the operation control unit 103 stops exerting a braking force on the driven roller 2. Subsequently, the operation control unit 103 starts the job as shown in step S34 and finishes it as shown in step S35. Once the job is finished, the operation control unit 103 determines whether or not there is a next job as shown in step S36. If there is a next job, the process returns to step S32. If there is no further job, the operation control unit 103 stops operating the apparatus as shown in step S41.
The belt position can be controlled regardless of whether no senor is provided which can sense the belt position across the width of the belt or sensors are installed at two particular points so as to be able to sense the presence of the belt.
In the sensor arrangement shown in
If the lateral displacement exceeds the threshold in step S53, the process shifts to step S56. The operation control unit 103 applies a braking force to the driven roller for a preset time to correct the belt position as shown in step S56. As shown in step S57, the operation control unit 103 subsequently stops applying the braking force. The process returns to step S52.
If the operation control unit 103 does not sense any lateral displacement in step S53, it starts the job as shown in step S54. As shown in step S55, the operation control unit 103 subsequently finishes the job. As shown in step S58, the operation control unit 103 determines whether or not there is a next job. The operation control unit 103 then branches the process to step S52 or S59 depending on the determination. If there is a next job, the process returns to step S52. If there is no further job, the operation control unit 103 stops operating the apparatus as shown in step S59.
In the above control, the belt position has only to be sensed for only a part of the belt 3. The above control is thus applicable if it is difficult to measure the belt position over the entire range within which the belt is expected to have moved. The time during which the brake is operated may be preset by, for example, measuring the time required to correct the belt position.
The speed at which to correct the lateral displacement of the belt generally varies depending on the magnitude of the braking force applied to the driven roller. The belt can thus be held at a specified target running position by continuously controlling the magnitude of the braking force.
As shown in step S61, the operation control unit 103 senses the amount of displacement of the belt while the belt 3 is running. As shown in step S62, the operation control unit 103 determines whether the amount of lateral displacement has increased or decreased with respect to a predetermined position on the basis of the measured amount of displacement of the belt and a temporal variation in the amount. If the amount of lateral displacement has increased with respect to the target belt position, the process shifts to step S63. If the operation control unit 103 determines that the amount of lateral displacement has not changed, the process shifts to step S65. If the operation control unit 103 determines that the amount of lateral displacement has decreased to move the belt 3 closer to the predetermined position, the process shifts to step S64.
In step S63, the operation control unit 103 increases the braking force to rapidly return the belt to within the predetermined tolerable range of lateral displacement. In step S64, the operation control unit 103 reduces the braking force to slowly return the belt to within the predetermined tolerable range of lateral displacement, thus making the brake ready to be released. In step S65, the operation control unit 103 determines that the belt 3 has been returned to within the predetermined tolerable range of lateral displacement. The operation control unit 103 thus does not change the braking force. After the braking force is controlled in steps S63, S64, and S65, the control returns to step S61 to repeat controlling the braking force. The gain of the braking force control has a value specific to the apparatus.
The above flat belt 3 may have special marks that help the sensor sense the running distance or a positional deviation.
The running distance or positional deviation can be measured by drawing, on the belt 3, marks which are similar to register marks and which can be sensed by optical sensors as shown in
As in the case of marks such as those shown in
As described above, the belt driving mechanism in accordance with the present invention is configured as described below.
Therefore, the belt driving mechanism in accordance with the present invention can correct and prevent the positional displacement of the flat belt. In a media conveying apparatus into which flat belt conveyor system in accordance with the belt driving mechanism of the present invention is incorporated, the positional displacement of the flat belt can be easily corrected and prevented. This makes it possible to simplify the device configuration and to achieve precise conveyance.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
Number | Date | Country | Kind |
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2005-243182 | Aug 2005 | JP | national |
Number | Name | Date | Kind |
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3949864 | Montsant | Apr 1976 | A |
4133667 | Nitschke | Jan 1979 | A |
4715491 | Elderton | Dec 1987 | A |
4821873 | Crane | Apr 1989 | A |
Number | Date | Country |
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7-157129 | Jun 1995 | JP |
2004-45700 | Feb 2004 | JP |
2004-338854 | Dec 2004 | JP |
2005-96896 | Apr 2005 | JP |
Number | Date | Country | |
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20070045939 A1 | Mar 2007 | US |