Patent Grant
11048187
This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2020-045015 filed Mar. 16, 2020.
The present disclosure relates to an exposure control device, an image forming apparatus, and a non-transitory computer readable medium.
When an image is formed, density nonuniformity may occur due to, for example, eccentricity of a developing roller or a difference in a developing ability between a center and an end portion of the developing roller in an axial direction. It has been studied how to correct such density nonuniformity so as to form a good image without the density nonuniformity.
Japanese Patent No. 5825862 discloses that density nonuniformity is prevented by calculating correction pixel values according to pixel values and forming an image using the calculated correction pixel values (corrected image data).
The pixel value is represented by a digital value within a certain range such as 0 to 255. Therefore, when the pixel value is close to 0, that is, a density is low, even if the pixel value is different by 1, the density is greatly different, and there is a risk of overcorrection. When the pixel value is close to 255, that is, the density is high, since the pixel value cannot be corrected to 255 or more, the correction may be insufficient.
Aspects of non-limiting embodiments of the present disclosure relate to an exposure control device, an image forming apparatus, and a non-transitory computer readable medium that improve accuracy of correction as compared with a case of correcting pixel values.
Aspects of certain non-limiting embodiments of the present disclosure address the above advantages and/or other advantages not described above. However, aspects of the non-limiting embodiments are not required to address the advantages described above, and aspects of the non-limiting embodiments of the present disclosure may not address advantages described above.
According to an aspect of the present disclosure, there is provided an exposure control device includes an exposure light amount calculator and an exposure controller. The exposure light amount calculator is configured to obtain, for each of plural correction points that are associated with a respective one of primary correction values and are separated from each other, a correction factor for correcting the primary correction value of the correction point, based on a pixel value of the correction point, calculate, for each correction point, a secondary correction value based on the primary correction value and the correction factor of the correction point, and calculate a distribution of the secondary correction values on an image based on the plural secondary correction values of the plural correction points. The exposure controller is configured to cause an exposure unit to form a latent image by exposure to light having a corrected light amount obtained by correcting a light amount corresponding to a pixel value of each point based on the secondary correction value of the point.
Exemplary embodiment(s) of the present disclosure will be described in detail based on the following figures, wherein:
Hereinafter, exemplary embodiments of the present disclosure will be described.
The image forming apparatus 10 receives image data from a personal computer (which is not illustrated, and is hereinafter abbreviated as a “PC”) and forms an image on a sheet based on the image data.
The image forming apparatus 10 includes two housings of a first housing 10a and a second housing 10b that are connected to each other. Respective members that constitute the image forming apparatus 10 are separately provided in the two housings 10a and 10b.
The image forming apparatus 10 is configured to form an image using toners of four colors. Four toner cartridges 11Y, 11M, 11C, and 11K that accommodate the toners of the respective colors are arranged in an upper portion of the first housing 10a.
Herein, alphabets in reference numerals represent the colors of the toners accommodated in the toner cartridges. Among the alphabets, Y represents yellow, M represents magenta, C represents cyan, and K represents black.
Hereinafter, when it is not necessary to distinguish the colors, the alphabets indicating the colors may be omitted, and the reference numeral “11” is simply assigned to the toner cartridges. When it is necessary to distinguish the colors, the reference numerals each followed by a respective one of the above-described alphabets representing the colors will be used. The same applies to elements other than the toner cartridges 11.
The toner in each toner cartridge 11 is supplied to a developing unit 133 that constitutes an image forming unit 13 (which will be described later). Each toner cartridge 11 is replaceable. When the toner cartridge 11 becomes empty, the toner cartridge 11 is replaced with a new toner cartridge 11 accommodating the toner of the same color.
In the first housing 10a, four exposure units 12 and four image forming units 13 are provided below the toner cartridges 11.
The image forming unit 13 includes a drum-shaped image carrier 131 that rotates in a direction of an arrow A. A charging unit 132, the developing unit 133, a cleaning blade 134, and a static eliminator 135 are disposed around the image carrier 131. The exposure unit 12 is disposed above the image carrier 131. A primary transfer roller 15 is disposed at a position where an intermediate transfer belt 14 (which will be described later) is sandwiched between the image carrier 131 and the primary transfer roller 15.
The image carrier 131 is charged by the charging unit 132 while rotating in the direction of the arrow A.
The exposure unit 12 repeatedly scans the image carrier 131 with an exposure beam L (which is modulated according to the image data) in a direction perpendicular to a paper surface of
A developer containing the toner and a carrier is accommodated in the developing unit 133. The developing unit 133 includes a developing roller 133a. The developing roller 133a carries the developer accommodated in the developing unit 133 to a position where the developing roller 133a faces the image carrier 131, while rotating in a direction of an arrow R. The developing roller 133a develops the electrostatic latent image on the image carrier 131 with the toner in the developer to form a toner image on the image carrier 131. The toner is supplied from the corresponding toner cartridge 11 (see
The toner image formed on the image carrier 131 by an action of the developing unit 133 is transferred onto the intermediate transfer belt 14 that moves in a direction of an arrow B by an action of the primary transfer roller 15 that rotates in a direction of an arrow C while receiving application of a transfer bias.
The toner remaining on the image carrier 131 after the transfer is scraped and collected from the image carrier 131 by the cleaning blade 134. Then, the image carrier 131 is neutralized by the static eliminator 135 to erase the latent image remaining therein, and is newly charged by the charging unit 132.
Returning to
Below the four image forming units 13, the endless intermediate transfer belt 14 is provided. The intermediate transfer belt 14 is supported by plural rollers 16 including a driving roller 16a and a backup roller 16b. The intermediate transfer belt 14 circularly moves in the direction of the arrow B while being in contact with the image carriers 131 that constitute the image forming unit 13.
A secondary transfer roller 17 is provided at a position where the secondary transfer roller 17 faces the backup roller 16b with the intermediate transfer belt 14 sandwiched therebetween. The toner images sequentially transferred to the intermediate transfer belt 14 in a superimposed manner by the action of the primary transfer rollers 15 provided corresponding to the respective image forming units 13 are further transported by the intermediate transfer belt 14 in the direction of the arrow B. Then, the toner images on the intermediate transfer belt 14 are secondarily transferred by an action of the secondary transfer roller 17 onto a sheet transported to a position sandwiched between the intermediate transfer belt 14 and the secondary transfer roller 17. Accordingly, an unfixed toner image is formed on the sheet.
Two sheet accommodating units 18a and 18b are provided in a lower portion of the first housing 10a. A large number of sheets P are accommodated in each sheet accommodating units 18a and 18b in a stacked state. The paper P is taken out from the sheet accommodating units 18a and 18b during image formation. Bottom plates 181a and 181b rise as the number of sheets P accommodated in the sheet accommodating units 18a and 18b decreases.
When the image is formed, the uppermost sheet among the sheets P accommodated in one of the sheet accommodating units 18a and 18b, which is designated automatically or manually by an operator, is taken out by a pickup roller 19a. When the plural sheets P are taken out at once, a retard roller 19b reliably separates one sheet from the plural sheets P. Then, the one sheet is transported by a transport roller 19 onto transport paths 20a, 20b, and 20c, and a leading end of the transported sheet reaches a registration roller 19c. The first housing 10a is provided with an intake port 111 through which the sheet is taken in from the outside of the first housing 10a. When the paper is taken in from the intake port 111, the taken-in sheet is transported on the transport paths 20d and 20c, and a leading end of the sheet reaches the registration roller 19c. The registration roller 19c corrects a posture of the transported sheet, adjusts subsequent timing at which the sheet is fed, and further feeds the sheet downstream in a transport direction.
The registration roller 19c feeds the sheet such that the sheet is transported to a position of the secondary transfer roller 17 at the same timing as the toner image on the intermediate transfer belt 14 is transported to the position of the secondary transfer roller 17.
The sheet on which the toner image is transferred by the action of the secondary transfer roller 17 is transported by a transport belt 21, enters the second housing 10b, and reaches a fixing unit 22. The fixing unit 22 includes a heating belt 221 and a pressure roller 222. The sheet transported to the fixing unit 22 is heated and pressed while being sandwiched between the heating belt 221 and the pressure roller 222, so that the toner image on the sheet is fixed on the sheet. The sheet that has passed through the fixing unit 22 is transported by a transport belt 23, and reaches a decurler 24. A warp of the sheet is corrected by the decurler 24.
The sheet that has passed through the decurler 24 is cooled by a cooling unit 25. The cooling unit 25 cools the sheet by sandwiching the sheet between two endless belts 251 and 252. An optical measuring unit 26 measures an image (that is, the fixed toner image) on the sheet discharged from the cooling unit 25. The optical measuring unit 26 monitors whether the image is correctly formed on the sheet during normal image formation. During adjustment, the optical measuring unit 26 performs measurement for the adjustment, for example, in the following manners. That is, (i) the image forming apparatus 10 arranges various charts and color patches on a sheet, and the optical measuring unit 26 measures the charts and color patches for color tone adjustment, or (ii) the image forming apparatus 10 forms an image for adjustment of an image formation position or image magnification on a sheet, and the optical measuring unit 26 measures this image to adjust the image formation position or the image magnification. Furthermore, the image forming apparatus 10 forms an image having a uniform color and a uniform density on a sheet, and the optical measuring unit 26 measures the image to check if scratch or density unevenness is generated on the image.
The sheet that has passed through the optical measuring unit 26 is discharged onto a sheet discharge table 28 by a discharge roller 27.
After the toner image is secondarily transferred onto the sheet by the action of the secondary transfer roller 17, the intermediate transfer belt 14 still moves in the direction of the arrow B and reaches a cleaner 41. The cleaner 41 removes the toner remaining on the intermediate transfer belt 14 from the intermediate transfer belt 14.
A process of forming an image only on a first surface of the sheet has been described above. A process of forming images on both surfaces of the sheet will be described below. In this case, the image is formed on the first surface of the sheet by the same process as above, and then the sheet passes through the optical measuring unit 26. The sheet that has passed through the optical measuring unit 26 enters a transport path 20e before reaching the discharge roller 27, is transported on the transport path 20e and further enters a transport path 20f. When the sheet enters the transport path 20f, rotation directions of transport rollers that constitute the transport path 20f reverse, and the sheet is fed out in an opposite direction from the transport path 20f, returns to the first housing 10a, is transported on the transport paths 20b and 20c, and reaches the registration roller 19c. At this time, the sheet is in a posture in which a second surface on which the image has not yet been formed faces the intermediate transfer belt 14. By the time the sheet reaches the registration roller 19c through such a transport path, the image forming unit 13 forms toner images corresponding to an image to be formed on the second surface of the sheet and transfers the toner images onto the intermediate transfer belt 14. Thereafter, similar to the manner in which the image is formed on the first surface of the sheet, the sheet is fed out from the registration roller 19c, and the toner images are transferred to the second surface of the sheet by the action of the secondary transfer roller 17, and then the sheet passes through the fixing unit 22, the decurler 24, the cooling unit 25, and the optical measuring unit 26, and is then discharged onto the sheet discharge table 28 by the discharge roller 27.
An image processor and controller 30 is provided in an upper part of the second housing 10b of the image forming apparatus 10. The image processor and controller 30 includes a memory, an operating circuit, and a control circuit. The memory stores the image data and the like sent from the outside. The operating circuit performs various processing, such as image processing, for the image data. The control circuit controls the overall image forming apparatus 10. The image processor and controller 30 has an operating function of executing a program. The operating circuit and the control circuit that constitute the image processor and controller 30 provide functions implemented by a combination of hardware of the image processor and controller 30 and the program executed by the image processor and controller 30.
A power supply unit 33 is provided below the image processor and controller 30. The power supply unit 33 supplies necessary power to each member of the image forming apparatus 10.
The image forming apparatus 10 includes an environment sensor 34 that measures environmental temperature and humidity inside the image forming apparatus 10. The temperature and humidity measured by the environment sensor 34 are reported to the image processor and controller 30 and are reflected in various control of the image forming apparatus 10.
A monitor 31 and an operation panel 32 are placed on a lower step of the second housing 10b. The monitor 31 displays various statuses of the image forming apparatus 10. The operation panel 32 is operated by an operator.
The overall image forming apparatus has been described above. Hereinafter, description will be made on exposure control that is a feature of the present exemplary embodiment, that is, light amount control of the exposure beam L emitted from the exposure unit 12.
Except for a light amount adjuster 53, the exposure control device 50A is established in the image processor and controller 30 illustrated in
The exposure control device 50A includes an image editing unit 51, a data converter 52, the light amount adjuster 53, and a light amount controller 54. Herein, the light amount controller 54 includes a primary correction value table 61 and a correction magnification lookup table (LUT) 62.
The image data transmitted from the external PC is input to the image editing unit 51. The image data includes (i) information indicating components on data that constitutes an image, such as graphic data and character data, and (ii) information indicating a type of a screen for halftone dot printing. The image editing unit 51 generates multi-level data of each of pixels constituting the image by integrating the input data in various formats. The multi-level data of each pixel has a numerical value of in a range of 0 to 255. In a screen image (halftone dot image), a pixel value of 0 refers to a dot percent of 0%, and a pixel value of 255 refers to a dot percent of 100%. Other numerical values are also similar.
The multi-level data generated in the image editing unit 51 is input to the data converter 52. Information on the screen is also passed to the data converter 52. The data converter 52 converts the multi-level data received from the image editing unit 51 into binary data representing a screen image (halftone dot image) according to an instructed screen. Two values of the binary data will be described as white and black for the sake of understanding. It is noted that this notation is used on data, but an actual color is not white or black. The actual color is different for each of the toners of the four colors.
The binary data is data representing a pixel of multi-level data using a screen image (halftone dot image) having a set of white and black dots. For example, when a certain pixel has a dot percent of 50% that is a central value of 127 in the multi-level data from 0 to 255, the pixel is represented by half white dots and half black dots that are arranged according to a designated screen. The same applies to the multi-level data of other values. Herein, the white dots on the image refer to dots that are not irradiated with the exposure beam L, and the black dots refer to dots that are irradiated with the exposure beam L.
The binary data generated in the data converter 52 is input to the light amount adjuster 53. The binary data is also input to the light amount controller 54. Description on the light amount controller 54 will be given later.
The light amount adjuster 53 is provided in the exposure unit 12 illustrated in
The information on the screen and the binary data are input to the light amount controller 54. In the first exemplary embodiment illustrated in
In an exposure control device 50B according to a second exemplary embodiment illustrated in
The light amount controller 54 includes the primary correction value table 61 and the correction magnification LUT 62. The primary correction value table 61 and the correction magnification LUT 62 are created in advance and installed in the light amount controller 54.
First, the primary correction value table 61 and the correction magnification LUT 62 will be described.
The primary correction value table 61 is created for each image forming apparatus 10 at a preparatory stage before use of the image forming apparatus 10 starts or before factory shipment.
Herein, first, a uniform image, for example, an image having a dot percent of 60% is formed on a sheet (step S01), and a density of each correction point is measured by the optical measuring unit 26 (step S02).
Herein, as an example, thirty two (32) correction points are arranged at equal intervals within a length of one cycle of the developing roller 133a (see
In the image forming apparatus 10 illustrated in
Returning to
In step S03 of
The primary correction value table 61 is a table having 32 columns by 32 rows. Each cell corresponds to a respective one of the correction points. In each cell, the primary correction value of the corresponding one of the correction points is written.
Herein, the uniform image having the dot percent of 60% is formed, and the density of each correction point is measured. Therefore, each correction point has an expected value of the density corresponding to the dot percent of 60%. A pixel value measured at each correction point is ideally a pixel value representing the density as expected, but does not always match the expected value due to various error factors. The primary correction value in each cell of the primary correction value table 61 illustrated in
The primary correction value table 61 created in this way is installed in the light amount controller 54 illustrated in
In
As described above, in the exposure control device 50A of the first exemplary embodiment illustrated in
The light amount controller 54 calculates the correction magnification based on the estimated Cin with reference to the correction magnification LUT 62 (step S12). The light amount controller 54 reads the primary correction value with reference to the primary correction value table 61, and multiplies the read primary correction value by the calculated correction magnification to calculate a light amount adjustment value (step S13). The calculated light amount adjustment value is an example of a secondary correction value according to the present disclosure. The light amount controller 54 outputs the calculated light amount adjustment value to the light amount adjuster 53.
The light amount adjuster 53 adjusts the light amount of the exposure beam L for each pixel according to the input light amount adjustment value. The image carrier 131 is exposed with the exposure beam L whose light amount is adjusted.
A method of calculating the correction magnification and a method of calculating the light amount adjustment value will be described.
The correction magnification LUT 62 illustrated in
It is assumed that the pixel value of the pixel overlapping the correction point at the upper left corner in
It is assumed that Cin at a correction point that is to the right of the correction point at the upper left corner in
Similarly, it is assumed that a correction point that is second to the right of the correction point at the upper left corner has Cin=35% in forming the user image. At this time, similar to the above, a primary correction value −2% at the corresponding correction point in
The light amount of the exposure beam L is adjusted for the pixel overlapping each correction point as described above.
Next, a method of adjusting a light amount of the exposure beam L for a pixel between two adjacent correction points will be described.
It is assumed that a light amount correction value relating to the pixel overlapping the correction point at the upper left corner in
For a pixel at a position shifted from the correction points in both the width direction and the process direction, a light amount correction value is obtained by two-dimensional linear interpolation on the light amount correction values of four pixels overlapping four surrounding correction points. An algorithm of the two-dimensional linear interpolation has been well known, and the description thereof is omitted here. In the above description, the linear interpolation is adopted. It is noted that the linear interpolation does not have to be adopted. A higher-order interpolation may be adopted.
The uniform image described with reference to
Next, a method of estimating Cin in step S11 of
Herein, Cin is estimated by counting the number of the white dots and the number of black dots in a region, having a size which is determined according to the screen used this time, around one correction point, and calculating a ratio of the white dots and the black dots.
The region where the number of the white dots and the number of the black dots are counted for Cin estimation is switched according to the screen. For example, for a 212 lpi screen at a 45-degree screen angle that is used in general, when a lighting resolution is 2,400 dpi, a region of a multiple of 8 lines (here, 16 lines that is twice 8 lines) is selected.
This is based on the following calculation formulas. That is, a screen at a 45-degree screen angle has a repetition period of square root of 2 times, that is, about 1.4 times in a 0-degree direction. The 212 lpi screen at the 45-degree screen angle has the same repetition period in the 0-degree direction as a 300 lpi screen at a 0-degree screen angle. The term “212 lines per inch (lpi)” refers to 212 dots in 1 inch (≈25.4 mm). That is, dots of 0.12 mm (≈25.4 mm/212) are arranged. In a 300 lpi screen, dots of 0.085 mm (≈25.4 mm/300) are arranged. Herein, one dot of an image output at 2,400 dpi is 25.4/2400≈0.011 mm Therefore, the 300 lpi screen at the 0-degree screen angle repeats in a unit of (25.4 mm/300)/(25.4/2400)=8 dots. Then, for the 212 lpi screen at the 45-degree screen angle, 8×2=16 lines in the process direction are adopted as a region for Cin estimation. In the width direction, a wide 127-dot region is adopted. When a region having the same length in the process direction as that in the width direction is adopted, estimation errors of Cin decrease, but a huge memory capacity is required. Therefore, a region is set to be twice as large as the number of repeated dots.
For a 190 lpi screen at a 45-degree screen angle, a region having a multiple of 9 (here 9×2=18 lines) is similarly adopted. This region has 127 dots in the width direction.
A screen at a screen angle other than 0 degree or 45 degrees has no repetition period with a small number of dots in the 0-degree direction. Therefore, it is not necessary to pay particular attention to the number of repeated dots when determining the region.
In this way, the region where the number of the white dots and the black dots of the binary data is counted is set around each correction point, and the number of data representing the white dots and the number of data representing the black dots in the region are counted. For example, when a percentage of the white dots is 40% and a percentage of the black dots is 60%, it is estimated that Cin=60%. Further, for example, when the percentage of white dots is 80% and the percentage of the black dots is 20%, it is estimated that Cin=20%.
For the 212 lpi screen at the 45-degree screen angle, when the region of 16 lines is selected as in the calculation formula described above, the estimation errors of Cin are reduced compared to selecting a region of 17 lines or 18 lines.
Further, for a 190 lpi screen at a 45-degree screen angle, when the region of 18 lines is selected, the estimation errors of Cin are reduced compared to selecting the region of 16 lines or 17 lines.
A 205 lpi screen at a 20-degree screen angle or a 70-degree screen angle, and a 185 lpi screen at a 12-degree screen angle or a 67-degree screen angle have no repetition period with a small number of dots in the 0-degree direction. Therefore, the estimation errors of Cin are at the same level regardless of which region of 16 lines, 17 lines, or 18 lines is selected.
Herein, the example has been described in which information on the screen to be used this time is obtained and the region where the number of the white dots and the black dots are counted is set according to the screen. When the screen to be used is determined in advance and initialized, a region for the initialized screen may be always adopted.
In this way, when Cin is estimated in step S11 of
In the exposure control device 50A of the first exemplary embodiment illustrated in
On the other hand, the exposure control device 50B of the second exemplary embodiment illustrated in
Similar to the exposure control device 50A of the first exemplary embodiment, the exposure control device 50B of the second exemplary embodiment adjusts the light amount of the exposure beam L emitted from the exposure unit 12 without adjusting the value of Cin on the data (for example, rewriting Cin=35 as Cin=38). Therefore, it is possible to adjust the light amount more finely than in Japanese Patent No. 5825862 in which the value of Cin is adjusted on the data.
The tandem image forming apparatus for forming a color image has been described as an example. It is noted that the present disclosure is applicable to a monochrome printer and the like.
The foregoing description of the exemplary embodiments of the present disclosure has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The embodiments were chosen and described in order to best explain the principles of the disclosure and its practical applications, thereby enabling others skilled in the art to understand the disclosure for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the disclosure be defined by the following claims and their equivalents.
| Number | Date | Country | Kind |
|---|---|---|---|
| JP2020-045015 | Mar 2020 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 8508800 | Abe | Aug 2013 | B2 |
| 20120288291 | Miyadera | Nov 2012 | A1 |
| Number | Date | Country |
|---|---|---|
| 5825862 | Dec 2015 | JP |
