Patent Application
20210173336
Embodiments relate to an image forming apparatus, a determination apparatus, and a control method.
An on-demand fixing method has been proposed as a technique for reducing power consumption in an image forming apparatus. In the on-demand fixing method, a film is driven by a rotating member provided with an elastic layer, and a conveyed sheet and developer are heated by a heater through the film. In recent years, a configuration in which a plurality of heaters are arranged in a main scanning direction instead of a single heater has begun to be adopted.
A heater element (or heating element) typically has a long life. In order to prevent the occurrence of improper image formation by sudden disconnection when the service life of the heating element has reached its end, it is necessary to replace the heating element earlier than its service life. Therefore, a heating element that is operating properly and can still be used is discarded, so that waste is caused. Further, the individual heating elements are deposited on the sheet substrate of the heater, and it is often impossible to replace one heating element by itself. Therefore, when one of the heating elements is to be replaced, the other heating elements on the same sheet substrate are also replaced. As a result, the yield of the image forming apparatus is reduced from what it could actually achieve.
According to an embodiment, an image forming apparatus includes a fixing device, an image reading unit located downstream of the fixing device, and a control unit. The fixing device includes a plurality of heating elements arranged in a main scanning direction, a band-shaped thin film which slides on the surface of the heating element while being in contact with the heating element on one side, and a rotatable body configured to press against a surface of the thin film to cause the thin film to rotate. The fixing device heats the plurality of heating elements when an inspection sheet is passed through the fixing device, the inspection sheet having plural images formed by using a developer that becomes decolored when subject to heating, each of the images having an image density that differs in a sub-scanning direction of the image forming apparatus. The image reading unit reads an image of the heated inspection sheet and the control unit determines an operative state of each of the plurality of heating elements based on the read image.
Hereinafter, an image forming apparatus, a determining apparatus and a control method according to an embodiment will be described with reference to the accompanying drawings.
The image forming apparatus 100 forms an image on a sheet by using a developer such as toner. The developer is fixed on the sheet by being heated. The sheet may be, for example, standard print paper or label paper. The sheet may be any material as long as the image forming apparatus 100 can form an image on the surface thereof.
The display 110 is an image display device such as a liquid crystal display, an organic EL (Electro Luminescence) display, or the like. The display 110 displays various pieces of information related to the image forming apparatus 100.
The control panel 120 is provided with a plurality of buttons. The control panel 120 accepts an operation performed by the user. The control panel 120 outputs a signal corresponding to the operation performed by the user to the control unit 160 of the image forming apparatus 100. Note that the display 110 and the control panel 120 may be configured as a single touch panel.
The image forming unit 130 forms an image on a sheet based on image information generated by the image reading unit 200 or image information received via a communication network. The image forming unit 130 includes, for example, a developing device 10, a transfer device 20, and a fixing device 30. The image forming unit 130 forms an image by, for example, the following steps. The developing device 10 of the image forming unit 130 forms an electrostatic latent image on the photosensitive drum based on the image information. The developing device 10 of the image forming unit 130 forms a visible image by adhering the developer to the electrostatic latent image. A specific example of the developer is toner. Examples of the toner include a decolorable toner, a non-decolorable toner (ordinary toner), and a decorative toner. Some developers exhibit a reduced color based on an amount of heating applied to the developer. Such a developer is referred to as a “decolorable developer” in the following description. The decolorable toner is a specific example of the decolorable developer.
The transfer device 20 of the image forming unit 130 transfers the visible image onto the sheet. The fixing device 30 of the image forming unit 130 fixes the visible image on the sheet by heating and pressurizing the sheet. The sheet on which the image is formed may be a sheet accommodated in the sheet accommodating unit 140, or may be a manually inserted sheet.
The sheet accommodating unit 140 accommodates a sheet used for image formation in the image forming unit 130.
The storage unit 150 is configured by using a storage device such as a magnetic hard disk device or a semiconductor storage device. The storage unit 150 stores data necessary for the image forming apparatus 100 to operate. The storage unit 150 may temporarily store data of an image formed in the image forming apparatus 100.
The control unit 160 includes a processor such as a CPU (Central Processing Unit) and a memory. The control unit 160 reads out and executes a program stored in the storage unit 150 in advance. The control unit 160 controls the operations of the respective devices included in the image forming apparatus 100.
The control unit 160 controls the electric power supplied to a heating element set 45 (see also
The image reading unit 200 reads the image information to be read as light data (e.g., bit value “1”) and dark data (e.g., bit value “0”). The image reading unit 200 records the image information that has been read. The recorded image information may be transmitted to another information processing apparatus via the network. The recorded image information may be imaged onto the sheet by the image forming unit 130. The image reading unit 200 may include an automatic document feeder (ADF).
The pressure roller 30p can press and drive the surface of the film unit 30h. When the surface is pressed against the film unit 30h, the pressure roller 30p forms a nip N with the film unit 30h. The pressure roller 30p pressurizes the visible image of the sheet entering the nip N. When the pressure roller 30p is driven to rotate, it conveys the sheet in accordance with rotation of the sheet. The pressure roller 30p includes, for example, a core metal 32, an elastic layer 33, and a release layer (not shown).
The core metal 32 is made of a metal material such as stainless steel, and is formed in a cylindrical shape. Both end portions in the axial direction of the core metal 32 are rotatably supported. The core metal 32 is driven to rotate by a motor (not shown). The core metal 32 comes into contact with a cam member (not shown).
The elastic layer 33 is formed of an elastic material such as silicone rubber. The elastic layer 33 is formed to have a constant thickness on the outer peripheral surface of the core metal 32. A release layer (not shown) is formed on the outer peripheral surface of the elastic layer 33. The release layer is formed of a resin material such as PFA (tetrafluoroethylene perfluoroalkyl vinyl ether copolymer).
The pressure roller 30p is rotated by a motor. When the pressure roller 30p rotates in the state where the nip N is formed, the cylindrical film 35 of the film unit 30h is driven to rotate. The pressure roller 30p conveys the sheet in the conveying direction W by rotating the sheet in a state where the sheet is placed in the nip N.
The film unit 30h heats the visible image of the sheet that has entered into the nip N. The film unit 30h includes a cylindrical film 35, a heater unit 40, a heat transfer member 49, a support member 36, a stay 38, a heater thermometer 62, a thermostat 68, and a film thermometer 64.
The cylindrical film 35 is formed in a cylindrical shape. The cylindrical film 35 is provided with a base layer, an elastic layer, and a release layer in this order from the inner peripheral side. The base layer is formed in a cylindrical shape by a material such as nickel (Ni) or the like. The elastic layer is laminated and arranged on the outer peripheral surface of the base layer. The elastic layer is formed of an elastic material such as silicone rubber. The release layer is laminated and arranged on the outer peripheral surface of the elastic layer. The release layer is formed of a material such as a perfluoroalkoxy alkane (PFA) resin.
A heating element set 45 is formed on the surface of the substrate 41. The heating element set 45 is provided with a plurality of heating elements 46. Each of the heating elements 46 is formed by using a heating resistor such as a silver-palladium alloy. In the example shown in
As shown in
The support member 36 is made of a resin material such as a liquid crystal polymer. The support member 36 supports the heater unit 40. The support member 36 supports the inner peripheral surface of the cylindrical film 35 at both end portions of the heater unit 40.
The stay 38 is formed of a steel sheet material or the like. The cross section of the stay 38 may be formed, for example, in a U-shape. The stay 38 is mounted so as to block the opening of the U with the support member 36. Both end portions of the stay 38 are fixed to the housing of the image forming apparatus 100. As a result, the film unit 30h is supported by the image forming apparatus 100.
The heater thermometer 62 is disposed in the vicinity of the heater unit 40. The heater thermometer 62 measures the temperature of the heater unit 40.
The thermostat 68 is arranged in the same manner as the heater thermometer 62. When the temperature of the heater unit 40 exceeds a predetermined temperature, the thermostat 68 cuts off the power supply to the heating element set 45.
In the example of the inspection sheet shown in
Next, an inspection method using an inspection sheet will be described. The inspection sheet passes through the heated fixing device 30. When the inspection sheet is heated by the fixing device 30 as described above, the image formed on the inspection sheet is decolored. When the inspection using the inspection sheet is performed as described above, the fixing device 30 is controlled by the energization amount (hereinafter, referred to as “inspection energization amount”) which becomes a temperature at which the image having the highest density is not completely (sufficiently) decolored in the inspection sheet. For example, the fixing device 30 may be controlled by the control unit 160 to a power supply amount of about 50% of the maximum energization amount. In this manner, an operation mode (hereinafter referred to as “inspection mode”) for performing the inspection using the inspection sheet may be set in the image forming apparatus 100 in advance. Based on the inspection sheet heated by the fixing device (hereinafter referred to as “post-heating inspection sheet”), the operative state of each heating element 46a-46e of the fixing device 30 is determined.
The control unit 160 of the image forming apparatus 100 operates in the determination mode to determine whether or not a failure of the heating element 46 has occurred. When the image forming apparatus 100 is operated in the determination mode, the control unit 160 of the image forming apparatus 100 reads an image of the inspection sheet by the image reading unit 200 after the heating. The control unit 160 determines the operative state of the fixing device 30 of the image forming apparatus 100 to be inspected based on the read image (hereinafter, referred to as “post-heating image”) and the reference information. For example, an operative state (e.g., normal state or failed state) of each of the heating elements 46 of the image forming apparatus 100 may be determined by comparing the reference information with reference information for each row in the main scanning direction after heating. When the post-heating inspection sheet heated by the own apparatus is used, the control unit 160 may determine correction information of the heating element 46 of the own apparatus.
In the heating element 46d of the fixing device 30 of the image forming apparatus 100 in which the post-heating image shown in
The control unit 160 records the data of the post-heating image read by the image reading unit 200 in the storage unit 150. The control unit 160 reads out the reference information stored in the storage unit 150 in advance (ACT202). The control unit 160 reads an image of an area corresponding to the heating element 46 to be a determination target from the post-heating image stored in the storage unit 150. For example, when the heating element 46 to be a determination object is the heating element 46a, the control unit 160 reads the image of the column a from the post-heating image. Then, the control unit 160 acquires the difference information based on the read post-heating image and the reference information (ACT203).
The control unit 160 determines whether or not the acquired difference information satisfies the first condition (ACT204). When the difference information satisfies the first condition (ACT204—YES), the control unit 160 determines that the heating element 46 which is a determination target is a failure and needs to be replaced (ACT205). The control unit 160 records information indicating the determination result to the storage unit 150 in association with identification information indicating the heating element 46 which is a determination target.
When the difference information does not satisfy the first condition (ACT204—NO), the control unit 160 determines whether or not the acquired difference information satisfies the second condition (ACT206). When the difference information satisfies the second condition (ACT206—YES), the control unit 160 determines that there is no need to exchange the heating element 46 which is the object to be determined, but requires correction to the amount of energization. In this case, the control unit 160 acquires the correction information of the heating element based on the difference information (ACT207). The control unit 160 records information indicating the determination result to the storage unit 150 in association with identification information indicating the heating element 46 which is a determination target.
When the difference information does not satisfy both the first condition and the second condition (ACT206—NO), the control unit 160 determines that the heating element 46 is normal for the determination object (ACT208). Thereafter, until the determination is completed for all of the heating elements 46, the control unit 160 repeatedly executes the processing of the ACT203-ACT208 for each of the heating elements 46 (ACT209—NO).
When the determination is completed for all of the heating elements 46 (ACT209—YES), the control unit 160 displays characters or images indicating the determination result on the display 110. For example, when it is determined that one or more heating elements 46 are failed, the control unit 160 may display a character or an image for recommending replacement of the heater unit 40 on the display 110. For example, when there is no heating element 46 determined to be a failure, but the correction information is acquired for one or more heating elements 46, the control unit 160 may display on the display 110 a character or image indicating that the control of the heating element 46 has been completed. For example, when there is no heating element 46 determined to be in a failed state and there is no heating element 46 in which correction information is acquired, the control unit 160 may display characters or images indicating that all of the heating elements 46 are normal on the display 110.
All or a part of the operation of the control unit 160 may be realized by using hardware such as an ASIC (Application Specific Integrated Circuit), a PLD (Programmable Logic Device), or an FPGA (Field Programmable Gate Array). The program may be recorded on a computer-readable recording medium. The computer-readable recording medium is, for example, a flexible disk, a magneto-optical disk, a portable medium such as a ROM, a CD-ROM, or the like, a storage device such as a hard disk incorporated in a computer system, or the like. The program may be transmitted over a telecommunications line.
According to at least one embodiment described above, it is possible to determine the operative state of the heating element 46 of the image forming apparatus 100 based on the post-heating image generated by heating the inspection sheet by the image forming apparatus 100. Further, based on the difference information between the post-heating image and the reference image, correction information of control for operating each of the heating elements 46 in a state that is closer to the normal state may be acquired. In this case, the control unit 160 of the image forming apparatus 100 controls each of the heating elements 46 based on the acquired correction information. By performing such control as described above, it is possible to continue to use the heater unit 40, which has a difference in calorific value, and to improve the yield.
Among the processing of the control unit 160 in the embodiment described above, the processing for determining the operative state of each heating element 46 based on the post-heating image and the processing for acquiring the correction information may be executed in the information processing apparatus (also referred to herein as a determination apparatus) instead of the image forming apparatus 100. For example, the determination apparatus that received the post-heating image via the network may perform judgment of the operative state and acquisition of correction information, and may transmit the determination result to the apparatus (for example, the image forming apparatus 100) that is the transmission source of the post-heating image.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The embodiments and variations thereof are included within the scope and spirit of the invention, and are included within the scope of the appended claims and their equivalents.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2019-019097 | Feb 2019 | JP | national |
This application is a continuation of U.S. patent application Ser. No. 16/703,064, filed on Dec. 4, 2019, which application is based upon and claims the benefit of priority from Japanese Patent Application No. 2019-019097, filed on Feb. 5, 2019, the entire contents of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16703064 | Dec 2019 | US |
| Child | 17179238 | US |
