Patent Grant
9360786
1. Field of the Invention
The present invention relates to an image forming apparatus that forms an image by using developer.
2. Description of the Related Art
Electrophotographic color image forming apparatuses form a multicolor image by layering toners each having a different color. Therefore, so-called color misregistration could occur when the layering positions of the toners having different colors are misaligned from their respective ideal positions. One approach to reduce the color misregistration and to improve the color registration (alignment) is to actually form a color pattern in each color on the intermediate transfer belt, measure the amount of color misregistration (misalignment) of each color, and then adjust the image write start timing with respect to each color according to the amount of color misregistration. The intermediate transfer belt is extended under tension between a plurality of rollers, and rotates in a predetermined running direction (sub-scanning direction). When the plurality of rollers are not in parallel or the outer diameter of any of the rollers is not uniform, the intermediate transfer belt diagonally moves or meanders, and causes another color misregistration problem. To solve this problem, Japanese Patent Laid-Open No. 2008-281833 proposes a technology of detecting the inclination of the intermediate transfer belt between adjacent photosensitive drums, and adjusting the write start positions on the photosensitive drums. Japanese Patent Laid-Open No. 2010-85422 discloses a technology of measuring and recording the inclination of the intermediate transfer belt at the time of detection of the amount of color misregistration by using color registration patterns, and adjusting the write start positions by comparing the recorded inclination with the inclination at the time of image formation.
According to Japanese Patent Laid-Open No. 2008-281833 and Japanese Patent Laid-Open No. 2010-85422, the influence of the diagonal movement and meandering of the intermediate transfer belt is reduced by changing the offset values used for adjusting the write start position according to the inclination of the intermediate transfer belt. In order to accurately determine an offset value used for adjusting a write start position, it is necessary to obtain the inclination of the transfer belt immediately before the transfer of the corresponding toner image. However, there are cases in which the calculation of the write start position cannot be completed in time with respect to the color that is used first for forming a toner image, from among the plurality of colors. For example, when toner images in yellow, magenta, cyan, and black are sequentially transferred to the intermediate transfer belt in this order, there is the possibility that the write start position of the yellow toner image cannot be accurately determined. In order to accurately determine the offset value used for adjusting the write start position, it is necessary to detect the inclination of the transfer belt immediately before the transfer of the toner image. However, in some cases, a long time gap occurs from the detection of the inclination of the intermediate transfer belt to the start of the writing of the toner image, because of the waiting time for the rasterization of image data, the waiting time for the preparatory operations by the paper discharge unit, etc. In such cases, a difference occurs between the calculated inclination and the actual inclination, and this difference degrades the accuracy of the color registration adjustment.
The present invention performs a color registration adjustment in an accurate manner without depending on the start timing of the image formation.
The present invention provides an image forming apparatus comprising the following elements. A plurality of image forming units is configured to form images each having a different color. A transfer unit is configured to perform primary transfer, to a transfer member, of images respectively generated by the plurality of image forming units. A detection unit is configured to detect a color pattern formed on the transfer member, the color pattern being used for detecting color misregistration. A first correction unit is configured to: control the plurality of image forming units so that the plurality of image forming units form, on the transfer member, a plurality of color patterns each having a different color; detect, by using the detection unit, the amount of color misregistration, relative to a forming position of a color pattern having a reference color among the plurality of color patterns, of a forming position of a color pattern having another color among the plurality of color patterns; and determine an offset value for adjusting an image write start timing of the other color according to the amount of color misregistration of the color pattern having the other color. A measuring unit is configured to measure the inclination of the transfer member. A second correction unit is configured to determine, according to the inclination measured by the measuring unit, an offset value for adjusting the image write start timing of each of the plurality of image forming units and for adjusting, relative to the write start timing of a reference color, the write start timing of another color. The reference color for the first correction unit is different from the reference color for the second correction unit.
Further features of the present invention will become apparent from the following description of exemplary embodiments (with reference to the attached drawings).
The following describes an embodiment for implementing the present invention, with reference to the drawings. It should be noted that the following embodiment is not intended to limit the invention recited in the claims, and all combinations of features described in the embodiment are not necessarily mandatory as solutions provided by the invention.
The image reading unit 700 forms an image of a document 702 on a color sensor 706 via an illumination lamp 703, a group of mirrors 704A, 704B, and 704C, and a lens 705. The color sensor 706 reads color image information of the document for each color-separated light of the colors blue (B), green (G), and red (R) for example, and transforms the color image information into electrical image signals. These signals are transmitted to a calculation unit 733. The calculation unit 733 performs color conversion processing based on the intensity levels of the color-separated image signals corresponding to the colors R, G, and B, thereby generating image data corresponding to the colors Y, M, C, and K. The calculation unit 733 may transmit or receive external input data from a telephone line or a network via an external interface. When received data is page description language (PDL) data, color image data may be obtained by a PDL processing unit expanding the data into image information.
In the image forming unit 701, laser scanner units 707Y, 707M, 707C, and 707K, which are provided in one-to-one correspondence with the toners having different colors, transform the color image data from the image reading unit 700 into optical signals, and perform optical writing according to the document image. Thus, an electrostatic latent image is formed on the photosensitive members 708Y, 708M, 708C, and 708K. The photosensitive members 708Y, 708M, 708C, and 708K rotate counterclockwise as indicated by the arrow. Charger units 709Y, 709M, 709C, and 709K, and developing units 710Y, 710M, 710C, and 710K are disposed around the photosensitive members 708Y, 708M, 708C, and 708K, respectively. The intermediate transfer belt 711 serves as an image carrier as well as a transfer member. The intermediate transfer belt 711 is extended under tension between primary transfer blades 712Y, 712M, 712C, and 712K, a drive roller 715, a steering roller 713, and a driven roller 714. Each of the developing units 710Y, 710M, 710C, and 710K in the image creation systems described above is made up from, for example, a developing sleeve that rotates while bringing a brush of developer into contact with the surface of the photosensitive member in order to develop the electrostatic latent image, and a developing paddle that rotates in order to pick up and stir the developer.
A secondary transfer roller 716 is disposed at a position opposing the driven roller 714 of the intermediate transfer belt 711, and has a distance control mechanism by which the secondary transfer roller 716 can be moved apart from or brought in contact with the intermediate transfer belt 711.
In addition, a belt cleaning unit 717 is provided on the surface of the intermediate transfer belt 711, at a predetermined position opposing the drive roller 715. The belt cleaning unit 717 is separated from the belt surface during the period from the start of a printing to the end of the transfer, to the belt, of the trailing edge of the image having the last color. When the transfer is completed, the belt cleaning unit 717 is brought into contact with the belt surface by a distance control mechanism (not shown in the drawing), and performs cleaning.
In a color printer unit, image formation using the color yellow is started first. After that, image formation using the color magenta is started with a delay corresponding to the distance between the photosensitive member 708Y and the photosensitive member 708M in consideration of the rotation speed of the intermediate transfer belt 711. Subsequently, image formation using the color cyan is started with a delay corresponding to the distance between the photosensitive member 708M and the photosensitive member 708C in consideration of the rotation speed of the intermediate transfer belt 711. Subsequently, image formation using the color black is started with a delay corresponding to the distance between the photosensitive member 708C and the photosensitive member 708K in consideration of the rotation speed of the intermediate transfer belt 711.
The calculation unit 733 reads image data stored in an image memory 603. Based on this image data, the laser scanner units 707Y, 707M, 707C, and 707K perform optical writing using a laser beam, onto the photosensitive members 708Y, 708M, 708C, and 708K, which have been uniformly charged by the charger units 709Y, 709M, 709C, and 709K with predetermined timing. The following provides a description of image formation with the drum for yellow as a representative of the four drums. When laser exposure for the photosensitive member 708Y is started, the developing sleeve of the developing unit 710Y starts rotating and applying a developing bias, in order to realize the development starting from the leading edge of the Y-color latent image. Since then, the development operation is continued for the development of the Y-color latent image, and the development operation is stopped when the trailing edge of the latent image passes through the developing position for Y. A yellow toner image formed on the photosensitive member 708Y is transferred to the intermediate transfer belt 711 by the primary transfer blade 712Y, and is retained on the intermediate transfer belt 711.
One paper cassette is selected from among paper cassettes 740, 741, and 742, and a sheet of paper fed from the selected tray is conveyed via a registration roller 723. The paper feed timing and starting timing of the laser exposure scanning on the photosensitive drum are determined according to a page synchronization signal (ITOP signal) generated by the calculation unit 733. Accordingly, the paper feed timing and the image formation timing are brought into synchronization, and the color toner images developed on the photosensitive members 708Y, 708M, 708C, and 708K are layered on the intermediate transfer belt 711, and are transferred to the sheet of paper by the secondary transfer roller 716. Sheets of paper to which toner images have been transferred are separated and conveyed, and undergo the fixing performed by a fixing device 724. The fixing device 724 includes therein a fixing roller, which has a built-in halogen heater, and a pressure roller, and fixes a toner image on a sheet of paper by application of heat and pressure. After the fixing, a sheet of paper with the fixed toner image is ejected onto a catch tray 743.
A belt edge sensor 751 for detecting meandering of the intermediate transfer belt 711, and a belt edge sensor 750 are disposed at a side edge of the intermediate transfer belt 711. The belt edge sensor 751 detects meandering of the belt, and a steering motor 205 controls the steering roller 713 so as to regulate the meandering of the intermediate transfer belt 711 to be within a predetermined range. Also, the inclination of the intermediate transfer belt 711 is detected by using the two sensors, namely the belt edge sensor 750 and the belt edge sensor 751.
The calculation unit 733 has various functions. A first correction unit 781 causes the image forming unit 701 to form a plurality of color patterns each having a different color, which are used for color misregistration detection (color registration adjustment/color alignment). Furthermore, using a color misregistration sensor 735, the first correction unit 781 detects the amount of the misregistration (misalignment), relative to the forming position of the color pattern having a reference color among the plurality of color patterns, of the amount of the misregistration of the forming position of a color pattern having another color among the plurality of color patterns. The first correction unit 781 determines the offset value (adjustment value) used for adjusting the image write start timing of the other color, according to the amount of the misregistration of the color pattern having the other color. The calculation unit 733, the belt edge sensor 750, and the belt edge sensor 751 serve as a measuring unit for measuring the inclination of the intermediate transfer belt 711. This inclination is the inclination from the ideal direction. The ideal direction is the image conveyance direction in design of the intermediate transfer belt 711. A second correction unit 782 determines the offset value used for adjusting the image write start timing of each of the plurality of image forming stations according to the measured inclination. The offset value is, in other words, a value for adjusting, relative to the write start timing of the reference color, the write start timing of another color. A decision unit 783 decides whether or not the offset values determined by the second correction unit 782 are greater than a threshold value. A steering unit 784 drives the steering motor 205 according to the result of the detection by the belt edge sensor 751, thereby adjusting the position of the side edge of the intermediate transfer belt 711.
Based on the result of the detection by the belt edge sensor 751, the calculation unit 733 recognizes that the intermediate transfer belt 711 has moved toward the +α direction from the reference position. The calculation unit 733 drives the steering motor 205 to move the steering roller 713 toward the +β direction, thereby moving the intermediate transfer belt 711 toward the −α direction. When detecting that the intermediate transfer belt 711 has moved toward the −α direction from the reference position, the calculation unit 733 drives the steering motor 205 to move the steering roller 713 toward the −β direction, thereby moving the intermediate transfer belt 711 toward the +α direction. By this steering control, the intermediate transfer belt 711 is controlled so as not to deviate from the reference position and reach a side edge of the steering roller 713.
Next, a description is given to the belt inclination detection. The belt edge sensor 751 has two functions, namely the function of belt steering control and the function of the belt inclination detection. The belt edge sensor 750 may be used only for detecting the inclination of the belt. A belt inclination calculation unit included in the second correction unit 782 detects the inclination of the belt in the main scanning direction based on two detection results, namely the detection result from the belt edge sensor 750 and the detection result from the belt edge sensor 751.
Consequently, the amount of the light guided to the photosensor 305 is reduced by being blocked by the flag 309, and in contrast the amount of light guided to the photosensor 306 increases.
In
Next, a description is given to the color registration adjustment. The color registration adjustment is processing of forming color patterns for the color registration adjustment on the intermediate transfer belt 711, thereby detecting the amount of color misregistration relative to the reference color for each of the other three colors, and then adjusting the write start position (write start timing) of each of the three colors so as to reduce the amount of color misregistration. This color registration adjustment can be divided into two types of processing, namely processing for correcting the color misregistration caused by distortion of the entire framework of the image forming apparatus, distortion of the shape of the laser scanner unit, etc., and processing for correcting the color misregistration caused by the meandering of the intermediate transfer belt 711.
The color registration adjustment using the color registration patterns takes into consideration the distortion in the entire framework, and accordingly determines, from among the four colors of the image forming units, the color of the image forming unit located in the middle to be the reference color. In the present embodiment, magenta is determined to be the reference color from among yellow, magenta, cyan, and black. In other words, relative to the forming position of the magenta toner image as the reference position, the forming positions of the toner images having the other three colors (yellow, cyan, and black) are adjusted to be their respective ideal positions. In other words, the write start timings of the toner images having the other three colors are adjusted.
While the image forming unit 701 is in the standby state or is executing a job, the calculation unit 733 forms color registration patterns on the photosensitive members 708Y, 708M, 708C, and 708K, and performs primary transfer of the color registration patterns to the intermediate transfer belt 711. The calculation unit 733 reads the color registration patterns by using the color misregistration sensor 735 disposed to oppose the intermediate transfer belt 711, and obtains the positional relationship among the colors yellow, magenta, cyan, and black. Based on the positional relationship among the colors, the calculation unit 733 calculates the amount of the misregistration in the main scanning direction and the amount of the misregistration in the sub-scanning direction for each of the colors yellow, cyan, and black relative to the color magenta, and calculates offset values used for correcting the misregistration in the main scanning direction and offset values used for correcting the misregistration in the sub-scanning direction.
Assume that the color registration patterns are formed on the intermediate transfer belt 711 in the manner shown in
Δdmy=dy2−dy1 (1)
The calculation unit 733 calculates the amount of the misregistration of cyan and black as well in the same manner. The calculation unit 733 also determines the offset values so as to reduce the amount of the misregistration of each color to zero. These offset values are set to the exposure control units 811Y, 811M, 811C, and 811K, and thus the color misregistration of yellow, cyan, and black will be corrected.
Next, a description is given to the color registration adjustment by correcting the color misregistration caused by meandering of the belt.
If the intermediate transfer belt 711 is inclined as shown in
g=Δd1 (mm)/d1(mm) (2)
As shown in
g′=Δd2 (mm)/d2 (mm) (3)
Since the inclinations of the belt should be the same, g=g′ is satisfied.
Δd1 (mm)/d1 (mm)=Δd2 (mm)/d2 (mm) (4)
Therefore, the amount Δd1 of the misregistration in the main scanning direction of yellow relative to black, which is caused by inclination of the intermediate transfer belt 711, can be obtained by the following equation.
Δd1=(Δd2×d1)/d2 (mm) (5)
Thus, the amount Δd1 of the misregistration can be obtained by detecting the inclination by using the belt edge sensor 750 and the belt edge sensor 751. The calculation unit 733 calculates offset value ta for adjusting the write start timing by dividing the misregistration amount Δd1 by the scanning speed v of the laser beam on the photosensitive member 708Y for yellow, and sets the offset value ta to the exposure control unit 811Y. The exposure control unit 811Y corrects the write start timing of yellow to be earlier by the offset value ta, which has been set by the calculation unit 733.
Next, a description is given to the color registration adjustment by correcting the color misregistration caused by meandering of the belt, with respect to each color. Here, assume that the transfer position of the yellow toner image, which is formed first, is the reference position.
As shown in
The amount of the misregistration in the main scanning direction of each color can be obtained by using the equation (5).
Δd1m=(Δd2×d1m)/d2 (mm)
Δd1c=(Δd2×d1c)/d2 (mm)
Δd1k=(Δd2×d1k)/d2 (mm)
d1m denotes the distance between the photosensitive member 708Y for yellow and the photosensitive member 708M for magenta. d1c denotes the distance between the photosensitive member 708Y for yellow and the photosensitive member 708C for cyan. d1k denotes the distance between the photosensitive member 708Y for yellow and the photosensitive member 708K for black. Δd1m denotes the amount of the misregistration in the main scanning direction of magenta relative to yellow. Δd1c denotes the amount of the misregistration in the main scanning direction of cyan relative to yellow. Δd1k denotes the amount of the misregistration in the main scanning direction of black relative to yellow. The calculation unit 733 shifts the write start timings of the magenta, cyan, and black toner images by time (offset value) corresponding to Δd1m, Δd1c, and Δd1k so as to reduce these misregistration amounts to zero. Consequently, the color misregistration can be reduced even if the intermediate transfer belt 711 rotating is inclined relative to the ideal direction. In addition, since this color registration adjustment does not depend on the timing of the image formation, the color misregistration can be reduced appropriately with respect to even the color of the toner image that is formed first, from among a plurality of colors.
At S2012, the calculation unit 733 detects the inclination of the intermediate transfer belt 711 by using the belt edge sensor 750 and the belt edge sensor 751, in order to calculate the offset value used for correcting the color misregistration of the C toner image. At S2013, the calculation unit 733 calculates the offset value Δd1c for correcting the misregistration of the write start position of the C toner image caused by the meandering of the intermediate transfer belt 711, based on the inclination thus detected. At S2014, the calculation unit 733 decides whether the offset value is greater than a threshold value or not. When the offset value is greater than the threshold value, the calculation unit 733 advances to S2016, and sets 1 to the abnormality flag, which indicates that the offset value is abnormal. Meanwhile, if the offset value is not greater than the threshold value, the calculation unit 733 advances to S2015, and sets the calculated offset value to the exposure control unit 811C. Subsequently, at S2017, the calculation unit 733 controls the exposure control unit 811C, thereby forming the C toner image.
At S2018, the calculation unit 733 detects the inclination of the intermediate transfer belt 711 by using the belt edge sensor 750 and the belt edge sensor 751, in order to calculate the offset value used for correcting the color misregistration of the K toner image. At S2019, the calculation unit 733 calculates the offset value Δd1k for correcting the misregistration of the write start position of the K toner image caused by the meandering of the intermediate transfer belt 711, based on the inclination thus detected. At S2020, the calculation unit 733 decides whether the offset value is greater than a threshold value or not. When the offset value is greater than the threshold value, the calculation unit 733 advances to S2022, and sets 1 to the abnormality flag, which indicates that the offset value is abnormal. Meanwhile, if the offset value is not greater than the threshold value, the calculation unit 733 advances to S2021, and sets the calculated offset value to the exposure control unit 811K. Subsequently, at S2023, the calculation unit 733 controls the exposure control unit 811K, thereby forming the K toner image.
At S2024, the calculation unit 733 decides whether there is any unformed image with respect to the job that is being executed, based on the job data. If there is an image to be formed next, the calculation unit 733 advances to S2003. If the formation of every image has been completed, the calculation unit 733 advances to S2025.
At S2025, the calculation unit 733 decides whether or not the abnormality flag is 1 and an automatic adjustment flag is 1. The automatic adjustment flag is a flag used for management as to whether to automatically control the position of the intermediate transfer belt 711 when the offset value is greater than the threshold value. When set to 1, the automatic adjustment flag indicates that the position of the intermediate transfer belt 711 is reset automatically, and when set to 0, the automatic adjustment flag indicates that the resetting of the position of the intermediate transfer belt 711 is not performed automatically. In other words, when the automatic adjustment flag is 0, the calculation unit 733 performs the resetting after an explicit instruction is input by the user. When the abnormality flag is not 1 or the automatic adjustment flag is not 1, the calculation unit 733 skips the resetting of the position of the intermediate transfer belt 711, and advances to S2027. On the other hand, when the abnormality flag is 1 and the automatic adjustment flag is 1, the calculation unit 733 advances to S2027. At S2027, the calculation unit 733 resets the position of the intermediate transfer belt 711 by driving the steering motor 205 so that the intermediate transfer belt 711 rotates stably. For example, the calculation unit 733 acquires an output value output by the belt edge sensor 751 while driving the intermediate transfer belt 711, and decides whether the intermediate transfer belt 711 is meandering or not. The calculation unit 733 changes the position of the intermediate transfer belt 711 by controlling the steering motor 205, and finds the position at which the meandering of the intermediate transfer belt 711 is minimized. Note that the calculation unit 733 determines the position that minimizes the meandering to be the central position of the belt deviation control. At S2027, the calculation unit 733 stops the belt drive motor 202 to stop the intermediate transfer belt 711.
At S2028, the calculation unit 733 decides whether or not the abnormality flag is 1 and an automatic adjustment flag is 0. If the abnormality flag is not 1, the calculation unit 733 ends this processing. When the abnormality flag is 1 and the automatic adjustment flag is 0, the calculation unit 733 advances to S2029. At S2029, the calculation unit 733 may display a message 999 as shown in
As described above, according to the present embodiment, the first correction unit 781 detects the color misregistration caused by environmental change or a problem associated with the durability by using color patterns, and determines the offset values used for adjusting the write start timings of the images. Also, the second correction unit 782 determines the offset values (adjustment values) used for adjusting the write start timings of the images in order to correct the color misregistration caused by inclination of the intermediate transfer belt 711. Note that the offset values to be provided to the exposure control units may be modified according to the difference between the inclination at the time the first correction unit 781 determines the offset values and the inclination at the time the second correction unit 782 determines the offset values. In the present embodiment, it should be particularly noted that the reference color used for the determination of the offset values by the first correction unit 781 is different from the reference color used for the determination of the offset values by the second correction unit 782. This configuration allows for more accurate color registration adjustment not depending on the start timing of the image formation with respect to all of the plurality of colors. The reference color for the second correction unit 782 is, among the plurality of colors different from each other, the color that is used first for forming a toner image. In the present embodiment, the Y toner image is formed first, followed by the M, C, and K toner images in this order. Therefore, yellow is the color that is used first for forming a toner image. The reference color for the first correction unit 781 is, among the colors assigned to the plurality of image forming stations, the color of the second or later toner image in the order of formation, but is not the color of the last toner image in the order of formation. In the present embodiment, the Y toner image is formed first, followed by the M, C, and K toner images in this order. Therefore, magenta and cyan can be the reference color.
When the decision unit 783 decides that the offset values determined by the second correction unit 782 are greater than the predetermined threshold value (No at S2008, No at S2014, No at S2020), the second correction unit 782 does not necessarily set the offset values to the plurality of image forming stations. This is because if the offset values are too large, it means that the inclination of the intermediate transfer belt 711 is too large, and it is desired to adjust the inclination of the intermediate transfer belt 711. In other words, when the offset values determined by the second correction unit 782 are greater than the threshold value, the steering unit 784 drives the steering motor 205 so as to reduce the inclination of the intermediate transfer belt 711. As described for S2029, when the offset values determined by the second correction unit 782 are greater than the threshold values, a message prompting for adjustment of the inclination of the intermediate transfer belt 711 may be displayed on the display unit 610.
As described with reference to
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2014-107482, filed May. 23, 2014 which is hereby incorporated by reference herein in its entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014-107482 | May 2014 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 8023873 | Nakatsu | Sep 2011 | B2 |
| 20120229585 | Higashiyama | Sep 2012 | A1 |
| Number | Date | Country |
|---|---|---|
| 2008-281833 | Nov 2008 | JP |
| 2010-085422 | Apr 2010 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20150338760 A1 | Nov 2015 | US |
