Patent Grant
9335707
This application is based on Japanese Patent Application No. 2012-206690 filed on Sep. 20, 2012, the content of which is incorporated herein by reference.
1. Field of the Invention
The present invention relates to an image forming apparatus including a rotating member adapted to support an image and a transmission mechanism that transmits a drive force generated by a drive source to the rotating member.
2. Description of Related Art
An image forming apparatus as mentioned above is disclosed in Japanese Patent Laid-Open Publication No. 2010-102247, for example. In Japanese Patent Laid-Open Publication No. 2010-102247, the transmission mechanism includes a drum drive gear, a coupling disc, an encoder head, and a control circuit.
The drum drive gear is positioned coaxially with a rotating shaft of a photoreceptor drum, which is an example of the rotating member. The coupling disc engages with the photoreceptor drum and the drum drive gear. The encoder head detects information about the rotation of the coupling disc. The control circuit controls the rotation of the photoreceptor drum on the basis of the rotation information detected by the encoder head.
Here, the drum drive gear and the coupling disc engage with each other via a viscoelastic member. By passive vibration control using the viscoelastic member, a resonant frequency of the photoreceptor drum or the like is shifted from original value, thereby reducing transmissibility of input vibrations having the certain frequency.
However, such passive vibration control simply shifts the resonant frequencies, so that resonance characteristics of other frequency bands (e.g., a low-frequency band) persist. The persistence of the resonance characteristics causes a problem where conventional drive force transmission mechanisms cannot suppress the vibration of the photoreceptor drum (i.e., the rotating member) upon input of vibration that is difficult to predict.
An image forming apparatus according to an embodiment of the present invention includes: a rotating member adapted to support an image; a first drive source configured to generate a drive force; a transmission mechanism configured to transmit the drive force generated by the first drive source toward the rotating member, the mechanism including an upstream gear and a downstream gear configured to receive the drive force from the upstream gear; a sensor configured to output a signal indicating a rotational status of the rotating member; a control circuit configured to generate a control signal appropriate for non-uniform rotation of the rotating member, on the basis of the signal outputted by the sensor; and an actuator configured to cause a rotation axis of the first drive source or the transmission mechanism to pivot, in accordance with the control signal generated by the control circuit, thereby changing a force with which the upstream gear pushes the downstream gear into rotation such that the non-uniform rotation of the rotating member is cancelled out.
Hereinafter, an image forming apparatus according to an embodiment of the present invention will be described.
First, the X-, Y-, and Z-axes shown in some figures will be defined. The X-axis represents the left-right (width) direction of the image forming apparatus, and the Y-axis represents the front-back direction of the image forming apparatus. Moreover, the Z-axis represents the top-bottom (height) direction of the image forming apparatus.
Furthermore, for some components, the suffix A, B, C, or D is assigned at the ends of their reference numerals. The suffixes A, B, C, and D represent yellow (Y), magenta (M), cyan (C), and black (Bk), respectively. For example, an imaging unit 11A is intended to mean an imaging unit 11 for yellow. Moreover, in the case where none of the suffixes is assigned to a reference numeral which can be assigned any one of the suffixes, the reference numeral is intended for collective reference to all colors. For example, an imaging unit 11 is intended to mean an imaging unit for any one of the colors Y, M, C, and Bk.
The supply unit 1 has unprinted sheets S stacked in an unillustrated supply tray. From the supply tray, the sheets S are fed one by one from the top by a supply roller (not shown) that is rotating, toward the uppermost stream of a feeding path P (see the long dashed short dashed line).
The image forming unit 2 includes imaging units 11A to 11D. The image forming unit 2 further includes a scanning optical system 12, primary transfer rollers 13A to 13D, an intermediate transfer belt 14, rollers 15 and 16, a secondary transfer roller 17, a fusing unit 18, and an ejection roller pair 19.
The imaging units 11 are arranged in the left-right direction immediately below the intermediate transfer belt 14 to be described later. Each imaging unit 11 has a photoreceptor drum 110, which is a typical example of the rotating member. There are arranged different types of components around each photoreceptor drum 110, such that one component from each type is provided, e.g., one charger, one developer, etc., are arranged around the photoreceptor drum 110. Each charger charges the circumferential surface of the photoreceptor drum 110 for its corresponding color. The charged circumferential surface of the photoreceptor drum 110 is irradiated with an optical beam for the corresponding color generated by the scanning optical system 12. As a result, an electrostatic latent image in the corresponding color is formed and supported on the circumferential surface of the photoreceptor drum. The developer supplies toner onto the circumferential surface of the photoreceptor drum for the corresponding color and develops the electrostatic latent image. As a result, a toner image in the corresponding color is formed on the circumferential surface of the photoreceptor drum.
The intermediate transfer belt 14 is stretched around the rollers 15 and 16, etc., in a looped form, so as to contact the circumferential surfaces of the photoreceptor drums. The intermediate transfer belt 14 is rotated in the direction of arrow α by the rollers 15 and 16 being rotated by drive forces provided by unillustrated motors.
Each primary transfer roller 13 is disposed so as to be opposed vertically to the photoreceptor drum for its corresponding color with respect to the intermediate transfer belt 14. The primary transfer roller 13 transfers a toner image supported on the photoreceptor drum for the corresponding color onto the intermediate transfer belt 14 moving in the direction of arrow α, approximately in the same position (i.e., primary transfer). Ultimately, a composite toner image (i.e., a full-color image) composed of overlapping toner images in their respective colors is formed on the surface of the intermediate transfer belt 14. Moreover, the composite toner image supported on the intermediate transfer belt 14 is carried to the position of a transfer nip to be described later.
Furthermore, the secondary transfer roller 17 is disposed so as to be opposed to the roller 16 with respect to the intermediate transfer belt 14. The secondary transfer roller 17 and the intermediate transfer belt 14 are in contact with each other so that there is a transfer nip formed therebetween. A sheet S fed by the supply unit 1 as mentioned above is introduced to the transfer nip. Moreover, a transfer bias voltage is applied to the secondary transfer roller 17, so that the composite toner image is attracted to the secondary transfer roller 17 by the transfer bias voltage, and is transferred onto the sheet S introduced to the transfer nip (secondary transfer). The sheet S subjected to the secondary transfer is forwarded from the transfer nip toward the fusing unit 18.
Upon the introduction of the sheet S subjected to secondary transfer, the fusing unit 18 heats and presses the sheet S, thereby fixing the composite toner image on the sheet S. The sheet S subjected to the fixing process is forwarded as a print from the fusing unit 18 being rotated, and thereafter ejected by the ejection roller pair 19 being rotated counterclockwise, into the output tray 3 provided above the image forming unit 2.
In
The motor 21 is secured to, for example, the frame of the image forming unit 2. The motor 21 rotates its own rotating shaft under control of a control circuit 28.
Note that to reduce the number of parts, in some cases, the motor 21 might be shared between photoreceptor drums 110 for a plurality of colors. In such a case, a drive system for at least one of the colors Y, M, C, and Bk has the configuration shown in
The transmission mechanism 22 consists of a gear 22a, which is provided on the rotating shaft of the motor 21, a small-diameter gear 22b, a two-stage gear unit 22c, and a large-diameter gear 22d.
The gear 22a is provided on the rotating shaft of the motor 21 so as to rotate in synchronization therewith. As a result, the drive force generated by the motor 21 is inputted to the transmission mechanism 22. The gear 22a is provided at the uppermost stream of the transmission mechanism 22, so as to transmit the inputted drive force from the motor 21, toward the downstream. The drive force is used at least for rotating the photoreceptor drum 110 for a corresponding color.
The small-diameter gear 22b is provided immediately downstream from the gear 22a, so as to mesh with the gear 22a. The small-diameter gear 22b is rotated about its own shaft by the drive force transmitted from the gear 22a.
The two-stage gear unit 22c is provided immediately downstream from the small-diameter gear 22b, and includes an input gear and an output gear. The input gear and the output gear are provided coaxially. Moreover, in the example illustrated in the figure, the input gear has a larger diameter than the output gear. The input gear meshes with the small-diameter gear 22b, and is rotated about the shaft of the two-stage gear unit 22c by the drive force transmitted by the small-diameter gear 22b. On the other hand, the output gear is rotated about the two-stage gear unit 22c at the same angular velocity as the input gear.
The large-diameter gear 22d is provided immediately downstream from the two-stage gear unit 22c. In the present embodiment, the large-diameter gear 22d is provided at the lowermost stream of the transmission mechanism 22. The large-diameter gear 22d meshes with the output gear of the two-stage gear unit 22c, so as to be rotated about its own shaft by the drive force transmitted by the output gear.
The joint member 23 has an approximately cylindrical shape. The joint member 23 is fixed at one end to the shaft of the large-diameter gear 22d. Moreover, the joint member 23 has a protrusion or a groove formed at the other end. The joint member 23 is rotated at the same rotational speed as the large-diameter gear 22d.
The coupling member 24 has an approximately cylindrical shape. The coupling member 24 has a protrusion or a groove formed at one end so that it can engage with the protrusion or groove of the joint member 23. Moreover, the coupling member 24 is fixed at the other end to the rotating shaft of the photoreceptor drum 110.
With the above configuration, the drive force generated by the motor 21 is transmitted to the photoreceptor drum 110 via the transmission mechanism 22, the joint member 23, and the coupling member 24. The photoreceptor drum 110 is rotated at a predetermined rotational speed by the drive force transmitted thereto.
Such a drive system has a problem in that non-uniform rotation (i.e., a variation in rotational speed) occurs due to the vibration generated by meshing of the gears 22a to 22d in the transmission mechanism 22 and also due to the vibration per rotational cycle of the photoreceptor drums 110.
To suppress such non-uniform rotation, the drive system includes an encoder 25, a hinge member 26, a piezoelectric element 27, which is a typical example of an actuator, and a control circuit 28, as shown in
The encoder 25 is a sensor that outputs a signal indicating the rotational status of the photoreceptor drum 110. More specifically, the encoder 25 outputs a signal indicating non-uniform rotation for a rotational cycle of the photoreceptor drum 110. The encoder 25 thus configured is attached to the rotating shaft of the photoreceptor drum 110.
The hinge member 26 is a plate-like member having a predetermined shape (in the example of
The piezoelectric element 27 is, for example, of a laminated type, and it extends and contracts in the direction of the lamination upon application of a voltage. Here, the amount of extension/contraction of the piezoelectric element 27 is about 5 μm. The piezoelectric element 27 is preferably positioned as described below. The piezoelectric element 27 is fixed at one end in the direction of the lamination to, for example, the frame of the image forming apparatus. Moreover, the piezoelectric element 27 is fixed at the other end in the direction of the lamination to the hinge member 26. In addition, the piezoelectric element 27 is oriented so as to extend and contract in direction γ perpendicular to line β extending between the centers of the through-holes 26a and 26b.
By positioning the piezoelectric element 27 as above, the hinge member 26 vibrates clockwise or counterclockwise about the shaft of the large-diameter gear 22d, as indicated by arrow 8, in synchronization with the extension and contraction of the piezoelectric element 27. The vibration instantaneously strengthens or weakens the force with which the teeth of the output gear of the two-stage gear unit 22c push the teeth of the large-diameter gear 22d. This instantaneously accelerates or decelerates the rotational speed of the large-diameter gear 22d, hence the rotational speed of the photoreceptor drum 110. Here, in the case where the amount of extension/contraction of the piezoelectric element 27 is about 5 μm, the photoreceptor drum 110 is rotated instantaneously faster or slower within the range of ±1 μm in the rotational direction.
The control circuit 28 is configured by a processor, random-access memory (RAM), etc. To suppress non-uniform rotation, the control circuit 28 receives an output signal from the encoder 25. From the received signal, the control circuit 28 reads information about non-uniform rotation for a rotational cycle of the photoreceptor drum 110. The control circuit 28 generates a control signal in opposite phase to the non-uniform rotation according to the obtained information, and applies the signal to the piezoelectric element 27.
Note that the control signal does not have to be in complete opposite phase to non-uniform rotation, and it simply deals with non-uniform rotation so that the actuator (i.e., the piezoelectric element 27) can eliminate the non-uniform rotation substantially. This also applies to second through fifth configuration examples to be described later.
Furthermore, the control signal may be updated every rotational cycle of the photoreceptor drum 110, or it may be left unupdated for more than one rotation for which the degree of non-uniform rotation can be considered completely insignificant.
In the present drive system, because of the positions of the hinge member 26 and the piezoelectric element 27, as well as the control signal from the control circuit 28, the transmission mechanism 22 experiences a rotational variation in opposite phase to non-uniform rotation for a rotational cycle of the photoreceptor drum 110. As a result, the non-uniform rotation of the photoreceptor drum 110 can be cancelled out by the rotational variation caused to the transmission mechanism 22, leading to suppression of the non-uniform rotation of the photoreceptor drum 110.
Here, it is assumed that none of the hinge member 26, the piezoelectric element 27, and the control signal is provided. In such a case, the teeth of the output gear in the two-stage gear unit mesh with the teeth of the large-diameter gear without jostling or coming out of contact with each other, as shown at the top right panel of
On the other hand, in the case of the drive system shown in
Assuming here that the rotation angle of the large-diameter gear 22d is Y, and the rotation angle of the hinge member 26 is X, Y is represented by equation (1) below:
Y=(Z4/Z3)·(Z2/Z1)·X (1),
where Z1 is the number of teeth of the large-diameter gear 22d, Z2 is the number of teeth of the output gear in the two-stage gear unit 22c, Z3 is the number of teeth of the input gear in the two-stage gear unit 22c, and Z4 is the number of teeth of the small-diameter gear 22b.
In the case where there is an increase in the rotational speed of the photoreceptor drum 110, as illustrated at the bottom center panel of
Note that in the state shown at the bottom right panel of
Drive systems without vibration control are prone to non-uniform rotation (a variation in speed) every rotational cycle of the photoreceptor drum, as shown at the top panel of
Furthermore, in general, the drive system has such a frequency characteristic that the level of vibration transmission varies depending on an input vibration frequency. A quantified version of such a frequency characteristic is called a frequency response function. In the frequency response function, the frequency at which the level of vibration transmission is maximized is a resonant frequency, and the level of vibration transmission at the resonant frequency is called resonance magnification.
In the case of the drive system without vibration control, the level of vibration transmission for the drive system peaks at the resonant frequency, as indicated by curve C3. For the conventional drive system with passive vibration control, for example, the resonant frequency of the drive system is shifted to the lower side of the frequency, and the level of vibration transmission is reduced, as indicated by curve C2. Accordingly, upon input of vibration that is not expected by design, the passive vibration control, in some cases, might not be able to suppress the vibration completely. On the other hand, as for the drive system of the present embodiment indicated by curve C1, the control circuit 28 reads information about non-uniform rotation of the photoreceptor drum 110 from an output signal of the encoder 25. Through the piezoelectric element 27, the control circuit 28 provides the transmission mechanism 22 with a rotational variation in opposite phase to the non-uniform rotation according to the obtained information. As a result, the image forming apparatus can appropriately suppress vibration within a wide range of frequencies.
Furthermore, for the present drive system, vibration control is performed by a simple configuration using the encoder 25, the piezoelectric element 27, and the control circuit 28, which can contribute to cost reduction of the image forming apparatus.
The second configuration example shown in
The hinge member 31 is a plate-like member having a predetermined shape. The hinge member 31 has a first through-hole 31a and a second through-hole 31b provided therein, the first through-hole 31a has inserted therein the shaft of the large-diameter gear 22d located on the downstream side, and the second through-hole 31b has inserted therein the shaft of the two-stage gear unit 22c located upstream from the large-diameter gear 22d. The shaft of the large-diameter gear 22d is not fixed to the first through-hole 31a, and the shaft of the two-stage gear unit 22c is not fixed to the second through-hole 31b.
Here, the direction from the center of the through-hole 31a toward the center of the through-hole 31b is denoted by β. The hinge member 31 is toothed at the edge in direction β. The toothed edge will be referred to below as a rack gear 31c.
The motor 32 is preferably an ultrasonic motor, assuming that the drive system receives high-frequency vibration. The motor 32 rotates its own rotating shaft in response to a control signal from the control circuit 33. The rotating shaft has a gear 32a provided thereon. The gear 32a meshes with the rack gear 31c. Here, for the dimensions and the number of teeth, the gear 32a and the rack gear 31c are designed to have values such that the photoreceptor drum 110 can be rotated faster or slower within the range of about 1 μm in the rotational direction.
With the above configuration, the hinge member 31 pivots clockwise or counterclockwise on the shaft of the large-diameter gear 22d, as indicated by arrow δ, in synchronization with the forward or backward rotation of the motor 32. This pivoting action instantaneously accelerates or decelerates the rotational speed of the photoreceptor drum 110 in the same manner as described in conjunction with the first configuration example.
The control circuit 33 is configured by a processor, RAM, etc. To suppress non-uniform rotation, the control circuit 33 generates a control signal in opposite phase to non-uniform rotation for a rotational cycle of the photoreceptor drum 110, on the basis of an output signal from the encoder 25, and the control circuit 33 outputs the generated signal to the motor 32.
In the present drive system, through the hinge member 31 and the motor 32, the transmission mechanism 22 receives a rotational variation in opposite phase to non-uniform rotation for a rotational cycle of the photoreceptor drum 110, in accordance with the control signal from the control circuit 33. Thus, as in the first configuration example, the non-uniform rotation of the photoreceptor drum 110 can be cancelled out by the rotational variation caused to the transmission mechanism 22, leading to suppression of the non-uniform rotation of the photoreceptor drum 110.
The transmission mechanism 41 differs from the transmission mechanism 22 in
The two-stage gear unit 41a has an input gear and an output gear. The input gear and the output gear are provided coaxially with each other. The input gear meshes with the small-diameter gear 22b provided upstream therefrom, and is caused to rotate about the shaft of the two-stage gear unit 41a by a drive force transmitted from the small-diameter gear 22b. On the other hand, the output gear is a helical gear that rotates about the shaft of the two-stage gear unit 41a at the same angular velocity as the input gear. The two-stage gear unit 41a thus configured is attached to, for example, the frame of the image forming apparatus so that it can be displaced in the direction of the rotating shaft. The amount of such displacement is about 5 μm.
The large-diameter gear 42b is a helical gear that meshes with the output gear of the two-stage gear unit 41a provided upstream therefrom and is caused to rotate about its own shaft by a drive force transmitted from the output gear. Here, the large-diameter gear 42b is attached to, for example, the frame of the image forming apparatus, such that, unlike the two-stage gear unit 41a, it cannot be displaced in the direction of its own rotating shaft.
The piezoelectric element 42 is, for example, of a laminated type, and it extends and contracts in the direction of the lamination (indicated by arrow β in the figure) upon application of a voltage. The amount of extension/contraction of the piezoelectric element 42 is about 5 μm. The piezoelectric element 42 thus configured is preferably positioned as described below. The piezoelectric element 42 is fixed at one end in the direction of the lamination to, for example, the frame of the image forming apparatus. Moreover, the piezoelectric element 42 is fixed at the other end in the direction of the lamination to the two-stage gear unit 41a. In addition, the piezoelectric element 42 is oriented so as to extend and contract in the direction of the rotating shaft of the two-stage gear unit 41a (the direction of arrow γ).
With the above configuration, the two-stage gear unit 41a vibrates in the direction of its own rotational shaft, in synchronization with the extension and contraction of the piezoelectric element 42. Due to this vibration, the tooth of the output gear in the two-stage gear unit 41a located on the upstream side instantaneously pushes the tooth of the large-diameter gear 41b located downstream therefrom, in the rotational direction of the large-diameter gear 41b, or it instantaneously comes out of contact therewith. Note that the displacement of the large-diameter gear 41b in the direction of the rotating shaft is restricted. Consequently, the foregoing action instantaneously accelerates or decelerates the rotational speed of the large-diameter gear 41b, hence the rotational speed of the photoreceptor drum 110. In this manner, in the third configuration example, as in the first configuration example, the rotational speed of the photoreceptor drum 110 is accelerated or decelerated instantaneously.
The control circuit 43 is configured by a processor, RAM, etc. To suppress non-uniform rotation, the control circuit 43 generates a control signal in opposite phase to non-uniform rotation for a rotational cycle of the photoreceptor drum 110, on the basis of an output signal from the encoder 25, and the control circuit 43 applies the generated signal to the piezoelectric element 42.
In the present drive system, through the piezoelectric element 42, the transmission mechanism 41 receives a rotational variation in opposite phase to non-uniform rotation for a rotational cycle of the photoreceptor drum 110, in accordance with the control signal from the control circuit 43. Thus, as in the first configuration example, the non-uniform rotation of the photoreceptor drum 110 can be cancelled out by the rotational variation caused to the transmission mechanism 41, leading to suppression of the non-uniform rotation of the photoreceptor drum 110.
The piezoelectric element 51 is, for example, of a laminated type, and it extends and contracts in the direction of the lamination (indicated by arrow β in the figure) upon application of a voltage. The amount of extension/contraction of the piezoelectric element 51 is about 5 μm. The piezoelectric element 51 thus configured is preferably positioned as described below. The piezoelectric element 51 is fixed at one end in the direction of the lamination to, for example, the frame of the image forming apparatus. Moreover, the piezoelectric element 51 is fixed at the other end in the direction of the lamination to an attachment plate 21a of the motor 21.
With the above configuration, the attachment plate 21a pivots on the rotating shaft of the small-diameter gear 22b provided downstream from the gear 22a, in synchronization with the extension and contraction of the piezoelectric element 51. Due to this pivoting action, the tooth of the gear 22a located on the upstream side instantaneously pushes the tooth of the small-diameter gear 22b located downstream therefrom, in the rotational direction of the small-diameter gear 22b, or it instantaneously comes out of contact therewith. The variation in speed of the small-diameter gear 22b due to such vibration is transmitted to the large-diameter gear 22d, and further to the photoreceptor drum 110. As a result, the rotational speed of the photoreceptor drum 110 is accelerated or decelerated instantaneously. In other words, in the fourth configuration example, the rotational speed of the photoreceptor drum 110 is accelerated or decelerated instantaneously, in the same manner as described in conjunction with the first configuration example.
The control circuit 52 is configured by a processor, RAM, etc. To suppress non-uniform rotation, the control circuit 52 generates a control signal in opposite phase to non-uniform rotation for a rotational cycle of the photoreceptor drum 110, on the basis of an output signal from the encoder 25, and the control circuit 52 applies the generated signal to the piezoelectric element 51.
In the present drive system, through the piezoelectric element 51, the transmission mechanism 22 receives a rotational variation in opposite phase to non-uniform rotation for a rotational cycle of the photoreceptor drum 110, in accordance with the control signal from the control circuit 52. Thus, as in the first configuration example, the non-uniform rotation of the photoreceptor drum 110 can be cancelled out by the rotational variation caused to the transmission mechanism 22, leading to suppression of the non-uniform rotation of the photoreceptor drum 110.
In the fourth configuration example, the piezoelectric element 51 extends and contracts to vibrate the attachment plate 21a of the motor 21. However, this is not restrictive, and the piezoelectric element 51 may vibrate a hinge member 61 fixed to the attachment plate 21a, as shown in
The foregoing has been described with respect to suppression of non-uniform rotation of the photoreceptor drum 110, which is a typical example of the rotating member. However, a similar technical problem might occur to the intermediate transfer belt 14 with a toner image supported thereon. Accordingly, each of the above configuration examples may be provided to suppress non-uniform rotation of the intermediate transfer belt 14, which is another example of the rotating member.
Although the present invention has been described in connection with the preferred embodiment above, it is to be noted that various changes and modifications are possible to those who are skilled in the art. Such changes and modifications are to be understood as being within the scope of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2012-206690 | Sep 2012 | JP | national |
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| Computer translation of JP2007-240687A to Masuda et al., publication date Sep. 20, 2007. |
| Notification of Reasons for Rejection dated Dec. 2, 2014 issued in the corresponding Japanese Patent Application No. 2012-206690 and English translation (7 pages). |
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| Number | Date | Country | |
|---|---|---|---|
| 20140079436 A1 | Mar 2014 | US |
