Patent Grant
9323200
1. Field of the Invention
The disclosures herein generally relate to an image forming apparatus.
2. Description of the Related Art
Japanese Published Patent Application No. H7-199561 discloses an image forming apparatus which performs a parameter correction process for correcting a control parameter so as to obtain a desired image quality based on a result of detecting image density of a toner image formed on a surface of an image carrier. The image forming apparatus obtains the toner image by developing an electrostatic latent image on a surface of a photoreceptor which is the image carrier using developer including toner and carrier. When the toner in the developer in a developing device is used for the developing, toner density in the developer decreases. Therefore, a control unit in the image forming apparatus supplies toner into the developing device by driving a toner supply device, when a result of the toner density detected by a toner density detection sensor that detects the toner density in the developer in the developing device becomes less than a predetermined target value. According to the above operation, the toner density in the developer is restored. However, even if the toner density is maintained at a constant level, when an environment (temperature or humidity) or a charge quantity of toner fluctuates, the image density of the toner image obtained by the developing may be greater than or less than the target value.
The control unit periodically performs a target value correction process as follows. That is, a test toner image for detecting the image density is formed on the surface of the photoreceptor, and the image density of the test toner image is detected by a reflection type photo sensor. Then, based on a difference between a result of detection and target image density, the target value of the toner density in the developer is corrected, thereby the target image density is obtained. According to the above configuration, even if the environment or the charge quantity of toner fluctuates, an image can be formed having the target image density.
However, in the above image forming apparatus, since test toner images are formed periodically, an amount of consumption of toner increases and the cost of operation rises.
It is a general object of at least one embodiment of the present invention to provide an image forming apparatus that substantially obviates one or more problems caused by the limitations and disadvantages of the related art.
In one embodiment, an image forming apparatus includes an image information acquisition unit that acquires image information; a toner image formation unit that forms, in response to a control parameter, a toner image on a surface of an image carrier based on the image information acquired by the image information acquisition unit; an image density detection unit that produces a detection result indicative of image density of the toner image formed on the surface of the image carrier; and a control unit that performs determination processing for determining whether to use a predetermined region in the toner image formed on the surface of the image carrier based on the image information for a detection of the image density of the toner image in parameter correction processing, and when the predetermined region is determined to be used for the detection of the image density in the determination processing, performs the parameter correction processing for correcting the control parameter used by the toner image formation unit based on the detection result so as to maintain the image density in the predetermined region within a predetermined range.
According to the present invention, a control parameter is corrected based on a result of detection for the image density of a toner image, which is formed based on an instruction by a user and is suitable for use for detecting the image density. Accordingly, without forming a test toner image dedicated for detecting the image density, the control parameter is corrected appropriately, thereby an inadequacy in the image density due to a fluctuation of the environment and a charge quantity of toner can be suppressed with a lower cost than that of the related art.
Other objects and further features of embodiments will be apparent from the following detailed description when read in conjunction with the accompanying drawings, in which:
In the following, embodiments of the present invention will be described with reference to the accompanying drawings.
In the following, an embodiment in which the present invention is applied to an electrophotographic printer as an image forming apparatus, which will be denoted simply as “printer” in the following, will be explained.
At first, a basic configuration of the printer according to the present embodiment will be explained.
The photoreceptor unit 2Y includes a drum-shaped photoreceptor 3Y as a latent image support body, a drum cleaning device 4Y, a neutralization device which is not shown, a charging device 5Y and the like. The charging device 5Y, as a charging means, uniformly charges by a charging roller 6Y a surface of the photoreceptor 3Y, shown in
Meanwhile, a charging means that makes another charging member such as a charging brush, instead of the charging roller 6Y, get close to or in contact with may be used. Moreover, a charging means such as a scorotoron charger that uniformly charges the photoreceptor 3Y by a charger method may be used. The surface of the photoreceptor 3Y uniformly charged by the charging device 5Y is exposed and scanned by laser light emitted from an optical writing unit 20 as a latent image forming means which will be described later, and supports an electrostatic latent image for Y toner.
In the above two agent container chambers which form a circulation route, a Y developing agent (not shown) which is a two-component developing agent including magnetic carrier and Y toner of a negative charge type is included. The first conveyor screw 8Y, rotationally driven by a driving means (not shown), conveys the Y developing agent in the first agent container chamber toward the near side in
The second conveyor screw 11Y in the second agent container chamber 14Y is rotationally driven by a driving means, which is not shown; thereby the Y developing agent is conveyed to the back side in
A part of the Y developing agent conveyed by the second conveyor screw 11Y is attracted to the surface of the developing sleeve 15Y by a magnetic force from the magnet roller 16Y. Then, after a layer thickness of the agent is regulated by the doctor blade 13Y arranged so as to maintain a predetermined gap with the surface of the developing sleeve 15Y, the agent is conveyed to a developing region opposing the photoreceptor 3Y, and the Y toner is attached to an electrostatic latent image for Y toner on the photoreceptor 3Y. According to this attachment, a Y toner image is formed on the photoreceptor 3Y. The Y developing agent which consumes Y toner for the developing is returned on the second conveyor screw 11Y by the rotation of the developing sleeve 15Y. Then, the Y developing agent conveyed to the end portion of the second agent container chamber 14Y by the second conveyor screw 11Y returns into the first agent container chamber 9Y through a communication port 19Y. In this way, Y developing agent is conveyed circularly in the developing unit 7Y.
A result of detection for the toner density of Y developing agent by the toner density sensor 10Y is sent as an electric signal to a control device which is not shown. This control device converts an output voltage from the toner density sensor 10Y into a toner density of the Y developing agent, and stores it in a not-shown RAM. Moreover, the control device converts output voltages from toner density sensors (10C, 10M and 10K) mounted on the developing units (7C, 7M and 7K) for C, M and K toners into toner densities of C, M and K developing agents, respectively. Meanwhile, the output voltage from the toner density sensor including the magnetic permeability sensor correlates with the toner density. The greater the toner density of the developing agent is, the lower the magnetic permeability of the developing agent is, and the output value from the toner density sensor decreases.
For the developing unit 7Y for Y toner, the result of detection for the toner density calculated based on the output voltage from the toner density sensor 10Y and a target value for control for the Y toner density stored in the RAM are compared. Then, a supply motor for Y toner in a toner supply device is driven for a length of time corresponding to an amount of Y toner which is supplied through a toner supply port based on the result of comparison. In this way, an appropriate amount of Y toner is supplied in the first agent container chamber 9Y to the Y developing agent in which they toner density has decreased due to the consumption of Y toner in the developing. Accordingly, the toner density of the Y developing agent in the second agent container chamber 14Y is maintained at around the target value for toner density. For developing agent in the developing unit 7C, 7M and 7K for the other colors, the toner density is maintained at around target value in the same way as above.
In
Below the image formation units 1Y, 1C, 1M and 1K, the optical writing unit 20 is arranged. The optical writing unit 20 transmits laser light L emitted based on image information onto the photoreceptors 3Y, 3C, 3M and 3K of the image formation units 1Y, 1C, 1M and 1K, respectively. Then, on the photoreceptors 3Y, 3C, 3M and 3K, electrostatic latent images for Y, C, M and K toners are formed, respectively.
Meanwhile, the optical writing unit 20 transmits the laser light L emitted from the light source, while deflecting it with a polygon mirror 21 rotationally driven by a motor, onto the photoreceptor 3Y, 3C, 3M and 3K via plural optical lenses and mirrors. Instead of the above configuration, a configuration with an LED array may be used.
Below the optical writing unit 20 a first paper feeding cassette 31 and a second paper feeding cassette 32 are arranged so as to be overlapped with each other in the vertical direction. In these paper feeding cassettes, recording paper sheets P which are recording media are stored as in a bundle of stacked recording paper sheets. A first paper feeding roller 31a and a second paper feeding roller 32a are in contact with the recording paper sheets P placed at tops of the respective bundles. When the first paper feeding roller 31a is rotationally driven in the counter clockwise direction in
In the paper feeding path 33, plural pairs of conveying rollers 34 are arranged. The recording paper sheet P fed into the paper feeding path 33 is conveyed from the bottom to the top of
At an end of the paper feeding path 33, a pair of resist rollers 35 is arranged. As soon as the resist roller pair 35 nips the recording paper sheet P fed by the pair of conveying rollers 34, the rotation of the resist roller pair 35 is stopped. Then, the pair of resist rollers 35 sends the recording paper sheet P to the secondary transferring nip, which will be described later, at an appropriate timing.
Above the processing image formation units 1Y, 1C, 1M and 1K, a transferring unit 40 which moves the intermediate transfer belt 41 endlessly in the counter-clockwise direction while stretching the intermediate transfer belt 41 is arranged. The transferring unit 40 includes, in addition to the intermediate transfer belt 41, a belt cleaning unit 42, a first bracket (not shown), a second bracket (not shown) and the like. Moreover, the transferring unit 40 also includes four primary transfer rollers 45Y, 45C, 45M and 45K, a secondary transfer backup roller 46, a driving roller 47, an auxiliary roller (not shown), a nip entering roller 49, and the like. The intermediate transfer 41 is stretched over these rollers, and moved endlessly in the counter-clockwise direction in
The four primary transfer rollers 45Y, 45C, 45M and 45K nip the intermediate transfer belt 41, moving endlessly, with the photoreceptors 3Y, 3C, 3M and 3K, respectively, and form primary transferring nips. Then, to the internal surface of the intermediate transfer belt 41, a transfer bias having a polarity (a plus in the present embodiment) opposite to that of the toner is applied. While the intermediate transfer belt 41 sequentially goes through the primary transferring nips for Y, C, M and K, the intermediate transfer belt 41 moves endlessly, and toner images of the colors, formed on the respective photoreceptors 3Y, 3C, 3M and 3K are primarily transferred to the external surface of the intermediate transfer belt 41 so that the images overlap each other. In this way, an overlapping toner image (in the following, denoted “four-color toner image”) is formed on the intermediate transfer belt 41.
The secondary transfer backup roller 46 nips the intermediate transfer belt 41 with a secondary transfer roller 50 which is arranged outside a loop of the intermediate transfer belt 41, and forms a secondary transferring nip. The pair of resist rollers 35, as described above, sends the recording paper sheet P nipped between the rollers to the secondary transferring nip at a timing synchronized with the four-color toner image on the intermediate transfer belt 41. The four-color toner image on the intermediate transfer belt 41 is secondarily transferred onto the recording paper sheet P in the secondary transferring nip under an influence from the secondary transfer electric field formed between the secondary transferring roller 50 on which a secondary transfer bias is applied and the secondary transfer backup roller 46 and from nip pressure. Along with a white color of the recording paper sheet P, a full color toner image is obtained.
On the intermediate transfer belt 41 after going through the secondary transferring nip, residual toner, not transferred onto the recording paper sheet P remains attached. This is cleaned by the belt cleaning unit 42. Meanwhile, the belt cleaning unit 42 holds a cleaning blade 42a in contact with a front surface of the intermediate transfer belt 41, and removes the residual toner by wiping the residual toner on the belt 41 with the blade 42a.
Meanwhile, the first bracket of the transferring unit 40 fluctuates in a predetermined rotation angle around a rotation axis of the auxiliary roller with an operation of ON and OFF for driving a solenoid which is not shown.
The printer according to the present embodiment, in the case of forming a monochromatic image, slightly rotates the first bracket in the counter clockwise direction in
Above the secondary transferring nip in
At a point where the fixing belt 64 is stretched over the heating roller 63, the pressing and heating roller 61 which is rotationally driven in the clockwise direction in
Outside the loop of the fixing belt 64, a temperature sensor which is not shown is arranged facing the front surface of the fixing belt 64 with a predetermined gap with it, and detects a temperature at the surface of the fixing belt 64 right before entering the fixing nip. A result of the detection is sent to a fixing power circuit which is not shown. The fixing power circuit controls ON and OFF for a supply of power to the heat source included in the heating roller 63 or the heat source included in the pressing and heating roller 61, based on the detection result of the temperature sensor. In this way, the temperature of the fixing belt 64 at the surface is maintained at about 140° C.
The recording paper sheet P, which goes through the secondary transferring nip, is separated from the intermediate transfer belt 41 and sent into the fixing unit 60. Then, while the recording paper sheet P is conveyed from the bottom to the top in
The recording paper sheet P, thus having the fixing process applied, is ejected to the outside after passing between rollers of a pair of paper ejecting rollers 67. On the top surface of the chassis of the printer, a stacking unit 68 is formed, and the recording paper sheets P ejected by the pair of paper ejecting rollers 67 are stacked sequentially on the stacking unit 68.
Above the transferring unit 40, four containers for toner, toner bottles 72Y, 72C, 72M and 72K, for storing respectively Y toner, C toner, M toner and K toner, are provided. The toners of respective colors in the toner bottles 72Y, 72C, 72M and 72K are supplied appropriately to the developing units 7Y, 7C, 7M and 7K of the image formation units 1Y, 1C, 1M and 1K by a toner supply device 70 (See
In
The holder unit 74Y, as shown in
As shown by an arrow X1 in
On the other hand, in the toner supply device 70 in a state where the toner bottle 72M is not attached, as shown by an arrow X2 in
On outer circumferences of head portions of the bottle units 73K, 73Y, 73C and 73M of the toner bottles 72K, 72Y, 72C and 72M, respectively, gear units, which are not shown, are formed. The gear units are covered by the holder units 74K, 74Y, 74C and 74M. However, in a part of the circumference of each of the holder units 74K, 74Y, 74C and 74M, a cutout, which is not shown, is formed to expose the gear unit partially, and a part of the gear unit is exposed from the cutout.
When the holder unit 74K, 74Y, 74C or 74M of the toner bottle 72K, 72Y, 72C or 72M is engaged with the bottle driving unit 96, a bottle driving gear, which is not shown, for K, Y, C or M provided in the bottle driving unit 96 is engaged with the gear unit of the bottle unit 73K, 73Y, 73C or 73M via the cutout. Then, the bottle driving unit for K, Y, C or M of the bottle driving unit 96 is rotationally driven by a driving system, which is not shown, thereby the bottle unit 73K, 73Y, 73C or 73M is rotationally driven on the holder unit 74K, 74Y, 74C or 74M.
In
The holder unit 74Y of the toner bottle is engaged with a hopper unit 76Y of the toner supply device. The hopper unit 76Y has a flat shape along a direction perpendicular to the surface of the drawing, and is located in front of the intermediate transfer belt 41 in
The Y toner sent from the bottle unit of the toner bottle to the folder unit 74Y is dropped into the hopper 76Y by its own weight. In the hopper unit 76Y, a flexible pressing film 78Y fixed on a rotatable rotating shaft member 77Y rotates with the rotating shaft member 76Y. On an inner wall of the hopper unit 76Y, a toner detection sensor 82Y including a piezoelectric element that detects a presence of Y toner in the hopper unit 76Y is fixed.
The pressing film 78Y made of polyethylene terephthalate (PET) presses the Y toner against a detection surface of the toner detection sensor 82Y along with its rotation. In this way, the toner detection sensor 82Y can detect the Y toner in the hopper 76Y reliably. The rotational driving of the bottle unit of the toner bottle is controlled so that the toner detection sensor 82Y detects the Y toner reliably. Therefore, as long as sufficient toner is in the bottle unit, a sufficient amount of the Y toner drops into the hopper 76Y via the holder unit 74Y from the bottle unit, and inside the hopper unit 76Y is filled with a sufficient amount of the Y toner. Assume that it is changed from the above state to a state where the Y toner is hardly detected by the toner detection sensor 82Y though the holder unit is frequently rotationally driven. Then, a control device, which is not shown, considers that an amount of the Y toner remaining in the bottle unit is small, and provides a user with an alarm of “toner near-end”.
To a lower part of the hopper unit 76Y, a lateral conveying pipe 79Y is connected. The Y toner in the hopper unit 76Y slides along a taper by its own weight and drops into the lateral conveying pipe 79Y. In the lateral conveying pipe 79Y, a toner supply screw 80Y is arranged. Along with a rotational driving of the toner supply screw 80Y, the Y toner is laterally conveyed along the longitudinal direction of the lateral conveying pipe 79Y.
To a first end part in the longitudinal direction of the lateral conveying pipe 79Y, a drop guide pipe 81Y is connected extending in the vertical direction. A bottom end of the drop guide pipe 81Y is connected to the toner supply port 17Y of the first agent container chamber 9Y of the developing unit 7Y. When the toner supply screw 80Y in the lateral conveying pipe 79Y rotates, the Y toner conveyed to the first end part in the longitudinal direction of the lateral conveying pipe 79Y drops into the first agent container chamber 9Y of the developing unit 7Y through the drop guide pipe 81Y and the toner supply port 17Y. In this way, the Y toner is supplied into the first agent container chamber 9Y. Moreover, the toners of the other colors (C, M and K) are supplied in the same manner.
The control device 100 includes a CPU (Central Processing Unit) as a computing means, a RAM (Random Access Memory) as a data storing means, a ROM (Read Only Memory) or the like. The control device 100 can perform various calculation processing, or can execute control programs, and stores control target values for density of Y, C, M and K toners, respectively, in the RAM.
A supply control unit 102 in the control device 100 controls driving of the supply motors (71Y, 71C, 71M and 71K) for the respective colors in the toner supply device 70, based on prediction data calculated by a prediction data calculation unit 101 that functions as a prediction data calculation means. The prediction data calculation unit 101 calculates prediction data for temporal change in toner density of a developing agent, based on a detection result for toner density by the toner density sensor or on control target values for toner density and a calculation program and a calculation table stored in the ROM.
In the control device 100, at first, the detection result of toner density and the control target value of toner density are compared, and its result is input into a sensor calculation unit. Then, by a first supply amount calculation unit, based on the comparison result or the like, a toner supply amount for eliminating a difference between the detection result of toner density and the control target value of toner density is calculated. During an operation of a continuous printing, since the developing is performed continuously, only by supplying toner of an amount corresponding to the toner supply amount, the toner density cannot be adjusted to the control target value. Then, a toner supply amount so as to cancel the toner consumption amount in the developing is calculated in the second supply amount calculation unit based on information related to images to be output, such as information on the images or information on a paper. A final toner supply amount is obtained by adding the toner supply amount calculated in the first supply amount calculation unit and the toner supply amount calculated in the second supply amount calculation unit.
As show in
The control device of the printer according to the present embodiment is configured so that a process control processing as follows is executed right after the power is ON, or every time a printing of a predetermined number of sheets is performed. In the process control processing Y, C, M and K gradation pattern images including Y, C, M and K toners, respectively, are formed. Each of the gradation pattern images includes plural test toner images, and is formed in a central portion on the intermediate transfer belt 41 in the belt width direction so that it passes the opposed position to the optical sensor 150. The K gradation pattern image PK, as an example, includes the following test toner images, as shown in
The control device 100, based on the output voltage from the optical sensor 150 stored in the RAM and on an algorithm stored in the ROM in advance, converts the output voltages for Y, C, M and K toners into Y, C, M and K toner attraction amounts per unit area, respectively, and stores them in the RAM.
In the processing of starting up the apparatus (step S101), drives of various motors and various devices start, and until the drives of them become stable the proceeding of the process waits. The optical sensor 150 changes an output from the LED and changes a sensitivity of the reception unit according to a change in temperature or time degradation. Accordingly, even when a constant electric current is continuously supplied to the LED, the output voltage value from the reception unit of the optical sensor 150 upon detecting a background of the belt may change temporally. Also due to a change over time in a surface characteristic of the belt, the output voltage value from the reception unit may change temporally. In this way, in performing the process control processing, a calibration processing for the photo sensor is performed so that a constant voltage is output from the reception unit upon detecting the background part of the intermediate transfer belt 41.
In the calibration processing for the photo sensor (step S102), for the optical sensor 150, a supply amount of electric current to the LED (amount of emission of LED) is adjusted so that the output voltage value from the regular reflection reception unit falls within a predetermined range. In the following, the output voltage value from the reception unit at this stage is denoted “background output value” Vsg. As the supply amount of electric current to the LED increases, the amount of emission from the LED increases and the amount of reception at the regular reflection reception unit increases. Inversely, as the supply amount of electric current to the LED decreases, the amount of emission from the LED decreases and the amount of reception at the regular reflection reception unit decreases.
Detailed processing in the calibration processing for the photo sensor at step S102 is as follows. That is, for each of the photo sensors, after a supply of electric current to an LED starts, the supply amount of electric current to the LED is adjusted so that the output voltage value from the regular reflection reception unit falls within a range of 4±0.5 V. In the following, the supply amount of electric current at this stage is denoted an LED current Ifsg.
The control device 100 searches for the LED current Ifsg that can bring the output voltage value from the regular reflection reception unit close to 4.0 V by using a binary search method. In the case where as a result of the binary search method an LED current that can bring the output voltage value from the normal reflection reception unit within the range of 4±0.5 V does not exist, it is determined to be a background output value Vsg adjustment error. When the background output value Vsg adjustment error occurs successively three times, the process proceeds to a process of an anomalous occurrence error, the apparatus is urgently stopped, and a message to inform it is displayed. Meanwhile, in the printer according to the present embodiment, in order to prevent a breakage of the LED due to an overcurrent supplied, an upper limit of the LED current Ifsg is set to be 30 mA.
The control device 100, by using the binary search method, brings the output voltage value from the regular reflection reception unit within the range of 4±0.5 V, and when the LED current Ifsg that can bring it close to 4.0 V, stores the LED current in the RAM. Then, from this point until the process control processing ends, the LED current Ifsg is supplied to the LED.
Meanwhile, in the case where the initial value of the LED current Ifsg is set to a significantly small value, it requires a long time to adjust the background output value Vsg. For this reason, the control device 100 reads out the value of the LED current Ifsg when the previous calibration processing is performed from the RAM, and employs it for the initial value. Then, under the condition of the initial value, background output values Vsg are measured at a predetermined time interval, and an average value of them is obtained. In the case where the average value falls within the range of 4.0±0.5 V, the LED current Ifsg is employed.
When the control device 100 ends the calibration processing (step S102) for the optical sensor 150 in this way, next, the control device 100 performs the acquisition processing for the output value from the toner density sensor (step S103). In this acquisition processing, for the Y, C, M and K toner density sensors (10Y, 10C, 10M and 10K), as described above, output voltage values Vt are acquired and stored in the RAM, respectively. The acquired output voltage values Vt from the Y, C, M and K toner density sensors will be used later for correcting the control target values for toner density for Y, C, M and K toners, respectively.
Next, the control device 100 performs the generation processing of gradation pattern images (step S104), and Y, C, M and K gradation pattern images are formed on the intermediate transfer belt 41.
The sizes of each of the fourteen test toner images in the gradation pattern of each of the colors are as follows. That is, the length in the belt width direction is 10 mm, the length in the belt moving direction is 14.4 mm and the gap between the antecedent test toner image and the subsequent test toner image is 5.6 mm. The number of test toner images in the gradation pattern image is not limited to fourteen. However, the number falls preferably inside the range of distance between the centers of photoreceptors adjacent to each other. When a length of the gradation pattern image in the direction of the belt moving direction is greater than the distance between the centers of photoreceptors, it is not possible to start forming the gradation pattern image of each of the colors simultaneously. Therefore, in order not to overlap an end part of a preceding gradation pattern image with an apical part of the subsequent gradation pattern image, a forming timing needs to be delayed. According to the above processing, the operation time of the process control processing becomes longer.
In the printer according to the present embodiment, upon forming the gradation pattern image, regardless of the image density (toner attraction amount) of the test toner image, optical writing intensity for the latent image of the test toner image is set to be maximum (the intensity upon forming a solid image). Then, by making developing biases or charging biases different for the respective test toner images, the image densities of the respective test toner images are made different.
The printer according to the present embodiment, which detects the gradation pattern images of the respective colors only by one optical sensor 150, has the following advantages. That is, even in the case where an image density deviation occurs between an end part and the other end part in the belt width direction, without being affected by the image density deviation, the image density of the test toner image can be accurately detected. On the other hand, in the configuration where the gradation pattern images of the respective colors are formed at shifted positions from each other in the belt width direction and are detected by dedicated photo sensors, time for forming the gradation pattern images and for detecting them may be shortened, but they are affected by the image density deviation.
After the gradation pattern image of each of the colors is formed, the control device 100 executes the gradation pattern detection processing (step S105) and detects the toner attraction amount per unit area (image density) in the fourteen test toner images for each of the Y, M, C and K gradation pattern images. In the printer according to the present embodiment, for the test toner images of the K gradation pattern image, the toner attraction amount is detected by using only the regular reflection light amount. On the other hand, for the test toner images of the C, M and K gradation pattern images, the toner attraction amounts are detected by using the regular reflection light amount and the diffuse reflection light amount.
As described above, the gradation pattern images are formed so that the Y gradation pattern image is formed earlier than the other C, M and K gradation pattern images. A time from when the formation of the Y gradation pattern image starts to when the first test toner image of the Y gradation pattern image enters just below the optical sensor 150 (in the following, denoted as a detection time lag) is preliminarily determined by the following parameter or the like. That is, it is a process linear velocity upon executing the process control (velocity of the belt or the like) or a distance between the photoreceptor and the sensor. However, since the intermediate transfer belt 41 does not move exactly at the designed velocity and the distance between the photoreceptor and the sensor includes an error, the detection time lag also includes an error. Even when the greatest error that can be assumed occurs in the detection time lag, the control device 100 begins acquiring the output voltage value from the optical sensor 150 at a timing that can surely catch the head part of the Y gradation pattern image.
Next, the control device 100 executes calculation processing of the toner attraction amount (step S106). In this calculation processing, the toner attraction amount of the K test toner image in the K gradation pattern image is obtained as follows. That is, at first, the following quantities for the background output value from the normal reflection reception unit Vsg and the toner image output value Vsp are obtained according to the following formulas.
ΔVsg_reg=Vst_reg−Voffset_reg Formula 1
ΔVsp_reg[n]=Vsp_reg[n]−Voffset_reg Formula 2
In the above formulas, the character string “_reg” represents the output voltage value from the regular reflection reception unit. In the above formulas, for the background output value Vsg and the toner image output value Vsp, differences from the offset voltage Voffset are obtained. The offset voltage Voffset represents an output voltage value from the reception unit when the emission of the LED is turned off. Moreover, the argument “n” in the above formula represents the number of the K test toner image. That is, for all the fourteen K test toner images in the gradation pattern image, the differences are obtained. By obtaining the differences between the measured values and the offset voltage Voffset, an increase in the toner attraction amount of the K test toner image can be perceived.
Next, the control device 100 obtains a normalized value of the difference using the following formula.
Normalized value Rn[n]=ΔVsp_reg[n]/Vsg_reg Formula 3
Then, the toner attraction amounts of the respective K test toner images are obtained based on the preliminarily stored algorithm showing a relation between the normalized value Rn and the toner attraction amount (graph, calculation formula, data table or the like).
Moreover, the toner attraction amounts of the test toner images in the Y gradation pattern image, the C gradation pattern image and the M gradation pattern image are obtained as follows.
ΔVsp_reg·[n]=Vsp_reg·[n]−Voffset_reg Formula 4
ΔVsp_dif·[n]=Vsp_dif·[n]−Voffset_dif Formula 5
Next, in order to perform a correction for the toner image output value Vsp_dif from the diffuse reflection reception unit according to sensitivity of the diffuse reflection reception unit, a sensitivity correction coefficient α is obtained by the following formula.
α=min(ΔVsp_reg[n]/Vsp_dif·[n]) Formula 6
A ratio of the sensitivity correction coefficient α is obtained by the minimum, because it is previously known that the minimum of a regular reflection component in the toner image output value Vsp_reg from the regular reflection light reception unit is positive and almost zero. By multiplying the toner image output value Vsp_dif[n] from the diffuse reflection reception unit by the sensitivity correction coefficient α obtained in this way, the graph representing the relation between the difference of the toner image output value Vsp_dif and the toner attraction amount is corrected, as shown in
Next, for the difference of the toner image output value Vsp_ref from the regular reflection reception unit, a diffuse reflection light component and a regular reflection light component are decomposed respectively as in the following formulas. Meanwhile, ΔVsp_reg_dif[n] in Formula 7 represents the diffuse reflection light component of the difference. Moreover, ΔVsp_reg_reg[n] in Formula 8 represents the regular reflection light component of the difference.
ΔVsp_reg·_dif·[n]=ΔVsp_dif·[n]×α Formula 7
ΔVsp_reg·_reg·[n]=ΔVsp_reg·[n]−ΔVsp_reg·_dif·[n] Formula 8
In this way, from the difference of the toner image difference value Vsp_reg from the regular reflection light reception unit, the diffuse reflection light component is separated, and a pure regular reflection light component is extracted. Accordingly, as shown in
Next, by the following formula, for the regular reflection reception unit, fourteen regular reflection components corresponding to the fourteen test toner images, respectively, are normalized.
Normalized value β[n]=—AVsp_reg·_reg/ΔVsg_reg·_reg(=exposure ratio of background part of the transfer belt) Formula 9
Moreover, by the following formula, for the diffuse reflection reception unit, a diffuse light output component of the background output value Vsp=dif is removed from the toner image output value Vsp_dif.
ΔVsp_dif′=[diffuse output voltage]−[belt background part output]×[normalized value of regular reflection component]=ΔVsp_dif(n)−ΔVsg_dif×β(n) Formula 10
As described above, in a low toner attraction amount region having sensitivity for the regular reflection light, from the regular reflection light, only a regular reflection light component which can unambiguously express a relation with the toner attraction amount is extracted. When the “diffuse reflection light component directly reflected from the belt background part” is removed from the diffuse reflection light, a sensitivity correction for the diffuse reflection light output is performed based on them. The sensitivity correction is performed in order to perform the following correction. That is, it is a correction related to a solid error in the sensitivity of the LED and the reception unit, and a correction related to a temperature characteristic or a time degradation characteristic of the LED and the reception unit.
This correction is performed as follows. That is, as shown in
A method of approximating a point plotted on a graph is as follows. That is, for the “normalized value of the regular reflection component of the regular reflection light”, a plot curve on which diffuse light outputs after the background part fluctuation correction are plotted is approximated by a polynomial (approximated by a quadratic expression), and a sensitivity correction coefficient η is calculated. In more detail, at first, the plot curve is approximated by an approximated quadratic expression (y=ξ1x2+ξ2x+ξ3), and the coefficients ξ1, ξ2 and ξ3 are obtained by using the least square method as in the following formulas. Meanwhile, an integer “m” in the following formulas represents a number of data. Moreover, x[i] is a normalized value of a regular reflection component of the regular reflection light. Moreover, y[i] represents a diffuse light output after the background part fluctuation correction. The range for x used in the calculation is, for example, assumed to be 0.1≦x≦1.00.
Next, the sensitivity correction coefficient η which makes a normalized value a calculated by the plot line approximated as above a predetermined value b is obtained by the following formula.
η=b/(ξ1a2+ξ2a+ξ3) Formula 14
Moreover, as in the next expression by multiplying the diffuse light output after the background part fluctuation correction obtained by Formula 10 as above by the sensitivity correction coefficient η the relation between the toner attraction amount and the diffuse output is corrected to be a preliminarily determined relation. Meanwhile, ΔVsp_dif′ in the next expression represents the diffuse light output obtained by Formula 10 as above.
ΔVsp_dif″=[diffuse light output after background part fluctuation correction]×[sensitivity correction coefficient: η]=ΔVsp_dif[n]′×β Formula 15
According to the correction as above the output fluctuation in the LED or the reception unit due to temperature change, time degradation or the like is suppressed, and the relation between the output voltage value from the reception unit and the toner attraction amount can be corrected to an unambiguous relation.
Next, by using an attraction amount conversion table ΔVsp_dif″ is converted into a toner attraction amount. By referring to the attraction amount conversion table based on the output voltage value after correction, the output voltage value can be converted into the toner attraction amount.
When toner attraction amounts of the respective fourteen test toner images for the gradation pattern image for each of the colors as above, next a calculation processing for a developing bias which is a target attraction amount is performed (step S108). Specifically, at first as shown in
Next, based on the approximated line, a developing potential in which a target toner attraction amount (in the example shown in the drawings, 4.5 mg/cm2) is obtained is obtained. Then, from the result a developing bias in which the target toner attraction amount is obtained is calculated (developing bias Vb−V=(developing potential−|latent image potential|)×(−1)). Meanwhile, a charging bias Vc during forming an image is preliminarily determined so that a background part potential of the photoreceptor is a value where a magnetic carrier in the developing agent does not become attached to the photoreceptor.
When the developing bias Vb is obtained, the developing bias Vb as a control parameter upon forming images subsequently is corrected to the same value as the obtained value. Next, correction processing for the toner density control target value (Vtref) is performed (step S109). Based on the developing γ and the toner density sensor output Vt the toner density control target value Vtref is corrected. Specifically, a solution of “Δγ=developing γ detected value−developing γ target value” is obtained. The developing γ target value is preliminarily determined for every apparatus. For example, it is about 1.0 mg/cm2/−kV. This value indicates that when the developing potential is 1−kV toner of 1.0 mg/cm2 is attached to the photoreceptor. When the developing start voltage is 0−kV and the target toner attraction amount is 0.5 mg/cm2 the developing potential of 500−V is required. Since the developing potential −V is obtained by “Vb−Vl (latent image potential)”, when the latent potential Vl=50−V, the developing bias Vb is 550−V. Since when Δγ exceeds a predetermined value, the developing bias Vb may exceed a settable range or a failed image may occur, the toner density control target value Vtref is corrected so that Δγ falls within a target range. However, when the toner density sensor output Vt is significantly different from the toner density control target value Vtref, the correction is not performed.
For example, assume that Δγ≧0.30 mg/cm2/−kV and Vt−Vtref≧0.2 V. In this case, since Vtref is equal to Vt−0.2 V, the toner density control target value Vtref is corrected so as to make the toner density less than the present value. Moreover, for example, assume that Δγ≦0.30 mg/cm2/−kV and Vt−Vtref≦0.2 V. In this case, since Vtref is equal to Vt+0.2 V, the toner density control target value Vtref is corrected so as to make the toner density greater than the present value. In a case other than the above two cases the present value of the toner density control target value Vtref is maintained.
By periodically performing the process control processing as above it is possible to form a toner image the image density of which is close to a target value over a long period regardless of an environmental fluctuation. However, when an environment or a toner charge quantity changes drastically, in a period until the next process control processing is performed an excessive image density or an insufficient image density may occur. Especially, when in a successive print mode in which images are formed on plural recording sheets successively a temperature inside the apparatus rises drastically, or the toner charging quantity inside the developing apparatus becomes larger or smaller drastically, the excessive image density or the insufficient image density may be easily generated.
Then, conventionally an image processing apparatus that performs the following target value correction processing in a successive print mode has been known. That is, in an interspace corresponding region on the intermediate transfer belt 41 (a region corresponding to an interspace between a preceding recording sheet and a subsequent recording sheet in the successive print mode) a patch-shaped solid toner image (in the following denoted a solid patch image) is formed. And, image density of the solid patch image is detected by an optical sensor unit, and the result of detection and target image density are compared. Then, by correcting the toner density control target value Vtref by an amount corresponding to a difference between them the target image density is obtained. According to the configuration as above in the successive print mode even when a drastic change in the temperature or in the toner charge quantity occurs the target image density can be obtained.
However, in the above configuration there has been a problem that by forming the solid patch image consumption of toner which a user does not intend occurs and a running cost increases.
Next, a characteristic configuration of the printer according to the present embodiment will be explained.
The write control unit 202 includes an image processing unit 203, a write data memory unit 204, an emission data generation unit 205, a determination unit 206 and the like. The image processing unit 203 performs predetermined image processing for the input image information. Moreover, the write data memory unit 204 temporarily stores image information after the image processing. Moreover, the emission data generation unit 205 after generating emission data for controlling driving a laser diode in the optical writing unit 20 based on the image information after the image processing outputs the emission data to a laser drive circuit which is not shown. Moreover, the determination unit 206 for a predetermined region in a toner image formed based on the image information after the image processing determines whether it is suitable for use for detecting the image density. When it is suitable for use, the determination unit 206 outputs suitability region data to the control device 100.
The determination unit 206 acquires image information for one sheet by dividing into plural segmented regions.
The determination whether it is suitable for use for detecting a toner attraction amount is performed based on density of recording pixels. Specifically, since an area cm2 of the segmented region is a value obtained by dividing a size of paper cm2 by a division number of the segmented regions, it is a preliminarily determined value for every paper size. For example, in the case of dividing a paper of the A3 size into 1260 pieces (30×42 division), an area of each of the segmented regions is “42 cm×29.7 cm/1260=0.99 cm2”.
Moreover, a number of pixels in each of the segmented regions is preliminarily determined. For example, in the case of dividing a paper of the A3 size into 1260 pieces, “234 [dot]×236 [dot]=55224 [dot]”. The determination unit 206 stores the numbers of division in the main-scanning direction and in the sub-scanning direction and the number of pixels in the segmented region for every size of paper.
The density of recording pixels is a value indicating a fraction of pixels on which dots are formed out of all the pixels in the segmented region. A body obtained by multiplying the result of dividing a number of the pixels on which dots are formed by the number of pixels in the segmented region by 100 is a recording pixel density percent [%]. In the case where the recording pixel density is greater than or equal to a predetermined value (for example greater than or equal to 95%), it would be fair to say that a solid image is formed in an almost entire region of the segmented region.
Then, the determination unit 206 calculates the density of recording pixels for each of the segmented regions of C1 to C10 based on the recording pixel number acquired from the write data memory unit 204 and the preliminarily stored pixel number of the segmented region. When the result of calculation is greater than or equal to a predetermined value it is determined that the segmented region is suitable for use for detecting a toner attraction amount. On the other hand, in the case where the result of calculation is less than the predetermined value it is determined that the segmented region is not suitable for use for detecting a toner attraction amount.
The above-described determination is performed in the order of the segmented region C1, segmented region C2, . . . , the segmented region C10. In the case where the segmented region suitable for use for detecting is found during the above process further determination is not performed.
As the positional information as shown in
When an image of each page is optically written on the photoreceptor, a writing start signal is generated. The writing start signal is sent from the write control unit 202 to the control device 100. In the following a time from when the control device 100 receive the writing start signal to when a front end of an image part in the segmented region C4 in the toner image on the intermediate transfer belt 41 enters a region opposed to the optical sensor 150 is denoted a “region entry time”. The “region entry time” can be obtained according to a predetermined calculation expression. Specifically, since a time from when the writing start signal is generated to when the front end of the paper enters a position opposed to the optical sensor 150 is determined by the process linear velocity, when the process linear velocity is a constant the paper front end entry time is also a constant. A result of dividing the distance L1 by the process linear velocity is a time required from when the paper front end enters the position opposed to the optical sensor 150 to when the front end of the segmented region which is a target enters the opposed position. Therefore, an expression of adding the result of dividing the distance L1 by the process linear velocity to the paper front end entry time is the above-mentioned predetermined calculation expression.
The control device 100 upon receiving the information of the distance L1 from the determination unit 206 calculates the “region entry time” using the calculation expression. Then, at timing when the “region entry time” elapses from the reception of the writing start signal a sampling is performed for outputs from the optical sensor 150. Then, based on the result of the sampling a toner attraction amount of the solid image part formed in the segmented region C4 is calculated and the toner control target value Vtref is corrected based on the result of the calculation.
In the configuration described above a correction amount for the toner control target value Vtref as a control parameter is calculated based on the result of detecting the toner attraction amount of the region which is suitable for use for detecting a toner attraction amount in a toner image formed based on an instruction from a user. Then, without forming a dedicated solid patch image for detecting a toner attraction amount in the interspace corresponding region on the intermediate transfer belt 41 the toner control target value Vtref can be corrected appropriately. Accordingly, an inadequacy in the image density due to a fluctuation of an environment and a charge quantity of toner can be suppressed with a lower cost than that of the related art.
When the simple correction processing for the target value begins, the LED in the optical sensor 150 is turned on (step S201). Specifically, it is put into a state where a toner attraction amount can be detected by turning on the LED after the shutter of the optical sensor is opened and the LED is exposed at the same time as a preparation for starting up the apparatus in order to start a print operation is performed.
Next, a print condition is acquired (step S202). The print condition includes the process linear velocity, a wiring resolution, a size of paper or the like. When these print conditions are acquired, information on the recording pixel number (image information) for every segmented region is acquired (step S203). Then, for the segmented region C4 density of recording pixels is calculated based on the recording pixel number and a number of pixels of the segmented region (step S204). It is determined whether the segmented region is suitable for use for detecting a toner attraction amount based on the result of calculation (step S205). When in this determination a segmented region suitable for use for detecting a toner attraction amount does not exist (step S205: NO), the printing ends (step S211) the LED in the optical sensor 150 is turned off (step S212) and the print job ends.
On the other hand, when there is a segmented region suitable for use for detecting a toner attraction amount out of plural segmented regions of the row C (step S205: YES) after the segmented region is detected by the optical sensor 150 (step S206) the toner attraction amount is calculated based on the result of detection (steps S207). Meanwhile, a method of converting the detection result of the optical sensor 150 into the toner attraction amount is the same method as the process control processing. When the toner attraction amount is calculated a correction amount for the toner density control target value Vtref is calculated based on a difference between the result of calculation for the toner attraction amount and the target attraction amount (step S208). When the result of calculation is greater than the target attraction amount the correction amount is obtained so as to reduce the toner attraction amount by an amount corresponding to the difference. Moreover, when the result of calculation is less than the target attraction amount the correction amount is obtained so as to increase the toner attraction amount by the amount corresponding to the difference. When the correction amount is obtained in this way the result is stored (step S209) and the toner density control target value Vtref is corrected (step S210). When the print ends (step S211: YES) the LED of the optical sensor 150 is turned off (step S212) and the print job ends.
In the simple correction processing for the target value described above a series of flows of steps S206 to S210 function as a first control parameter processing for correcting the toner density control target value Vtref as a control parameter based on the result of detection for the toner attraction amount. In the printer according to the present embodiment separately from the simple correction processing for the target value provided with the first control parameter processing as above a process control processing a flow of which is shown in
Specifically, the toner density control target value Vtref is corrected according to the following method which will be exemplified as follows. That is, as shown in
As shown in
Specifically, in the case where the toner attraction amount of the segmented region exceeds the upper threshold value 2, i.e., it is substantially greater than the target attraction amount, by making the toner density control target value Vtref greater by 0.1 V the toner density is made lower. Accordingly, the toner attraction amount is made lower and is made closer to the target attraction amount. Meanwhile, the developing bias is a minus polarity. Moreover, in the case where the toner attraction amount of the segmented region is less than the upper threshold value 2 and greater than or equal to the upper threshold value 1, i.e., it is slightly greater than the target attraction amount, by making the toner density control target value Vtref greater by 0.05 V the toner density is made a little lower. Accordingly, the toner attraction amount is made lower and is made close to the target attraction amount. Moreover, in the case where the toner attraction amount of the segmented region is greater than the lower threshold 1 and less than or equal to the upper threshold value 1, since the target toner attraction amount is basically obtained the correction for the toner density control target value Vt is not performed. Moreover, in the case where the toner attraction amount of the segmented region is less than the lower threshold value 1 and greater than or equal to the lower threshold value 2, i.e., it is slightly less than the target attraction amount, by making the toner density control target value Vtref less by 0.05 V the toner density is made a little greater. Accordingly, the toner attraction amount is made greater and is made close to the target attraction amount. Moreover, in the case where the toner attraction amount of the segmented region is less than the lower threshold value 2, i.e., it is substantially less than the target attraction amount, by making the toner density control target value Vtref less by 0.1 V the toner density is made greater. Accordingly, the toner attraction amount is made greater and is made close to the target attraction amount.
Meanwhile, though an example of correcting the toner density control target value Vtref as a control parameter in the simple correction processing for the target value is explained instead of the toner density control target value Vtref other control parameter may be corrected. For example, the developing bias may be corrected. In the case of correcting the developing bias the following correction may be performed. That is, as shown in
Specifically, in the case where the toner attraction amount of the segmented region exceeds the upper threshold value 2, i.e., it is substantially greater than the target attraction amount, by making an absolute value of the developing bias Vb lower by 4 V the developing potential is made lower by 4 V. Accordingly, the toner attraction amount is made lower and is made closer to the target attraction amount. Moreover, in the case where the toner attraction amount of the segmented region is less than the upper threshold value 2 and greater than or equal to the upper threshold value 1, i.e., it is slightly greater than the target attraction amount, by making the absolute value of the developing bias Vb lower by 2 V the developing potential is made lower by 2 V. Accordingly, the toner attraction amount is made lower and is made closer to the target attraction amount. Moreover, in the case where the toner attraction amount of the segmented region is greater than the lower threshold 1 and less than or equal to the upper threshold value 1, since the target toner attraction amount is basically obtained the correction for the developing bias Vb is not performed. Moreover, in the case where the toner attraction amount of the segmented region is less than the lower threshold value 1 and greater than or equal to the lower threshold value 2, i.e., it is slightly less than the target attraction amount, by making the absolute value of the developing bias Vb greater by 2 V the developing potential is made greater by 2 V. Accordingly, the toner attraction amount is made greater and is made close to the target attraction amount. Moreover, in the case where the toner attraction amount of the segmented region is less than the lower threshold value 2, i.e., it is substantially less than the target attraction amount, by making the absolute value of the developing bias Vb greater by 4 V the developing potential is made greater by 4 V. Accordingly, the toner attraction amount is made greater and is made close to the target attraction amount.
Moreover, as the control parameter a laser light quantity of the optical writing unit 20 may be corrected. In the case where the toner attraction amount of the segmented region is greater than the target attraction amount the laser light quantity is made smaller. On the other hand, in the case where the toner attraction amount of the segmented region is less than the target attraction amount the laser light quantity is made greater. In this way, by correcting the laser light quantity the toner attraction amount can be made closer to the target attraction amount.
Moreover, in the printer according to the present embodiment, by performing the simple correction processing for the target value an interval for conducting the process control processing in the successive print mode is made longer and a down time of the apparatus is made shorter. Specifically, the process control processing is basically conducted every time an accumulated number of printed sheets increases by 100. For example, assume that an increase in the accumulated number of printed sheets right before a successive print mode is conducted from the previous process control processing (in the following denoted “increased number of sheets”) is 80. Then, assume that the successive print mode in which images are output on 500 recording sheets successively starts. In this case, when images are output on 20 recording sheets from the start of the successive print mode the “increased number of sheets” is 100. Therefore, basically at this stage the successive print is temporarily halted and the process control processing is conducted. A user waits in the meantime.
On the other hand, in the printer according to the present embodiment the simple correction processing for the target value is conducted in each print. Then, in the simple correction processing for the target value it is determined whether there is a segmented region suitable for use for detecting a toner attraction amount. In the case where a suitable segmented region exists, the toner density control target value Vtref is corrected and the toner attraction amount can be made closer to the target attraction amount. Accordingly, in the case where in the successive print mode the toner density control target value Vtref can be corrected in the simple correction processing for the target value, the “increased number of sheets” is reset to zero. For example, assume that the successive print mode starts from the state where the “increased number of sheets” is 80 and afterwards at the tenth print the toner density control target value Vtref can be corrected. Then, at this time the “increased number of sheets” is reset to zero. Accordingly, the interval for conducting the process control processing is made longer and the down time of the apparatus can be made shorter.
Next, a printer according to an example which is the printer according to the embodiment to which the characteristic configuration is added will be explained. Meanwhile, unless particularly stated the configuration of the printer according to the example is the same as that in the embodiment.
By conducting the process control processing described above a target attraction amount (target image density) can be obtained in a solid image part. However, it does not necessarily obtain a target attraction amount for halftone in a halftone part. The toner attraction amount for halftone can be changed by adjusting LD power (electric power supplied to a laser diode) in the optical writing unit 20.
Then, in the printer according to the present example a halftone control processing is conducted right after the process control processing and the LD power is corrected so that the target attraction amount for halftone can be obtained in the halftone part of the image.
For the method of expressing a halftone in the present example a method of expressing a halftone with area gradation including five levels of PAT1 to PAT5 as shown by dot dispersion type dither matrices in
In the halftone control processing for each of the colors the following control is conducted individually. That is, at first a halftone pattern including five halftone test toner images expressed by the halftones of the file levels respectively is formed on the intermediate transfer belt 41. Then, toner attraction amounts for the halftone test toner images respectively are calculated based on a result of detecting the halftone test toner images by the optical sensor 150. This calculation is performed in the same way as the calculation of the toner attraction amount in the process control processing.
Next, as shown in
According to the halftone control processing described above also in the halftone part of the image a target attraction amount (target image density) can be obtained. However, when in the successive print mode in order to conduct the halftone control processing a successive print job is temporarily halted, a wait time for the user may be extended.
Moreover, assume that processing is conducted in which in order to avoid the above extension only one halftone test toner image is formed in the interspace corresponding region on the intermediate transfer belt 41 in the successive print mode and the LD power is corrected based on the toner attraction amount for it. Since even by referring to the toner attraction amount for one halftone test toner image an appropriate value of the correction amount of the LD power can be obtained with certain accuracy, by the processing in this way a substantial inadequacy in the halftone toner attraction amount can be suppressed. However, by forming halftone test toner images in the interspace corresponding region a consumption of toner which the user does not intend occurs and a running cost increases.
Then, in the printer according to the first example a simple correction processing for the LD power is conducted as follows. That is, the determination unit 206 for the respective segmented regions of C1 to C10 determines whether it is the segmented region as follows based on the image information acquired from the write data memory unit 204. That is, it is determined whether an entire region of the segmented region is expressed by the area gradation of PAT3 in the dither matrix (See
The above-described determination is performed in the order of the segmented region C1, segmented region C2, . . . , the segmented region C10. In the case where the segmented region suitable for use for detecting is found during the above process further determination is not performed.
The control device 100 upon receiving the information of the distance L2 which is the positional information of the halftone from the determination unit 206 calculates the “region entry time”. Then, at timing when the “region entry time” elapses from the reception of the writing start signal a sampling is performed for outputs from the optical sensor 150. Then, based on the result of the sampling a toner attraction amount of the halftone image part formed in the segmented region C4 is calculated and the LD power is corrected based on the result of the calculation.
In the configuration described above a correction amount for the LD parameter as a control parameter is calculated based on the result of detecting the toner attraction amount of the region which is suitable for use for detecting a halftone toner attraction amount in a toner image formed based on an instruction from a user. Then, without forming a dedicated halftone test toner image for detecting a toner attraction amount in the interspace corresponding region on the intermediate transfer belt 41, the LD power can be corrected appropriately. Accordingly, an inadequacy in the image density in the halftone part due to a fluctuation of an environment and a charge quantity of toner can be suppressed with a lower cost than that of the related art.
Meanwhile, instead of correcting the LD power as the control parameter, writing dot numbers in the dither matrix may be corrected. In the case where the toner attraction amount of the halftone image part is greater than the target attraction amount the writing dot numbers may be made smaller. On the other hand, in the case where the toner attraction amount of the halftone image part is less than the target attraction amount the writing dot numbers may be made greater.
Moreover, in the printer according to the present example, by performing the simple correction processing for the LD power an interval for conducting the halftone control processing in the successive print mode is made longer and a down time of the apparatus is made shorter. Specifically, the halftone control processing is basically conducted every time an accumulated number of printed sheets increases by 100. For example, assume that an increase in the accumulated number of printed sheets right before a successive print mode is conducted from the previous halftone control processing (in the following denoted “increased number of sheets for halftone”) is 80. Then, assume that the successive print mode in which images are output on 500 recording sheets successively starts. In this case, when images are output on 20 recording sheets from the start of the successive print mode the “increased number of sheets for halftime” is 100. Therefore, basically at this stage the successive print is temporality halted and the halftone control processing is conducted. A user waits in the meantime.
On the other hand, in the printer according to the present example the simple correction processing for the LD power is conducted in each print. Then, in the simple correction processing for the LD power it is determined whether there is a segmented region suitable for use for detecting a halftone toner attraction amount. In the case where a suitable segmented region exists, the LD power is corrected and the toner attraction amount in the halftone part can be made closer to the target attraction amount. Accordingly, in the case where in the successive print mode the LD power can be corrected in the simple correction processing for the LD power, the “increased number of sheets for halftone” is reset to zero. For example, assume that the successive print mode starts from the state where the “increased number of sheets for halftone” is 80 and afterwards at the tenth print the LD power can be corrected. Then, at this time the “increased number of sheets for halftone” is reset to zero. Accordingly, the interval for conducting the process control processing is made longer and the down time of the apparatus can be made shorter.
Since when an environment is fluctuated a potential decay characteristic of an exposure unit of the photoreceptor changes, a radius of a dot written by an exposure is altered slightly. Accordingly, a line width of a line image on which plural dots are arranged vertically and horizontally may be altered.
In the printer according to the present example, line width correction processing is periodically conducted and the LD power is corrected so as to obtain a target line width.
In the line width correction processing for each of the colors the following control is performed individually. That is, at first a line image in which plural dots are arranged in the main-scanning direction is formed on the intermediate transfer belt 41. Then, a line width of the line image is calculated based on the result of detecting the line image extending in the main-scanning direction by the optical sensor 150.
The greater the LD power is, the greater the line width is. The control device 100 upon calculating the line width of the line image compares the result of calculation with the target line width. Then, by correcting the LD power by an amount according to a difference between them the line width is made closer to, the target line width. For example, the line width correction processing described above is conducted every time print processing for 100 sheets is performed. In the successive print mode four line images of Y, M, C and K are formed in the interspace corresponding region on the intermediate transfer belt 41 and the optical sensor 150 detects the line images. Accordingly, it is not necessary to halt the successive print operation temporarily due to the line width correction processing.
However, by forming the line images in the interspace corresponding region a consumption of toner which the user does not intend occurs and a running cost increases.
In the printer according to the second example simple correction processing for a line width is conducted as follows. That is, the determination unit 206 for the respective segmented regions of C1 to C10 determines whether it is the segmented region as follows based on the image information acquired from the write data memory unit 204. That is, it is determined whether any of the Y, M, C and K line images exists in the segmented region. Then, in the case where any of the line images exists it is determined for the segmented region that it is suitable for use for detecting a line image. On the other hand, in the case where none of the line images exist it is determined for the segmented region that it is not suitable for use for detecting a line image.
The above-described determination is performed in the order of the segmented region C1, segmented region C2, . . . , the segmented region C10. The determination continues to the final segmented region C10 unless the line images of all the colors become detectable. For example, even if it is determined for the segmented region C1 that it is suitable for use for detecting a Y line image since M, C, K line images are not detectable, the determination continues for the segmented region C2 and further.
The control device 100 upon receiving the color information or the information of the distance L3 calculates the “region entry time”. Then, at timing when the “region entry time” elapses from the reception of the writing start signal a sampling is performed for outputs from the optical sensor 150. Then, based on the result of the sampling a line width of the line images formed on the segmented region C4 or the segmented region C10 and the LD power is corrected based on the result of the calculation.
In the configuration described above a correction amount for the LD parameter as a control parameter is calculated based on the result of detecting the line image in the region which is suitable for use for detecting a line image in a toner image formed based on an instruction from a user. Then, without forming a dedicated line image for detecting a line width in the interspace corresponding region on the intermediate transfer belt 41 the LD power can be corrected appropriately. Accordingly, an inadequacy in the image density in the halftone part due to a fluctuation of an environment and a charge quantity of toner can be suppressed with a lower cost than that of the related art.
Meanwhile, in the printer according to the present example, in the case of conducting the simple correction processing for the line width, the toner consumption amount can be suppressed omitting the line width correction processing by that amount. Specifically, the line width correction processing is conducted every time an accumulated number of printed sheets increases by 100. Assume that during an increased number of the accumulated number of printed sheets increases from 1 to 100, for example, the LD power can be corrected by the simple correction processing for the line width for the three colors of Y, M and C. In this case, in the line width correction processing only a K line image is formed and only the LD power for K is corrected.
A printer according to a third example when a print (page printing) where there is not a segmented region suitable for use for detecting a toner attraction amount in a matrix of an image region is performed continuously by a predetermined number of times conducts the following processing. That is, right after the simple correction processing for the target value a process control processing as a second control parameter correction processing is performed.
Next, the control unit updates a count value for number of sheets in process control processing C0 by incrementing by one (step S302). The count value for number of sheets in process control processing C0 is a variable that is counted up every time one sheet is printed in order to grasp an arrival of timing of conducting the process control processing. The control unit determines whether each of the segmented regions is suitable for use for detecting a toner attraction amount based on the recording pixel density (step S303) after the count up. Then, in the case where there is a segmented region suitable for a detection object (step S303: YES) a solid continuous non-detection count value C1 is reset to zero (step S304). The solid continuous non-detection count value C1 is to count a number of consecutive determinations in the case where the control unit determines consecutively that there is not a segmented region suitable for a detection object for the respective prints in the continuous printing. When the control unit resets the solid continuous non-detection count value C1 to zero at step S304, after detecting by the optical sensor the segmented region which is determined to be suitable for use for detecting a toner attraction amount (step S305) the control unit calculates the toner attraction amount based on the result of detection (step S306). Then, it is determined whether the result of calculation is within an adequate range (step S307).
On the other hand, in the case where there is not a segmented region suitable for a detection object (step S303: NO), after updating the solid continuous non-detection count value C1 by incrementing by one (step S318) the process flow proceeds to step S314 which will be described below.
Moreover, in the case where the control unit determines that the toner attraction amount is within the adequate range (step S307: YES), after resetting a continuous inadequacy count value for toner attraction amount C2 to zero (step S308) the control unit conducts a simple correction execution processing (step S309). The continuous inadequacy count value for toner attraction amount C2 is to count a number of consecutive determinations in the case where the control unit determines consecutively that the toner attraction amount is not in the adequate range for the respective prints in the continuous printing. Moreover, the simple correction execution processing (step S309) is a processing that performs the processes of steps S208 to S210 in the simple correction processing for the target value in the printer according to the embodiment. That is, it performs sequentially processing of calculating a correction amount for the toner density control target value Vtref based on the toner attraction amount, storing the correction amount and correcting with the correction amount. Then, after resetting the count value for number of sheets in process control processing C0 (step S310), it waits for an end of a print of one sheet (step S311), and right after that the LED of the optical sensor is turned off (step S312) so that the processing flow ends.
On the other hand, in the case where the control unit determines that the toner attraction amount is not within the adequate range (step S307: NO), the following processing flow is conducted. That is, after updating the continuous inadequacy count value for toner attraction amount C2 by incrementing by one (step S313) it is determined whether the solid continuous non-detection count value C1 exceeds a predetermined threshold value (step S314). Then, in the case where it exceeds the predetermined threshold value (step S314: YES), after resetting the count value for number of sheets in process control processing C0, the solid continuous non-detection count value C1 and the continuous inadequacy count value for toner attraction amount C2 to zero respectively (step S315) a process control flag is set to ON (step S316). Afterwards, through the processes of steps S311 and S312 the processing flow ends. When the simple correction processing for the target value is finished in this way, since the process control flag is on, the continuous printing job is temporarily halted and the process control as above is conducted.
Moreover, in the case where it is determined that the solid continuous non-detection count value C1 does not exceed the predetermined threshold value (step S314: NO) it is determined whether the continuous inadequacy count value for toner attraction amount C2 exceeds the predetermined threshold (step S317). In the case where it exceeds the predetermined threshold (step S317: YES), after executing the processes of steps S315, S316, S311 and S312 the processing flow ends in the same way as the case where it is determined that the solid continuous non-detection count value C1 exceeds the predetermined threshold. On the other hand, in the case where it is determined that the continuous inadequacy count value for toner attraction amount C2 does not exceed the predetermined threshold (step S317: NO), after executing the processes of steps S311 and S312 the processing flow ends.
In the simple correction processing for the target value described above in the case where it determines consecutively that a print does not include a segmented region suitable for use for detecting a toner attraction amount in a matrix of an image region by more than the predetermined number of times, the result of determination at step S314 is “YES”. Then, since the process control flag is set to ON at step S316, right after the simple correction processing for the target value the process control is conducted. Assume that in the configuration as above since it is determined consecutively that a print does not output a segmented region suitable for use for detecting a toner attraction amount by more than the predetermined number of times, a number of prints in which the simple correction for the toner density control target value Vtref cannot be performed exceeds a predetermined threshold. In this case since the toner density control target value Vtref is likely to deviate significantly from an appropriate value, the process control flag is set to ON at step S316 as above. Then, the image density can be controlled appropriately by temporarily halting the continuous printing job and conducting the process control processing right after the simple correction processing for the target value.
Moreover, in the printer according to the present example assume that it is determined at step S303 that it is determined to be suitable for use for detection and it is determined consecutively that a toner attraction amount is not within the adequate range at step S307 by more than a predetermined number of times. In this case the process control flag is set to ON at step S316 and the process control processing is conducted right after the simple correction processing for the target value. In this configuration as above in the case where the toner attraction amount deviates from the adequate range since the image formation condition such as the developing bias is different from an adequate value due to an environmental fluctuation or the like, the image formation condition is appropriately corrected by detecting it and conducting the process control processing. Accordingly, stable image density can be realized over a long period.
Moreover, in the printer according to the present example, assume that it is determined at step S303 that it is determined to be suitable for use for detection and it is determined that a toner attraction amount is within the adequate range at step S307. In this case the count value for number of sheets in process control processing C0 is reset to zero at step S310 and timing for conducting the next process control processing is extended rather than performed as scheduled. In the configuration as above in the case where the image formation condition is an adequate value and the toner attraction amount is within the adequate range, the timing for conducting the process control processing is extended rather than performed as scheduled. Accordingly, an occurrence of down time in the apparatus due to excessive process control processing can be avoided.
The embodiments and the examples explained as above are examples, and the present invention has a particular effect for each of the following aspects.
[Aspect A]
An aspect A is an image forming apparatus including an image information acquisition unit that acquires image information (for example the image data input unit 201), a toner image formation unit (for example the optical writing unit 20, image formation units 1Y, 1M, 1C and 1K, the transferring unit 40 or the like) that forms a toner image on a surface of an image carrier (for example the intermediate transfer belt 41) based on the image information acquired by the image information acquisition unit, an image density detection unit (for example the optical sensor 150) that detects image density of the toner image formed on the surface of the image carrier, a control unit (for example the control device 100 and the writing control unit 202) that performs a parameter correction processing for correcting a control parameter in the toner image formation unit so as to obtain a desired image quality based on a detection result by the image density detection unit. The aspect A has a feature that the control unit is configured to perform a determination processing for determining whether a predetermined region of the toner image formed based on the image information is suitable for use for detecting the image density in the parameter correction processing, and in the case where it is determined that the predetermined region is suitable for use for detection in the determination processing, perform a processing for correcting the control parameter based on a result of detecting the image density of the predetermined region by the image density detection unit as the parameter correction processing.
[Aspect B]
An aspect B has a feature that in the aspect A the control unit is configured to determine that the predetermined region is suitable for use for detection in the case where the predetermined region is a solid image part in the determination processing and perform a processing for correcting the control parameter so as to obtain desired image density in the solid image part in the parameter correction processing.
[Aspect C]
An aspect C has a feature that in the aspect A or B the control unit is configured to determine that the predetermined region is suitable for use for detection in the case where the predetermined region is a halftone image part in the determination processing and perform a processing for correcting the control parameter so as to obtain desired image density in the halftone image part in the parameter correction processing.
[Aspect D]
An aspect D has a feature that in any one of the aspects A to C the control unit is configured to determine that the predetermined region is suitable for use for detection in the case where the predetermined region is a line image part in the determination processing and perform a processing for correcting the control parameter so as to obtain a line image with a predetermined thickness in the parameter correction processing.
[Aspect E]
An aspect E has a feature that in the aspect B the control unit is configured to perform a processing for determining that the predetermined region is a solid image part in the case where a recording pixel density in the predetermined region is greater than or equal to a predetermined threshold in the determination processing.
[Aspect F]
An aspect F has a feature that in the aspect C the control unit is configured to perform a processing for determining that the predetermined region is suitable for use for detection in the case where all dots in the predetermined region is a predetermined gradation expressed by a dot dispersion type dither matrix (for example PAT3) in the determination processing.
[Aspect G]
An aspect G has a feature that in the aspect B, C, E or F the control unit is configured to perform the control parameter correction processing as a first control parameter correction processing (for example the simple correction processing for the target value or the simple correction processing for the LD power) and perform as a second control parameter correction processing (for example the process control processing, or the halftone control processing) for correcting the control parameter so as to obtain desired image density in a solid image part or in a halftone image part based on a result of forming a pattern image (for example the gradation pattern image) including plural toner images image densities of which are different from each other on the surface of the image carrier and detecting respectively image densities of the plural toner images by the image density detection unit.
[Aspect H]
An aspect H has a feature that in the aspect G the control unit is configured to perform the second control parameter correction processing in the case where it determines consecutively that the predetermined region is not suitable for use for detection by a predetermined number of times in the determination processing.
[Aspect I]
An aspect I has a feature that in the aspect G or H the control unit is configured to perform the second control parameter correction processing in the case where it determines consecutively that the predetermined region is suitable for use for detection in the determination processing and that a detection result of the image density is not within a predetermined adequate range by a predetermined number of times.
[Aspect J]
An aspect J has a feature that in any one of the aspects G to I the control unit is configured to perform a processing for extending timing for conducting the next second control parameter correction processing than scheduled in the case where it determines that the predetermined region is suitable for use for detection in the determination processing and that a detection result of the image density is within a predetermined adequate range.
[Aspect K]
An aspect K has a feature that in any one of the aspects G to J the control unit is configured to perform a processing for extending timing for conducting the next second control parameter correction processing than scheduled in the case where the first control parameter correction processing is performed based on the determination that the predetermined region is suitable for use for detection in the determination processing.
[Aspect L]
An aspect L has a feature that in the aspect D the control unit is configured to determine that the predetermined region is suitable for use for detection in the determination processing in the case where the line image part (for example the line image) extends in a main-scanning direction perpendicular to a surface moving direction on the surface of the image carrier.
[Aspect M]
An aspect M has a feature that in the aspect L the control unit is configured to use a reflection type photo sensor as the image density detection unit and perform a processing for correcting the control parameter based on a result of acquiring the thickness (for example the line width) of the line image part based on a detection result by the reflection type photo sensor in the parameter correction processing.
Further, the present invention is not limited to these embodiments, but various variations and modifications may be made without departing from the scope of the present invention.
The present application is based on Japanese Priority Applications No. 2013-029942 filed on Feb. 19, 2013 and No. 2014-018634 filed on Feb. 3, 2014, and claims the benefit of priority of Japanese Priority Application No. 2014-018634 filed on Feb. 3, 2014, the entire contents of which are hereby incorporated by reference.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014-018634 | Feb 2014 | JP | national |
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| Number | Date | Country | |
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| 20150220032 A1 | Aug 2015 | US |
