1. Field of the Invention
The present disclosure relates to a density control technique in an image forming apparatus.
2. Description of the Related Art
An image forming apparatus using an electrophotographic scheme is required to have output image density stability and the like. US2008/0131152 discloses a technique of forming a test pattern on a recording material using each of a plurality of values of an image forming condition (process condition), to determine an image forming condition that achieves target density. In US2008/0131152, the range of value of the image forming condition used when forming the test pattern is predetermined.
The diversification of the use environment of users and the printing mode can cause a situation where the target density is not included in the density range of the test pattern formed using the image forming condition in the predetermined range. In such a case, the image forming condition cannot be determined accurately. On the other hand, excessively widening the range of value of the image forming condition to be used so that the target density is included in the density range of the test pattern can lead to lower accuracy of density control.
According to an aspect of the present invention, an image forming apparatus includes: an image forming unit configured to form an image according to a process condition; a measurement unit configured to measure a measurement image formed by the image forming unit; an update unit configured to cause the image forming unit to form a first measurement image, cause the measurement unit to measure the first measurement image, and update the process condition based on a result of the measurement of the first measurement image by the measurement unit; a first determination unit configured to cause the image forming unit to form a plurality of second measurement images, cause the measurement unit to measure the plurality of second measurement images, and determine the process condition based on a result of the measurement of the plurality of second measurement images by the measurement unit, the plurality of second measurement images being formed according to a plurality of test process conditions; an obtaining unit configured to obtain environment information; and a second determination unit configured to determine the plurality of test process conditions, based on the environment information obtained by the obtaining unit and the process condition updated by the update unit.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
The following describes exemplary embodiments of the present invention with reference to drawings. Structural elements not necessary for the description of the embodiments are omitted from the drawings. The embodiments described below are merely illustrative, and the present invention is not limited to these embodiments.
The image forming units PM, PC, and PK have the same arrangement as the image forming unit PY except that the color of the toner used is different, and so the description of the image forming units PM, PC, and PK is omitted. In the following description, the reference signs without Y, M, C, and K at the end are used in the case where the colors need not be distinguished. The toner images formed on the photosensitive members 1 of the respective image forming units are transferred to the intermediate transfer belt 6 in a superimposed manner, as a result of which a multicolor toner image is formed on the intermediate transfer belt 6.
The intermediate transfer belt 6 is extended between three rollers 61, 62, and 63, and rotated in the direction of R2 in the drawing. A recording material P extracted from a cassette 65 is conveyed toward a secondary transfer point T2 composed of the roller 63 and a secondary transfer roller 64, by roller pairs 66 and 67. At the secondary transfer point T2, the toner image transferred to the intermediate transfer belt 6 is transferred to the recording material P. A fixing unit 11 applies heat and pressure to the recording material P, to fix the toner image. The recording material P is then ejected outside the apparatus.
A light source 103 in a reading unit 216 irradiates a recording material placed on a platen 102 with light. A CCD sensor 105 receives reflection light, to read an image on the recording material. A reader image processing unit 108 and a printer control unit 109 perform predetermined image processing on the image data read by the CCD sensor 105. The image forming apparatus 100 in this embodiment is capable of printing not only an image read by the reading unit 216 but also image data received via a phone line (fax) or image data received from a computer via a network. An operation unit 20 includes a display unit 218 for operating the image forming apparatus 100 by the user and displaying the state of the image forming apparatus 100 to the user. A control unit 110 integrally controls the image forming operation by the image forming apparatus 100, and includes a CPU 111, a RAM 112, and a ROM 113. The control unit 110 determines/obtains density information of the toner image formed on the photosensitive member 1, based on the signal from the density sensor 12. The CPU 111 controls the image forming apparatus 100 using programs and various data held in the ROM 113, with the RAM 112 as a work area. The CPU 111 executes these programs, thus realizing a determination unit that determines a range of value of an image forming condition used in density control and a correction unit that corrects, in correction control, the value of the image forming condition determined by the determination unit as described later. The image forming apparatus 100 also includes an environment sensor 30 for obtaining environment information in the image forming apparatus, such as at least one of the temperature and the humidity, and notifying the control unit 110 of the environment information.
The following describes density control in this embodiment. The density control is performed for each color. In this embodiment, the density control is executed according to operation by the user or when a predetermined condition is satisfied. In the density control, a toner image is formed on a recording material and fixed to the recording material, and the fixed toner image is read by the reading unit 216 to determine the density-related image forming condition. The value (hereafter referred to as “maximum density condition value”) of the image forming condition (process condition) for forming an image of desired maximum density (hereafter referred to as “target maximum density”) and a tone correction table for converting the value of input image data to achieve the target density are created in the density control. The created tone correction table is used to form a test pattern Q as a measurement image on the photosensitive member 1, using the determined maximum density condition value. The test pattern Q is a pattern having images of a plurality of levels of density (tone) including a solid part (maximum density part), as shown in
After this, each time a predetermined number of sheets pass through during continuous image formation, the image forming apparatus 100 in this embodiment transitions to a state called “correction control mode”. In the correction control mode, the test pattern Q shown in
The density control is described in detail below, with reference to
Next, in step S13, the control unit 110 forms a test pattern for tone correction, on a recording material.
The correction control performed in the correction control mode using the target density information obtained in the density control is described below, with reference to
The exposure amount adjustment in step S24 and step S26 is described in more detail below. Let α be the exposure amount which is the maximum density condition value determined in the density control shown in
The following describes the range of value of the image forming condition used to form the test pattern for maximum density adjustment in step S10 in the density control shown in
As shown in
The following describes the method of determining the change range of value of the image forming condition in the density control shown in
In the execution of the density control, in step S30 the control unit 110 computes a value γ according to the following expression (1):
γ=A×100/B−100(%) (1)
where the value γ represents, in percentage, the amount of increase/decrease of the exposure amount A used in image formation immediately before the execution of the density control with respect to the exposure amount B determined by the environment condition in the execution of the density control.
In step S31, the control unit 110 compares the value γ and a first threshold which is a negative value. When the value γ is less than the first threshold, the control unit 110 shifts the change range of value of the image forming condition in the negative direction in step S32. For example, in step S32, the control unit 110 may shift the change range to “γ(%) to +2×|X|−|γ|(%)”, where the first threshold is −|X|(%). When the value γ is greater than or equal to the first threshold, the control unit 110 compares the value γ and a second threshold which is a positive value in step S33. When the value γ is greater than the second threshold, the control unit 110 shifts the change range of value of the image forming condition in the positive direction in step S34. For example, in step S34, the control unit 110 may shift the change range to “−2×|X|+|γ|(%) to γ(%)”, where the second threshold is +|X|(%). When the results of step S31 and step S33 are both “No”, the change range of the image forming condition is set to the reference range “−|X|(%) to +|X|(%)”. In other words, the amount of shift is 0. The change range may be shifted in a predetermined unit such as 5%. In such a case, the value γ is rounded to the predetermined unit by round-up, round-down, round-off, or the like.
To check the advantageous effects of this embodiment, the image forming apparatus was installed in a high-temperature and high-humidity environment, and high-duty images were continuously printed. After this, the density control was executed using each of the fixed change range and the change range shifted according to this embodiment, and the results were compared. The fixed change range was set to “−20% to +20%”. Since high-duty images were continuously printed in the high-temperature and high-humidity environment, each density level of the formed test pattern was higher than the target maximum density in the case of the conventional fixed change range, as shown in
As described above, in this embodiment, the maximum density condition value is determined in the density control. After this, in the case where the correction control mode is performed at least once, in the next density control the change range of value of the image forming condition determined based on the environment condition is shifted so as to include the corrected maximum density condition value determined in the latest correction control mode. The corrected maximum density condition value in the present invention includes the case where the maximum density condition value is unchanged before and after the correction control mode. Moreover, the shifting includes the case where the change range is actually not shifted. On the other hand, in the case where the correction control mode is not performed between when the density control is performed and when the next density control is performed, the change range of value of the image forming condition determined based on the environment condition is shifted so as to include the maximum density condition value determined when the density control is last performed. With such an arrangement, the maximum density can be appropriately adjusted in the density control, and the excessive correction of the maximum density by the subsequently created tone correction table is prevented. High image quality can thus be attained.
In this embodiment, the change range of value of the image forming condition determined based on the environment condition is shifted so as to include the current maximum density condition value, in the density control. However, the present invention is not limited to such an arrangement. For example, with an arrangement in which the maximum density condition value immediately before the execution of the density control is compared with the center value of the change range of value of the image forming condition determined based on the environment condition and the change range is shifted based on the difference, the changed range need not include the maximum density condition value. In detail, in the case where the maximum density condition value immediately before the execution of the density control is greater than the center value of the change range of value of the image forming condition determined based on the environment condition, the change range is shifted to increase the upper limit. In the case where the maximum density condition value immediately before the execution of the density control is less than the center value of the change range of value of the image forming condition determined based on the environment condition, the change range is shifted to decrease the lower limit. This arrangement enables the maximum density to be adjusted appropriately in the density control, as compared with the use of the conventional fixed change range. In this embodiment, in the case where the value γ is included in the change range determined by the environment condition, the change range is used without being shifted. However, the change range may be shifted to reduce the difference between the value γ and the center value of the change range determined by the environment condition, as described above with regard to the comparison with the center range.
The following describes Embodiment 2, mainly focusing on the differences from Embodiment 1. In Embodiment 1, the width of the shifted change range is the same as the width of the reference range. In detail, the width of the change range is the same as the width of the reference range, i.e. 2×|X|(%), regardless of whether or not the change range is shifted. However, in the case where, despite a significant change in the state of the image forming apparatus resulting from component replacement or the like before the execution of the density control, the shift is performed in the density control based on the exposure amount before the component replacement, an appropriate change range of the image forming condition may not be able to be obtained. Suppose, in a state where the value γ exceeds the second threshold as a result of continuous printing of low-duty images, the developing unit 4 is replaced, causing the toner charge amount to decrease from the amount before the replacement. The density control performed in such a state shifts the change range in the positive direction, but there is a possibility that all density levels of the formed test pattern are higher than the target maximum density because the toner charge amount is lower. In this embodiment, when the value γ is less than the first threshold, only the lower limit of the change range is changed while maintaining the upper limit at the reference level. Likewise, when the value γ is greater than the second threshold, only the upper limit of the change range is changed while maintaining the lower limit at the reference level.
As described above, according to this embodiment, the change range of value of the image forming condition determined based on the environment condition is widened so as to include the maximum density condition value determined in the latest correction control mode, in the density control. With such an arrangement, even in the case where, after the density-related image forming condition such as the exposure amount is determined in the correction control mode, the state of the image forming apparatus changes significantly as a result of component replacement or being left for a long time before the next density control is executed, the maximum density can be adjusted accurately.
In Embodiments 1 and 2, the lower limit of the change range is set to the value γ when the value γ is less than the first threshold, and the upper limit of the change range is set to the value γ when the value γ is greater than the second threshold. Moreover, the problem and its solution in the case where the direction of the change of the image forming condition determined last in the correction control mode with respect to the reference range is opposite to the direction in which the state of the image forming apparatus changes as a result of being left for a long time or the like are described in Embodiment 2. However, there is also a possibility that the direction of the change of the image forming condition determined last in the correction control mode with respect to the reference range is the same as the direction in which the state of the image forming apparatus changes as a result of being left for a long time or the like. Hence, in this embodiment, the lower limit of the change range is set to “γ−|σ|” when the value γ is less than the first threshold, and the upper limit of the change range is set to “γ+|σ|” when the value γ is greater than the second threshold. The value σ is a predetermined value stored in the ROM 113 or the RAM 112. The value σ may be different between when changing the lower limit and when changing the upper limit. With such an arrangement, even in the case where, after the execution of the correction control mode, the state of the image forming apparatus changes significantly as a result of component replacement or being left for a long time before the density control, the maximum density can be adjusted accurately.
In Embodiments 1 to 3, the test pattern formed on the recording material is read by the reading unit 216 to perform the density control. Alternatively, the test pattern may be formed on the photosensitive member 1 or the intermediate transfer belt 6 which is an image carrier, to perform the density control. In this case, for example, the density control may be automatically performed each time a predetermined number of sheets are printed. In the case where the test pattern is formed on the photosensitive member 1, the density sensor 12 detects the density in the density control. In the case where the test pattern is formed on the intermediate transfer belt 6, a density sensor for detecting the test pattern on the intermediate transfer belt 6 is provided to detect the density in the density control. According to this embodiment, the density control can be appropriately executed without consuming the recording material. In Embodiments 1 to 3, the test pattern formed on the recording material is placed on the platen 102 by the user and read. Alternatively, a density sensor for measuring the density of the image on the recording material conveyed through the conveyance path after the fixture may be provided to detect the density.
In each of the embodiments described above, the definition of the change range of value of the image forming condition in the density control and the comparison of increase/decrease between the maximum density condition value and the exposure amount determined by the environment condition in the density control are made in percentage. Alternatively, the comparison of increase/decrease and the definition of the change range centering on the exposure amount determined by the environment condition may be made using actual values.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2013-222683, filed on Oct. 25, 2013 which is hereby incorporated by reference herein in its entirety.
Number | Date | Country | Kind |
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2013-222683 | Oct 2013 | JP | national |