The present invention relates to a technique for correcting magnification in a sub-scanning direction.
Electrophotographic image forming apparatuses generally adopt a process for fixing toner images to sheets through the processes of charging, exposing, developing, transferring, and fixing.
Image forming apparatuses using an intermediate transfer method adopt an image forming process of primarily transferring toner images formed in an image forming unit to an intermediate transfer belt and then secondarily transferring the toner images formed on the intermediate transfer belt onto sheets, such as paper media, fed or conveyed thereto.
The secondary transfer is performed at a secondary transfer nip formed by pushing a secondary transfer member (a secondary-transfer inner roller) that stretches the back of the intermediate transfer belt with a roller (a secondary-transfer outer roller) facing the secondary transfer member from the front of the intermediate transfer belt.
Here, since the shape of the secondary transfer nip (secondary transfer nip portion) varies according to the fed sheet, it is known that various problems occur in secondary transfer according to the conditions of the sheet (for example, stiffness, basis weight, and surface characteristics).
For example, when sheets of different thicknesses, such as thin paper and thick paper, are fed, or when sheets with different surface characteristics, such as fine paper and glossy paper, are fed, the conveying force of the intermediate transfer belt applied to the sheets changes, and as a consequence, the sheet conveying velocity changes.
Also when toner is present between the intermediate transfer belt and the sheet at the secondary transfer nip, the intermediate transfer belt applies a conveying force to the sheet via the toner, and as a consequence, the conveying velocity changes.
Also for a surface of the sheet adjacent to the secondary-transfer outer roller (that is, the second side in duplex printing), the sheet conveying velocity changes according to whether a toner layer subjected to a fixing process is present on the surface of the sheet. In particular, when the secondary-transfer outer roller is driven, the difference causes a problem.
The change in the sheet conveying velocity, described above, appears, if it appears in the surface of the sheet), as partial expansion and contraction of images (partial magnification change) in the sheet conveying direction (an image sub-scanning direction), and if it appears across the sheet surface, as total expansion and contraction of images (total magnification change) in the sub-scanning direction.
To solve the above problems and satisfy the requirements for high quality images for diversified sheets in the recent commercial printing market, PTL 1 discloses a technique for preventing a magnification change by detecting the linear velocity of an intermediate transfer belt and a paper conveying velocity downstream of a transfer portion and controlling the velocity of the secondary transfer roller on the basis of the detection results.
The above invention claims to be able to control the total magnification change even if the sheet thickness changes by calculating the average velocity in the sheet surface using a sensor for measuring the sheet velocity, provided downstream from the transfer nip, and determining the conveying velocity of the secondary-transfer outer drive roller.
However, since this configuration adopts a method of calculating the average velocity of one sheet, it cannot follow a partial magnification change in a sheet surface. This can cause a partial magnification change in a sheet surface in printing images of significantly different toner bearings in a sheet surface.
Accordingly, an object of the present invention is to correct the partial magnification of images formed on a sheet with high accuracy.
To achieve the above object, an image forming apparatus according to an aspect of the present invention includes an image forming unit configured to form a toner image on an image bearing member, a rotatable transfer member that forms a transfer portion with the image bearing member, the transfer member being configured to transfer the toner image on the image bearing member to a recording medium, a driving source configured to drive the transfer member, a control unit configured to control a rotation velocity of the transfer member rotated by the driving source, and a reading unit configured to read the image formed on the recording medium, wherein the control unit is capable of making the image forming unit form a test chart including a plurality of test images including a first test image of a first density and a second test image formed at a position different from a position of the first test image in a conveying direction of the recording medium, the second test image having a second density different from the first density, making the transfer member transfer the test chart from the image bearing member to the recording material, and outputting the test chart, and wherein the control unit is configured to control the rotation velocity of the transfer member at transfer based on a result of reading the test chart transferred to the recording medium with the reading unit.
The present invention allows the partial magnification of images formed on a sheet to be corrected with high accuracy.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
An image forming apparatus according to an embodiment of the present invention will be described hereinbelow with reference to the drawings. The following is an example in which the present invention is applied to an electrophotographic full-color image forming apparatus including a plurality of photosensitive drums. However, this is illustrative only, and the present invention can also be applied to various types of image forming apparatus and a single-color image forming apparatus.
The schematic configuration of the image forming apparatus of this embodiment will be first described with reference to
An image forming apparatus 1000 includes an image reading unit 300 and an image forming apparatus main body 400. The image reading unit 300 reads an original placed on a platen glass 302, in which the light emitted from a light source 303 is reflected by the original to form an image on a charge-coupled device (CCD) sensor 305 through an optical member 304 such as a lens. Such an optical unit moves in the direction of the arrow to convert the original to an electrical signal data string per line.
The image signals obtained by the CCD sensor 305 are sent to the image forming apparatus main body 400. The image signals are processed by an image processing unit 500 according to each image forming unit. The image processing unit 500 can receive external image signals input from, for example, a print server. The image forming apparatus main body 400 includes a plurality of image forming units Pa, Pb, Pc, and Pd, where images are formed on the basis of the image signals. In other words, the image processing unit 500 transmits image signals to a control unit 309, where the image signals are converted to pulse-width modulated (PWM) laser beams. In
Reference sign Pa denotes a yellow (Y) image forming unit, Pb denotes a magenta (M) image forming unit, Pc denotes a cyan (C) image forming unit, and Pd denotes a black (Bk) image forming unit, which form corresponding color images. Since the image forming units Pa to Pd are substantially the same, the details of the Y image forming unit Pa will be described below, and descriptions of the other image forming units will be omitted. In the Y image forming unit Pa, 200a denotes a photosensitive drum, on which a toner image is formed in accordance with the image signal.
Reference sign 201a denotes a primary charger, which charges the surface of the photosensitive drum 200a to a predetermined potential to prepare to form an electrostatic latent image. The laser beam from the polygon scanner 310 forms an electrostatic latent image on the surface of the photosensitive drum 200a charged to the predetermined potential. Reference sign 202a denotes a developer, which develops the electrostatic latent image on the photosensitive drum 200a to form a toner image. Reference sign 203a denotes a transfer roller, which discharges electricity from the back of an intermediate transfer belt 204 serving as an image bearing member to apply a primary transfer bias of a polarity opposite to that of the toner to transfer the toner image on the photosensitive drum 200a onto the intermediate transfer belt 204. The surface of the photosensitive drum 200a after the transfer is cleaned with a cleaner 207a.
The toner image on the intermediate transfer belt 204 is conveyed to the next image forming unit in the order of Y, M, C, and Bk to form a four-color toner image on a surface of the intermediate transfer belt 204. The toner image that has passed through the Bk image forming unit is secondarily transferred to a sheet P from the intermediate transfer belt 204 by receiving a secondary transfer electric field of the same polarity as that of the toner image on the intermediate transfer belt 204 at a secondary transfer portion constituted by a secondary transfer roller pair 205 and 206. A fed sheet P waits at a registration portion 208 and is then conveyed from the registration portion 208 at the timing controlled by a central processing unit (CPU) 600 (see
For a job to print on both sides of the sheet P, after the toner transfer and fixing processes on image-formation first side (the first side) are completed, the sheet P is taken into a reversing portion 209 in the image forming apparatus 1000 after the fixation, where the sheet P stops once and its conveying direction is reversed, so that the leading end and the trailing end of the sheet Pare reversed. The sheet P is then reversed inside out through a duplex conveying unit 210, toner transfer and fixing processes on the image-formation second side (the second side) are completed, and the sheet P is discharged out of the image forming apparatus 1000.
As described above, the partial magnification change and the total magnification change in the sub-scanning direction due to a change in sheet conveying velocity at the secondary transfer nip are caused by differences in the thickness and the surface characteristics of the sheet P and the density of toner on the intermediate transfer belt 204. This is because of a change in sheet velocity due to a change in the conveying force that the sheet P receives from the intermediate transfer belt 204, which causes a change in the difference between the velocity of the intermediate transfer belt 204 (toner image) and the sheet velocity. In the present invention, the sheet velocity is controlled, and the expanding and contracting components of the image itself are out of control, and descriptions thereof will be omitted.
To correct a change in sheet velocity relative to the intermediate transfer belt 204, a drive source M rotates the secondary-transfer outer roller. The velocity of the secondary-transfer outer roller can be changed independently from the velocity of the intermediate transfer belt 204. This allows the sub-scan magnification to be corrected, when the sheet velocity is faster than that of the intermediate transfer belt 204, by decreasing the rotation velocity of the secondary-transfer outer roller, and when the sheet velocity is lower than that of the intermediate transfer belt 204, by increasing the rotation velocity of the secondary-transfer outer roller. Since the image transferred to the sheet P need only have a correct magnification (1.00 times), the circumferential velocity of the intermediate transfer belt 204 and the rotation velocity of the secondary-transfer outer roller are not necessarily set equal.
Next, correction of partial magnification in the sub-scanning direction in the present invention will be described.
First, the user stores the sheets P to be used in a sheet feeding unit, sets sheet information via an operating unit 601, and presses a velocity-profile obtaining button displayed on the operating unit 601. This causes the control unit 309 of the image forming apparatus 1000 to start to print a test chart for obtaining the velocity profile.
The test chart has scale images at regular intervals in the conveying direction, as shown in
In the test chart, all the positions, the features, the width of the scale images, and the distribution of the coverage in the sheet are selectable.
The images on the first side of the test chart are transferred to the sheet at the transfer portion and are fixed at the fixing unit 700. The test chart is reversed at the reversing portion 209, passes through the duplex conveying unit 210 into the transfer portion and fixing unit 700 again, where the second side is printed, and is discharged out of the image forming apparatus 1000. The scale images are printed to form a test chart in the conveying direction also on the second side, as well as the first side, in which the coverage is distributed in the conveying direction.
The reason why the two kinds of velocities V1 and V2 of the secondary-transfer outer roller are obtained is because the slip curve between the secondary-transfer outer roller and the sheet changes according to the velocity of the secondary-transfer outer roller, and the degree of effect of adjustment of the velocity of the secondary-transfer outer roller to make the sheet velocity constant on the actual sheet velocity depends on the degree of change in the secondary-transfer outer roller velocity. Accordingly, the velocity sensitivity is calculated from the deviation amount of the sub-scan magnification at the two velocities V1 and V2 of the secondary-transfer outer roller in the area of the same coverage.
The difference ΔV between the velocities V1 and V2 is expressed as:
Since the coverage in the test chart is distributed, the deviation ΔS is obtained according to the coverage.
As shown in the velocity profile (
In other words, the secondary-transfer outer roller velocity V(α) at any toner density α is expressed as:
When the interval between the scale images printed on the sheet is long, that is, when the sheet velocity is higher than the velocity of the intermediate transfer belt, the scale images are transferred at an extended size, and as a consequence, the sub-scan magnification deviation S takes a positive value. In contrast,
when the sheet velocity is lower than the velocity of the intermediate transfer belt, the scale images are transferred in a reduced size, and as a consequence, the sub-scan magnification deviation S takes a negative value.
Thus, the target secondary-transfer outer roller velocity is determined according to each toner coverage. The above operation is performed on the first side, and the target velocity of the secondary-transfer outer roller in transferring the first side of the image is determined. The distribution of the target velocity of the secondary-transfer outer roller for the toner coverage on the first side is referred to as a first side velocity profile fs(c), where c is the function of the coverage.
For the second side, the scale images in the test chart are read by an internal or external reading unit, as for the first side. For the second side, the proportion of contact between the secondary-transfer outer roller and the sheet/toner changes according to the coverage of the toner image formed on the first side, and as a consequence, the efficiency of drive transmission to the sheet changes. For this reason, a second-side velocity profile fr(c) is the first side velocity profile fs(c) minus the effect of the first side toner coverage in image forming on the second side.
A first-side coverage effect profile f′s(c) is expressed as:
where f′r(c) is the velocity profile obtained from the image formed on the second side.
Therefore, the velocity profile fr(c) of the second side is expressed as:
where cs is the coverage of the intermediate transfer belt side (the second side), and cr is the coverage of the secondary-transfer outer roller side (the first side at image formation of the second side).
In this example, the same image is passed on the first side and the second side, as shown in
In this example of the test chart, the coverage of the first side image corresponding to the 50% coverage portion of the second side is 100%. Therefore, the target velocity of the secondary-transfer outer roller for the 50% coverage portion of the second side is expressed as:
The above example illustrates a method of using the reading unit of the image forming apparatus. As an alternative, scale images may be calculated from an external reading unit and the deviation of the scale images may be input via the operating unit of the image forming apparatus. As a further alternative, scale images may be automatically read using a reading unit provided in a conveying path of the image forming apparatus main body.
Next, the control block diagram of the image forming apparatus 1000 will be described with reference to
The operating unit 601 is a user interface (UI) (an input unit, a display unit) that transmits and receives electrical information to/from the CPU 600. The operating unit 601 is used to input setting and instruction for an image forming mode from the user (operator) to the CPU 600. The CPU 600 gives status information on the image forming apparatus 1000 for the user to the operating unit 601. The CPU 600 controls all of the mechanical components of the image forming apparatus 1000 as a whole.
The user selects a sheet and a sheet feeding stage to be used via the operating unit 601, and the control unit 309 uses a velocity profile associated with the selected sheet in the media library of the storage 501 according to the selected media information. The velocity profile has initial value settings for the sheet to be used for the first time. This is a general profile predicted from the information on the sheet, such as a basis weight and surface characteristics. Creating a profile for the sheet to be actually used is needed in reducing a sub-scan magnification change.
Therefore, the image forming apparatus 1000 is capable of overwriting velocity profile information in the media library for the sheet selected by the user with the obtained velocity profile. This allows a velocity profile associated with the sheet grade to be stored and allows for correction of the difference among the components, such as the diameters of the secondary transfer rollers, enabling a sub-scan magnification change to be prevented with higher accuracy.
As shown in
The image forming apparatus 1000 digitally processes image information in printing according to an input from an external processing unit or copying with the reading unit, and the image processing unit 500 notifies the control unit 309 of the processed image information as toner coverage distribution information on the sheet. The control unit 309 controls the secondary-transfer outer roller velocity in accordance with the toner coverage distribution information and the velocity profile information stored in the storage 501. The timing of velocity control of the secondary-transfer outer roller and the sheet position can be controlled by timing the sheet to the image with the registration portion 208 or using a conveyance sensor provided upstream from the secondary transfer portion.
For example, when a 100% coverage image is transferred on the first side, the secondary-transfer outer roller is operated at the target velocity obtained from fs(100). When the second side of the sheet has a 50% coverage image, the target secondary-transfer outer roller velocity is expressed as fr(50)=fs(50)−{fr(100)−fs(100)}. As will be understood, the more coverage information in the sheet conveying direction, that is, the more the number of divisions in the conveying direction, the more detailed control for the secondary-transfer outer roller driving velocity can be performed, allowing more detailed partial magnification correction.
The image forming apparatus 1000 described above changes the driving velocity of the secondary-transfer outer roller when obtaining the first side and second side velocity profiles. Alternatively, as shown in
If a sub-scan magnification change is still concerned even using the velocity profile stored in the media library, the user can manually adjust the velocity profile via the operating unit 601 as shown in
The present invention can also be realized by one or more processors of a computer of a system or apparatus that reads out and executes programs for performing the functions of one or more of the above-described embodiments recorded on a storage medium or via network to perform the functions and/or one or more circuits (e.g., application specific integrated circuit (ASIC)) for performing the functions of one or more of the above-described embodiments.
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.
Number | Date | Country | Kind |
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2020-180801 | Oct 2020 | JP | national |
This application is a Continuation of patent application Ser. No. 18/190,688, filed Mar. 27, 2023, which is a Continuation of International Patent Application No. PCT/JP2021/038617, filed Oct. 19, 2021, which claims the benefit of Japanese Patent Application No. 2020-180801, filed Oct. 28, 2020, both of which are hereby incorporated by reference herein in their entirety.
Number | Date | Country | |
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Parent | 18190688 | Mar 2023 | US |
Child | 18655156 | US | |
Parent | PCT/JP2021/038617 | Oct 2021 | WO |
Child | 18190688 | US |