The present invention relates to speed control of an image bearing member in an image forming apparatus that forms images on the image bearing member.
Electrophotography image forming apparatus form an electrostatic latent image on an image bearing member, and form an image by developing the electrostatic latent image using a developing agent. The developed image on the image bearing member is temporarily transferred to an intermediate transfer member, and thereafter the image on the intermediate transfer member is transferred to a sheet.
It is required of an image forming apparatus to control the speed (surface speed) of the surface of the image bearing member moving, and the speed (surface speed) of the surface of the intermediate transfer member moving, to a constant speed. The reason is that a laser beam for developing the electrostatic latent image on the image bearing member scans the image bearing member at a predetermined timing. In a case where the surface speed of the image bearing member changes, for example, the length of the image might change due to change in the pitch of scanning lines, and variance in density might occur in the image on the image bearing member. Accordingly, image forming apparatuses executed feedback control based on output of an encoder for example, to control the surface speed of the image bearing member and the surface speed of the intermediate transfer member.
Now, even if the surface speed of the image bearing member and the surface speed of the intermediate transfer member can be controlled to a constant speed, there has been the possibility that the surface speed of the image bearing member and the surface speed of the intermediate transfer member would become uncontrollable in accordance with a load state at a nip portion for transferring an image on the image bearing member onto the intermediate transfer member. That is to say, there has been the possibility that the motor load will suddenly change at the time of transitioning from a state where developing agent is interposed at the nip portion to a state where developing agent is not interposed at the nip portion, and the rotation speed of the motor will become uncontrollable. Image defects such as described above occur in a state where the rotation speed of the motor has become uncontrollable.
In an image forming apparatus described in U.S. Patent Application Publication No. 2015/0362867, a target speed of the image bearing member is adjusted so that the load on the motor in a state where developing agent is supplied to the nip portion and the load on the motor in a state where developing agent is not supplied to the nip portion are reduced. This image forming apparatus acquires motor drive signals while supplying developing agent to the nip portion and switching motor speed instruction values, and acquires motor drive signals while not supplying developing agent to the nip portion and switching motor speed instruction values. Note that this image forming apparatus executes feedback control so that the rotation speed of the motor is a speed corresponding to the speed instruction value, so the motor drive signals change in accordance with the load of the motor. That is to say, this image forming apparatus predicts motor load from motor drive signals.
However, the image forming apparatus in U.S. Patent Application Publication No. 2015/0362867 switches the motor rotation speed to adjust the target speed of the image bearing member. Accordingly, images cannot be formed on sheets while the image forming apparatus is acquiring motor speed instruction values. That is to say, this image forming apparatus has had a problem in that great downtime occurs in order to decide the target speed for the image bearing member.
The image forming apparatus described in U.S. Patent Application Publication No. 2015/0362867 adjusts the target speed of the image bearing member at a timing where image forming operations are not being executed. However, in a case where the image forming apparatus forms a great number of images, friction between the image bearing member and intermediate transfer member changes. Accordingly, there has been a problem that the motor load changes when transitioning from a state where developing agent is interposed at the nip portion to a state where developing agent is not interposed at the nip portion. Accordingly, updating of the target speed of the image bearing member could not be performed at an appropriate timing in a case of continuously forming multiple images with the image forming apparatus described in U.S. Patent Application Publication No. 2015/0362867. That is to say, the target speed of the image bearing member could not be corrected to an appropriate target speed while the image forming apparatus is continuously forming multiple images.
An image forming apparatus that forms an image on a sheet includes an image forming unit, an intermediate transfer member, a transfer member, a transfer unit, a motor, a motor control unit, and a controller. The image forming unit includes a photosensitive member and a developer bearing member configured to bear a developing agent, and is configured to form the image on the photosensitive member using the developing agent. The image is transferred onto the intermediate transfer member. The transfer member is configured to form a nip portion for transferring the image formed on the photosensitive member onto the intermediate transfer member. The transfer unit is configured to transfer the image transferred onto the intermediate transfer member onto the sheet. The motor is configured to rotate the photosensitive member. The motor control unit is configured to control the motor so that the rotation speed of the photosensitive member is a target rotation speed. The controller is configured to acquire first load information of the photosensitive member in a first period where the motor control unit controls the motor to rotate the photosensitive member, the developer bearing member rotates, and the intermediate transfer member rotates, acquire second load information of the photosensitive member in a second period where the motor control unit controls the motor to rotate the photosensitive member, rotation of the developer bearing member is stopped, and the intermediate transfer member rotates, and control whether or not to change the target rotation speed based on the first load information and the second load information. The image forming unit consecutively forms a plurality of images while rotating the developer bearing member. In a case where the number of sheets on which the image is formed reaches a predetermined number while the plurality of images are consecutively being formed, the controller stops the image formation by the image forming unit and acquires the first load information, stops rotation of the developer bearing member and acquires the second load information, and controls whether or not to change the target rotation speed based on the first load information and the second load information.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
A photosensitive drum 10 (10y, 10m, 10c, 10bk) is an image bearing member that bears electrostatic latent images and images (developing agent images). A photosensitive layer is formed on the surface of the photosensitive drum 10. Accordingly, the photosensitive drum 10 serves as a photosensitive member. A charger 21 (21y, 21m, 21c, 21bk) uniformly charges the surface of the photosensitive drum 10. An exposing device 22 (22y, 22m, 22c, 22bk) exposes the charged photosensitive drum 10 and forms an electrostatic latent image. A laser beam from the exposing device 22 scans the surface of the photosensitive drum 10. The direction in which the laser beam scans the photosensitive drum 10 is referred to as the “main scanning direction”. The exposing device 22 has optical members such as a rotary polygonal mirror rotationally driven to scan the laser beam, mirrors, lenses, and so forth. A developing unit 1 (1y, 1c, 1m, 1bk) develops the electrostatic latent image using developing agent, thereby forming an image. The developing agent is, for example, a two-component developing agent containing a non-magnetic developing agent and a magnetic carrier. Transfer bias Vtr1 is applied to a primary transfer roller 23 (23y, 23m, 23c, 23bk). Accordingly, the image borne by the photosensitive drum 10 is transferred by the primary transfer roller 23 onto an intermediate transfer belt 24. The intermediate transfer belt 24 functions as an intermediate transfer member onto which the image on the photosensitive drum 10 is transferred. Transfer bias Vtr2 is applied to a secondary transfer roller 29. Thus, the secondary transfer roller 29 transfers the image borne by the intermediate transfer belt 24 onto a sheet P.
A fixing unit 27 heats the image on the sheet P to fix the image onto the sheet P. A drum cleaner 26 (26y, 26c, 26m, 26bk) has a blade that comes into contact with the photosensitive drum 10. The drum cleaner 26 removes residual developing agent that was not transferred from the photosensitive drum 10 to the intermediate transfer belt 24. A blade of the drum cleaner 26 functions as a removal member that removes developing agent on the photosensitive drum 10. A belt cleaner 28 has a blade that comes into contact with the intermediate transfer belt 24, and removes residual developing agent that was not transferred from the intermediate transfer belt 24 to the sheet P. A developing agent supply bin 20 (20y, 20c, 20m, 20bk) supplies developing agent to the developing unit 1. A sensor 14 has a light emitting element and a light receiving element. The sensor 14 is an optical sensor that measures reflected light from a measuring image formed on the intermediate transfer belt 24. The measuring image is formed by the image forming units 5y, 5m, 5c, and 5bk.
Images formed by the image forming units 5y, 5m, 5c, and 5bk are transferred so as to be overlaid on the intermediate transfer belt 24. Accordingly, a full-color image is borne by the intermediate transfer belt 24. Accordingly, if the image formation positions (image formation timings) of the image forming units 5y, 5m, 5c, and 5bk are off, the color of the full-color image cannot be compensated. For example, there is a possibility that the image formation positions of the image forming units 5y, 5m, 5c, and 5bk may change due to temperature change of the image forming apparatus 100 or the number of images formed. Relative positional misalignment of images formed by the image forming units 5y, 5m, 5c, and 5bk is referred to as “color misregistration”.
In order to correct color misregistration, the image forming apparatus 100 forms a measuring image (pattern image) for each color on the intermediate transfer belt 24, and detects the color registration amount by the sensor 14. The image forming apparatus 100 then corrects the write timing (exposure timing) for the image forming units 5y, 5m, 5c, and 5bk to form electrostatic latent images, based on the detected color registration amount. This processing is referred to as “color registration adjustment”.
Color patterns 48y, 48m, 48c, and 48bk, each of a different color, are included in the pattern images, as illustrated in
The image forming apparatus 100 acquires the time at which each of the color patterns 48y, 48m, 48c, and 48bk passed the sensor 14, based on the output values of the sensor 14. The image forming apparatus 100 measures transit time Lys at which the yellow color pattern 48y, for example, has passed the measurement position of the sensor 14, based on the measurement results by the sensor 14. The transit time Lys corresponds to the time of one edge of the yellow color pattern 48y passing the measurement position of the sensor 14 in the conveyance direction of the intermediate transfer belt 24, until the other edge of the yellow color pattern 48y reaches the measurement position of the sensor 14 in the conveyance direction. The image forming apparatus 100 similarly acquires transit time Lms of magenta color pattern 48m, transit time Lcs of cyan color pattern 48c, and transit time Lbks of black color pattern 48bk, based on measurement results of the sensor 14.
The transit times Lys, Lms, Lcs, and Lbks represent the image formation positions of the color patterns in the main scanning direction (direction orthogonal to the conveyance direction of the intermediate transfer belt 24). That is to say, the transit times Lys, Lms, Lcs, and Lbks represent the relative positional relationship between the color patterns in the main scanning direction. Accordingly, the color misregistration amount in the main scanning direction can be corrected by correcting the write timing of the images of each color in the main scanning direction, so that the transit times Lys, Lms, Lcs, and Lbks are the same value.
Next, a method for correcting the write timing for images of each color in the sub-scanning direction will be described. Transit time Lym corresponds to the time of the center position of the color pattern 48y passing the measurement position of the sensor 14 until the center position of the color pattern 48m reaches the measurement position of the sensor 14 in the conveyance direction. That is to say, the transit time Lym represents the relative positional relationship between the yellow color pattern 48y and the magenta color pattern 48m in the sub-scanning direction. The image forming apparatus 100 corrects the write timing of the magenta image in the sub-scanning direction so that the transit time Lym is a predetermined target transit time.
The transit time Lyc corresponds to the time of the center position of the color pattern 48y passing the measurement position of the sensor 14 until the center position of the color pattern 48c reaches the measurement position of the sensor 14. The transit time Lybk corresponds to the time of the center position of the color pattern 48y passing the measurement position of the sensor 14 until the center position of the color pattern 48bk reaches the measurement position of the sensor 14. The image forming apparatus 100 corrects the write timing of the cyan image in the sub-scanning direction so that the transit time Lyc is a predetermined target transit time in the sub-scanning direction, and corrects the write timing of the black image in the sub-scanning direction so that the transit time Lybk is a predetermined target transit time in the sub-scanning direction.
Thus, the correction amount of write timings in the main scanning direction and the correction amount of write timings in the sub-canning direction are decided based on the transit times of the color patterns 48y, 48m, 48c, and 48bk. Color misregistration is corrected by the decided correction amounts being reflected in the write timings by the exposing devices 22 handling each color.
The photosensitive drum 10 and intermediate transfer belt 24 are rotationally driven while in contact. Accordingly, if the circumferential speed of the photosensitive drum 10 and the circumferential speed of the intermediate transfer belt 24 do not match, the length of the image may be incorrect, and banding may occur. Accordingly, the circumferential speed of the photosensitive drum 10 and the circumferential speed of the intermediate transfer belt 24 are adjusted to a level where incorrect image length and banding are not manifested. The image forming apparatus 100 has the target speed of the photosensitive drum 10 and the target speed of the intermediate transfer belt 24 set to different values, such that the circumferential speed of the photosensitive drum 10 is greater than the circumferential speed of the intermediate transfer belt 24, in order to increase transfer efficiency. The target value of the surface speed of the photosensitive drum 10 is around 0.15% faster than the target value of the surface speed of the intermediate transfer belt 24, for example.
The motor M3 drives the motor gear 31. The motor gear 31 meshes with the drum drive gear 35, and transmits the driving force transmitted from the motor M3 to the drum drive gear 35. The photosensitive drum 10 is fixed on a shaft of the drum drive gear 35, so the photosensitive drum 10 is rotated by the motor M3 driving the drum drive gear 35. The encoder 34 is fixed on the shaft of the drum drive gear 35. The encoder 34 is a rotating plate in which multiple slits are provided. The two speed sensors 32 and 33 are provided so as to detect these slits. The speed sensors 32 and 33 each have a light emitting element and a light receiving element, and count the number of rotations where light emitted from the light emitting element passes through the slits and reaches the light receiving element. The number of counts per unit of time is equivalent to the rotation speed of the photosensitive drum 10. The outputs of the two speed sensors 32 and 33 are averaged. This is to reduce the effect of eccentricity of the encoder 34.
The image forming apparatus 100 has a motor driver 1300 (
The image forming apparatus 100 performs feedback control of the current (PWM signals) flowing at the motor M4, so that the rotation speed of the drive gear 41 detected by the speed sensors 37 and 38 is the target speed. That is to say, the PWM signal value supplied to the motor M4 is controlled so that the moving speed of the intermediate transfer belt 24 is the target speed. The PWM signal value supplied to the motor M4 is equivalent to the value of the current flowing at the motor M4. Further, in a state where the rotation speed of the drive roller 40 is controlled to the target speed, the PWM signal value input to the motor M4 changes in accordance with the load on the drive roller 40. That is to say, the PWM signal value input to the motor M4 is information relating to torque, or load, of the intermediate transfer belt 24.
Next, the adverse effects of friction between the photosensitive drum 10 and intermediate transfer belt 24 increasing will be described in detail. Note that the target speed of the surface speed of the photosensitive drum 10 is, for example, 0.15% faster than the target speed of the surface speed of the intermediate transfer belt 24. That is to say, the circumferential speed difference between the intermediate transfer belt 24 and the photosensitive drum 10 is 0.15%.
There are generally two states regarding the friction acting between the photosensitive drum 10 and the intermediate transfer belt 24. One is a state where the photosensitive drum 10 rotates, the intermediate transfer belt 24 rotates, and the developing sleeve 8 rotates. The image forming apparatus 100 is in the first state when forming images. In the first state, developing agent is supplied to the nip portion of the photosensitive drum 10 and intermediate transfer belt 24 (developing nip portion). That is to say, developing agent is interposed at the plane of transfer between the photosensitive drum 10 and intermediate transfer belt 24. The second state is a state where the photosensitive drum 10 rotates and the intermediate transfer belt 24 rotates, but the developing sleeve 8 is stopped. In the second state, developing agent is not interposed at the nip portion of the photosensitive drum 10 and intermediate transfer belt 24. That is to say, no developing agent is interposed at the plane of transfer between the photosensitive drum 10 and intermediate transfer belt 24. This second state is a state after developing one page worth of images, or before image formation starts, for example.
When the developing sleeve 8 rotates, developing agent is supplied to the photosensitive drum 10, thereby consuming developing agent within the developing unit 1. Accordingly, the image forming apparatus 100 only rotates the developing sleeve for a minimally necessary amount of time for image formation. That is to say, the image forming apparatus 100 starts rotation of the developing sleeve 8 at a timing immediately before image formation, and stops rotation of the developing sleeve 8 promptly after ending image formation.
In a case of forming images based on image data, the image forming apparatus 100 transitions from a state where there is no developing agent interposed at the nip portion to state where developing agent is interposed at the nip portion. After forming images based on image data, the image forming apparatus 100 then transitions from state where developing agent is interposed at the nip portion so state where there is no developing agent interposed at the nip portion.
In a case where the friction force between the photosensitive drum 10 and intermediate transfer belt 24 greatly differs between the first state and the second state, a great load change will be placed upon the photosensitive drum 10 and intermediate transfer belt 24 when the state at the nip portion changes in the image forming apparatus 100. The state at the nip portion changes when starting image formation, so a load change occurs at the photosensitive drum 10 and intermediate transfer belt 24 every time the image forming apparatus 100 starts image formation. In a case where the amount of change in load exceeds a permissible range, the rotation speed of the motor M3 rotating the photosensitive drum 10 and the motor M4 rotating the drive roller 40 will become unstable. Forming images in a state where the rotation speed of the motor M3 or the rotation speed of the motor M4 is unstable will result in change in image density and occurrence of color misregistration.
Accordingly, the image forming apparatus 100 executes control to reduce the difference in the surface speed of the photosensitive drum 10 and the surface speed of the intermediate transfer belt 24, in accordance with the frictional force between the photosensitive drum 10 and intermediate transfer belt 24. Accordingly, the image forming apparatus 100 can reduce the difference in speed before image defects occur, and reduce frictional force.
Description will be made regarding the phenomenon where frictional force increases when the speed difference increases. Generally, there are two types of frictional force between objects; static frictional force and kinetic frictional force. Kinetic frictional force does not change in accordance with the relative speed between objects, and is a constant value. Accordingly, even if the difference in speed between the photosensitive drum 10 and intermediate transfer belt 24 changes, the kinetic frictional force is constant. However, it is generally known that kinetic frictional force becomes constant when the speed difference between objects is rather great. The speed difference between the photosensitive drum 10 and the intermediate transfer belt 24 in the image forming apparatus 100 is normally around 1% or so. Accordingly, the physical law that kinetic frictional force is constant does not apply here. It is also known that in systems where speed difference is minute, such as in this case, the greater the speed difference is, the greater the frictional force becomes, as illustrated in
The image forming apparatus 100 acquires the PWM signal value of the motor M3 in a state where developing agent is interposed at the nip portion, and the PWM signal value of the motor M3 in a state where no developing agent is interposed at the nip portion. The image forming apparatus 100 controls whether or not to change the target speed of the photosensitive drum 10, based on the PWM signal values acquired in the two states. Adjustment processing for adjusting the target speed of the photosensitive drum 10 will be described below. The image forming apparatus 100 can set the target speed of each of the photosensitive drums 10 of the image forming units 5y, 5m, 5c, and 5bk.
Motor M3y is the motor that rotates the photosensitive drum 10 forming yellow images (hereinafter referred to as photosensitive drum 10y) at the image forming unit 5y. Motor M3m is the motor that rotates the photosensitive drum 10 forming magenta images (hereinafter referred to as photosensitive drum 10m) at the image forming unit 5m. The image forming apparatus 100 further has a motor (omitted from illustration) that rotates the photosensitive drum 10 forming cyan images at the image forming unit 5c, and motor (omitted from illustration) that rotates the photosensitive drum 10 forming black images at the image forming unit 5bk.
Speed sensors 32y and 33y are optical sensors attached to the drive gear of the photosensitive drum 10y. The speed sensors 32y and 33y output detection results corresponding to rotation information of the photosensitive drum 10y. Further, speed sensors 32m and 33m are optical sensors attached to the drive gear of the photosensitive drum 10m. The speed sensors 32m and 33m output detection results corresponding to rotation information of the photosensitive drum 10m. The image forming apparatus 100 further has speed sensors that detection results corresponding to output rotation information of the photosensitive drum 10 that forms cyan images at the image forming unit 5c, and speed sensors that detection results corresponding to output rotation information of the photosensitive drum 10 that forms black images at the image forming unit 5bk.
A pattern generator 70 outputs measuring image data in a case where color registration adjustment is executed. The image forming units 5 form pattern images (
The color misregistration amount determining unit 1004 computes transit time Lys, Lms, Lcs, and Lbks, and transit time Lym, Lyc, and Lybk, based on the measurement results of the pattern images by the sensor 14. The color misregistration amount determining unit 1004 then determines the color misregistration amount in the main scanning direction from the transit time Lys, Lms, Lcs, and Lbks, and determines the color misregistration amount in the sub-scanning direction from the transit time Lym, Lyc, and Lybk. Color registration amount, containing the color misregistration amount in the main scanning direction and the color misregistration amount in the sub-scanning direction, is output to a color registration adjustment unit 1003.
The color registration adjustment unit 1003 corrects the write timing for the images of each color, based on the color registration amount. The method by which the color registration adjustment unit 1003 corrects the write timing based on the color registration amount is known technology, so description will be omitted here.
A motor driver 1300 belt controls PWM signal values input to the motor M4, so that the rotation speed of the drive roller 40 detected by the speed sensors 37 and 38 are at a target rotation speed. Accordingly, the current flowing at the motor M4 is controlled such that the rotation speed of the drive roller 40 for driving the intermediate transfer belt 24 is the target rotation speed.
Upon the target rotation speed of the photosensitive drum 10y having been set, the motor driver 1300y controls the PWM signal value input to the motor M3y, so that the rotation speed of the photosensitive drum 10y detected by the speed sensors 32y and 33y is the target rotation speed. Accordingly, current flowing at the motor M3y is controlled so that the rotation speed of the photosensitive drum 10y is the target rotation speed. The PWM signal value for controlling the motor M3y, output from the motor driver 1300y, is stored in the RAM 1200. This is for a later-described target speed deciding unit 1002y to decide the target rotation speed of the photosensitive drum 10y based on the PWM signal value of the motor M3y stored in the RAM 1200. The motor driver 1300y controls driving of the motor M3y.
Upon the target rotation speed of the photosensitive drum 10m having been set, the motor driver 1300m controls the PWM signal value input to the motor M3m, so that the rotation speed of the photosensitive drum 10m detected by the speed sensors 32m and 33m is the target rotation speed. Accordingly, current flowing at the motor M3m is controlled so that the rotation speed of the photosensitive drum 10m is the target rotation speed. The PWM signal value for controlling the motor M3m, output from the motor driver 1300m, is stored in the RAM 1200. This is for a later-described target speed deciding unit 1002m to decide the target rotation speed of the photosensitive drum 10m based on the PWM signal value of the motor M3m stored in the RAM 1200. The motor driver 1300m functions as a drive control unit that controls driving of the motor M3m.
The image forming apparatus 100 further has a motor driver (omitted from illustration) that controls driving of a motor (omitted from illustration) that rotates the photosensitive drum 10 by which cyan images are formed at the image forming unit 5c, and a target speed deciding unit that decides a target rotation speed of the motor. In the same way, the image forming apparatus 100 also has a motor driver (omitted from illustration) that controls driving of a motor (omitted from illustration) that rotates the photosensitive drum 10 by which black images are formed at the image forming unit 5bk, and a target speed deciding unit that decides a target rotation speed of the motor.
The target speed deciding unit 1002y may be realized by an application specific integrated circuit (ASIC), for example. The target speed deciding unit 1002y decides a target speed where the surface speed of the photosensitive drum 10 is faster than the surface speed of the intermediate transfer belt 24, unless the frictional force between the photosensitive drum 10 and the intermediate transfer belt 24 is not at a value to cause image defects. On the other hand, in a case where the frictional force between the photosensitive drum 10 and the intermediate transfer belt 24 has increased to a level that will cause image defects, the target speed deciding unit 1002y changes the target speed of the photosensitive drum 10y in the target speed adjustment processing. That is to say, the target rotation speed of the photosensitive drum 10y is set so that the difference between the target value of the surface speed for the photosensitive drum 10y and the target value of the surface speed for the intermediate transfer belt 24 is reduced. The target speed deciding unit 1002y reads out the PWM signal value in the first state and the PWM signal value in the second state that are stored in the RAM 1200, and decides a target value for the photosensitive drum 10y based on the PWM signal value in the first state and the PWM signal value in the second state. The target speed deciding unit 1002y may have a configuration where part of the functions of the CPU 1000 decides the target speed based on a PWM signal.
Image forming operations where the image forming apparatus 100 forms images based on image data will be described based on the flowchart in
First, the CPU 1000 rotates the photosensitive drum 10, intermediate transfer belt 24, and developing sleeve 8 (S800). The motor driver 1300 controls PWM signals input to the motor M3. The motor driver 1300 executes feedback control based on the detection results of the speed sensors 32 and 33, so that the rotation speed of the photosensitive drum 10 is the target speed. Note that each time an image is formed, the motor driver 1300 updates the PWM signal value. The motor M3 rotates the photosensitive drum 10 based on the PWM signal value input from the motor driver 1300. The motor driver 1300 belt executes feedback control based on the detection results of the speed sensors 37 and 38, so that the surface speed of the intermediate transfer belt 24 is the target speed. The motor driver 1300 belt updates the PWM signal value each time an image is formed. The motor M4 rotates the drive roller 40 of the intermediate transfer belt 24 based on the PWM signal value input from the motor driver 1300 belt. Note that the PWM signal value output from the motor driver 1300 (1300y, 1300m, 1300c, 1300bk) is not only supplied to the motor M3 (M3y, M3m, M3c, M3bk), but also is stored in the RAM 1200.
The motors M1 and M2 rotate the developing sleeve 8 and agitation member 6 of the developing unit 1 in step S800. Feedback control is executed so that the motor M1 that rotates the agitation member 6 rotates at a predetermined speed. Further, feedback control is executed so that the motor M2 that rotates the developing sleeve 8 rotates at a standard speed.
Upon the developing sleeve 8 rotating in step S800, a small amount of developing agent is supplied from the developing sleeve 8 to the photosensitive drum 10, regardless of the developing bias supplied from the power source unit 2. This small amount of developing agent is supplied to the nip portion of the photosensitive drum 10 and the intermediate transfer belt 24 in accordance with rotation of the photosensitive drum 10. The state at the photosensitive drum 10 and intermediate transfer belt 24 in step S800 thus transitions from a state where no developing agent is interposed at the nip portion to a state where developing agent is interposed at the nip portion. When developing agent is supplied to the nip portion of the photosensitive drum 10 and intermediate transfer belt 24, the frictional force between the photosensitive drum 10 and the intermediate transfer belt 24 decreases.
The CPU 1000 controls the image forming unit 5 (5y, 5m, 5c, 5bk) to form an image (S801). The image forming units 5 form a full-color image by sequentially overlaying images of the color components upon the intermediate transfer belt 24. After a first amount of time has elapsed after the image data has been transferred, the CPU 1000 stores the PWM signal value output from the motor driver 1300 (PWMduty1) in the RAM 1200 (S802). When the developing sleeve 8 starts to rotate, developing agent is supplied from the developing sleeve 8 to the photosensitive drum 10. The developing agent supplied to the photosensitive drum 10 is conveyed to the nip portion. The CPU 1000 stores the PWM signal value (PWMduty1) in the RAM 1200, after the first amount of time has elapsed from the time point at which the developing sleeve 8 started to rotate, in order to acquire the PWM signal value (PWMduty1) in the state where developing agent is interposed at the nip portion. Note that the first amount of time is decided by the distance from a developing position where the photosensitive drum 10 and developing sleeve 8 face each other to the nip portion of the photosensitive drum 10 and intermediate transfer belt 24, and the rotation speed of the photosensitive drum 10. The first amount of time is stored in the ROM 1100 beforehand.
The photosensitive drum 10, intermediate transfer belt 24, and developing sleeve 8 rotate as long as image formation is being executed. Accordingly, the state is the first state where toner is interposed at the nip portion, as long as image formation processing is being executed. The CPU 1000 stores the PWM signal value (PWMduty1) in the RAM 1200. The PWM signal value (PWMduty1) in the first state corresponds to a first signal value (first information) that changes in accordance with the torque of the motor M3.
Next, the CPU 1000 determines whether or not an image has been formed of the image data (S803). If formation of the image is not completed in step S803, the CPU 1000 transitions the processing to step S802. That is to say, the CPU 1000 continues updating PWMduty1 until image formation ends.
After formation of the image is completed in step S803, the CPU 1000 stops image formation at the image forming unit 5 (S804). In step S804, the CPU 1000 stops charging processing of the photosensitive drum 10 by the charger 21, and stops irradiation by laser beam by the exposing device 22.
Next, the CPU 1000 stops the rotation of the developing sleeve 8 (S805). In step S805, the CPU 1000 controls the motor driver 1300 to stop rotation of the motor M2. The photosensitive drum 10 and the drive roller 40 of the intermediate transfer belt 24 are continuing rotation at this time.
After a second amount of time has elapsed after rotation of the developing sleeve 8 has stopped in step S805, the CPU 1000 stores the PWM signal value (PWMduty2) output from the motor driver 1300 in the RAM 1200 (S806). When the rotation of the developing sleeve 8 stops, supply of developing agent from the developing sleeve 8 to the photosensitive drum 10 stops. However, there is a time lag from the developing sleeve 8 to stop rotating until the developing agent on the photosensitive drum 10 passes through the nip portion. The CPU 1000 stores the PWM signal value (PWMduty2) in the RAM 1200 after the second amount of time has passed from the time point that the developing sleeve 8 stops rotating, in order to acquire the PWM signal value (PWMduty2) in a state where there is no developing agent interposed at the nip portion. Note that the second amount of time is decided by the distance from a developing position where the photosensitive drum 10 and developing sleeve 8 face each other to the nip portion of the photosensitive drum 10 and intermediate transfer belt 24, and the rotation speed of the photosensitive drum 10. The second amount of time is stored in the ROM 1100 beforehand.
After the developing sleeve 8 stops rotating, the state at the nip portion is the second state where no toner is interposed. The CPU 1000 stores the PWM signal value (PWMduty2) is the RAM 1200 in this state. The PWM signal value (PWMduty2) in the second state corresponds to a second signal value (second information) that changes in accordance with the torque of the motor M3.
The CPU 1000 then stops rotation of the photosensitive drum 10, and stops driving of the intermediate transfer belt 24 (S807). The motor driver 1300 stops supplying PWM signals to the motor M3, and the motor driver 1300 belt stops supplying PWM signals to the motor M4. The CPU 1000 then ends the image formation operations. Next, the CPU 1000 executes adjustment processing to adjust the target speed of the photosensitive drum 10.
Adjustment processing will be described with reference to the flowchart in
First, the CPU 1000 determines whether or not a difference ΔPWMduty between PWM signal values is greater than a first threshold value Tha (S900). The target speed deciding unit 1002 reads out the PWM signal values stored in the RAM 1200. The RAM 1200 stores the PWM signal value (PWMduty1) of the state where developing agent is interposed at the nip portion, and the PWM signal value (PWMduty2) of the state where developing agent is not interposed at the nip portion. The target speed deciding unit 1002 computes the difference ΔPWMduty based on Expression (1) in step S900.
ΔPWMduty=PWMduty2−PWMduty1 Expression (1)
In a case where the difference ΔPWMduty of PWM signal values is greater than the first threshold value Tha, this means that the difference in frictional force between the state where developing agent is interposed at the nip portion and the state where developing agent is not interposed at the nip portion has increased to a level that will cause image defects. In a case where the difference ΔPWMduty of PWM signal values is greater than the first threshold value Tha in step S900, the target speed deciding unit 1002 changes the target speed of the photosensitive drum 10 (S901). In step S901, the target speed deciding unit 1002 decides the target speed of the photosensitive drum 10 based on Expression (2).
Target speed Vt(n+1)=current target speed Vt(n)−coefficient×ΔPWMduty Expression (2)
The CPU 1000 then executes color registration adjustment (S902), and ends adjustment processing. Note that the coefficient has a positive value.
When the target speed of the photosensitive drum 10 is changed, the length of the image in the rotational direction of the photosensitive drum 10, formed on the photosensitive drum 10, changes. For example, there is a possibility that the write position in the sub-scanning direction may be different for each color. Accordingly, in a case where the target speed of the photosensitive drum 10 is changed, the CPU 1000 executes color registration adjustment in step S902.
Also, in a case where the difference ΔPWMduty of PWM signal values is not greater than the first threshold value Tha in step S900, the CPU 1000 determines whether or not color registration adjustment execution conditions are satisfied (S903). In a case where an accumulated value of the number of sheets on which the image forming apparatus 100 has formed images (number of formed images) has reached a predetermined number after the previous color registration adjustment was performed in step S903, the CPU 1000 determines that execution conditions are satisfied. In a case where color registration adjustment execution conditions are satisfied in step S903, the target speed deciding unit 1002 determines whether or not the ΔPWMduty of PWM signal values is greater than a second threshold value Thb (S904). Note that this second threshold value Thb is a smaller value than the first threshold value Tha. In a case where the difference ΔPWMduty of PWM signal values is greater than the second threshold value Thb in S904, the CPU 1000 transitions to the processing in step S901 to change the target speed of the photosensitive drum 10.
On the other hand, in a case where the difference ΔPWMduty of PWM signal values is not greater than the second threshold value Thb in step S904, the CPU 1000 transitions the processing to step S902, executes color registration adjustment, and ends target speed adjustment processing. The target speed of the photosensitive drum 10 is not changed at this time.
In a case where execution conditions of color registration adjustment are not satisfied in step S903, the CPU 1000 ends the target speed adjustment processing without executing color registration adjustment. The target speed of the photosensitive drum 10 is not changed in this case.
The adjustment processing is executed for each motor that devices a photosensitive drum. Accordingly, in a case where the target speed is charged for even one photosensitive drum 10 out of the photosensitive drums 10 for yellow, magenta, cyan, and black, the CPU 1000 executes color registration adjustment.
The target speed of the photosensitive drum 10 is changed before the frictional force increases, by the processing described with reference to the flowcharts in
The image forming apparatus 100 has been configured to acquire PWM signal values of the motor M3 that rotates the photosensitive drum 10. There are the two following reasons for this. The first is that the target speed can be changed for each of the multiple photosensitive drums 10. In a case of changing the target speed of the photosensitive drum 10 based on the PWM signal value of the motor M4 that drives the intermediate transfer belt 24, for example, the photosensitive drum 10 at which frictional force is increasing cannot be identified. The second is that as long as there is no developing agent interposed at the nip portion of the photosensitive drum 10 of interest and intermediate transfer belt 24, the PWM signal value PWMduty1 can be acquired even if there is developing agent interposed at the nip portions of other photosensitive drums 10 and the intermediate transfer belt 24. In a case of changing the target speed of the photosensitive drum 10 based on the PWM signal value of the of the motor M4 driving the intermediate transfer belt 24, for example, the PWM signal value needs to be acquired in a state where there is no developing agent interposed at the nip portions of all of the photosensitive drums 10 and the intermediate transfer belt 24. Accordingly, in a case where image data is consecutively transferred, a state where there is not developing agent interposed at the nip portion between all photosensitive drums 10 and the intermediate transfer belt 24 does not occur, and there will be fewer opportunities to acquire the PWM signal value.
Now, there is a point that needs to be considered when acquiring load information of the photosensitive drum 10. Primary loads when driving the photosensitive drum 10 are frictional force due to the intermediate transfer belt 24 and frictional force due to the blade of the drum cleaner 26 that comes into contact with the photosensitive drum 10. The image forming apparatus 100 determines whether or not the frictional force between he photosensitive drum 10 and intermediate transfer belt 24 exceeds the permissible range, in a state where the developing sleeve 8 is rotating and developing agent is interposed at the nip portion, and a state where no developing agent is interposed at the nip portion. It can be assumed here that in either state, the frictional force due to the blade of the drum cleaner 26 will be constant. The frictional force between the photosensitive drum 10 and the blade is reduced by developing agent being interposed therebetween. On the other hand, when the developing agent between the photosensitive drum 10 and the blade is spent, the frictional force between the photosensitive drum 10 and the blade rises.
Accordingly, the image forming apparatus 100 acquires the PWM signal value during a period where developing agent is interposed between the photosensitive drum 10 and the blade, immediately after rotation of the developing sleeve 8 has stopped and developing agent adhered to the photosensitive drum 10 has passed the nip portion. Developing agent is interposed between the photosensitive drum 10 and the blade for a certain amount of time, as illustrated in
Sampling of the PWM signal value in a case where the developing sleeve 8 is rotating is preferably performed immediately before rotation of the developing sleeve 8 stops. The reason is that friction is constantly occurring between the photosensitive drum 10 and the blade even in a state where developing agent is interposed between the photosensitive drum 10 and the blade, causing the blade to wear due to the friction, and the load that is placed on the photosensitive drum 10 also changes.
In a case of using a developing agent with a high level of releasability, there is a possibility that developing agent may fly from the developing sleeve 8 to the photosensitive drum 10 by developing bias even if rotation of the developing sleeve 8 is stopped. It was found by experimentation that the amount of developing agent flying from the developing sleeve 8 to the photosensitive drum 10 could be reduced to 0 by setting the AC voltage for the developing bias to 0. Accordingly, the power source unit 2 (
Further, transfer bias supplied from the power source unit 3 (
Now, the image forming apparatus 100 illustrated in
According to the image forming apparatus 100 of the present embodiment, downtime to decide the target speed of the photosensitive drum 10 can be reduced.
The image forming apparatus 100 according to a second embodiment will be described below with reference to
Image formation processing that the image forming apparatus 100 according to the second embodiment executes will be described with reference to the flowchart in
First, the CPU 1000 rotates the photosensitive drum 10, intermediate transfer belt 24, and developing sleeve 8 (S1200). The motor driver 1300 controls PWM signals input to the motor M3. The motor M3 rotates the photosensitive drum 10 based on the PWM signal value input from the motor driver 1300. The motor driver 1300 belt controls PWM signals input to the motor M4. The motor M4 rotates the drive roller 40 of the intermediate transfer belt 24 based on the PWM signals input from the motor driver 1300 belt. The motors M1 and M2 rotate the developing sleeve 8 and agitation member 6 of the developing unit 1 in step S1200.
The motor driver 1300 updates the PWM signal value every 1 msec, for example. The PWM signal value output from the motor driver 1300 is not only supplied to the motor M3 but also is stored in the RAM 1200.
The CPU 1000 controls the image forming unit 5 (5y, 5m, 5c, 5bk) to form an image by sequentially overlaying images of the color components upon the intermediate transfer belt 24 (S1201). After the first amount of time has elapsed after the image data has been transferred, the CPU 1000 stores the PWM signal value output from the motor driver 1300 (PWMduty1) in the RAM 1200 (S1202). When the developing sleeve 8 starts to rotate, developing agent is supplied from the developing sleeve 8 to the photosensitive drum 10, and the developing agent supplied to the photosensitive drum 10 is conveyed to the nip portion. The CPU 1000 stores the PWM signal value (PWMduty1) in the RAM 1200, after the first amount of time has elapsed from the time point at which the developing sleeve 8 started to rotate, in order to acquire the PWM signal value (PWMduty1) in the state where developing agent is interposed at the nip portion.
The photosensitive drum 10, intermediate transfer belt 24, and developing sleeve 8 rotate as long as image formation is being executed. The CPU 1000 stores the PWM signal value (PWMduty1) in the RAM 1200 every 8 msec, for example. The PWM signal value (PWMduty1) in the first state corresponds to the first signal value (first information) that changes in accordance with the torque of the motor M3.
Next, the CPU 1000 determines whether or not formation of all images included in the image data has been completed (S1203). If formation of all images is completed in step S1203, the CPU 1000 stops image formation at the image forming unit 5 (S1204). In step S1204, the CPU 1000 stops charging processing of the photosensitive drum 10 by the charger 21, and stops irradiation by laser beam by the exposing device 22. The CPU 1000 then stops the processing of storing the PWM signal value (PWMduty1) in the RAM 1200.
Next, the CPU 1000 stops the rotation of the developing sleeve 8 (S1205). In step S1205, the CPU 1000 causes the motor driver 1300 to stop rotation of the motor M2. The photosensitive drum 10 and the drive roller 40 of the intermediate transfer belt 24 are continuing rotation at this time.
After the second amount of time has elapsed after rotation of the developing sleeve 8 has stopped in step S1205, the CPU 1000 stores the PWM signal value (PWMduty2) output from the motor driver 1300 in the RAM 1200 (S1206). When the rotation of the developing sleeve 8 stops, supply of developing agent from the developing sleeve 8 to the photosensitive drum 10 stops. However, there is a time lag from the developing sleeve 8 to stop rotating until the developing agent on the photosensitive drum 10 passes through the nip portion. The CPU 1000 stores the PWM signal value (PWMduty2) in the RAM 1200 after the second amount of time has passed from the time point that the developing sleeve 8 stops rotating, in order to acquire the PWM signal value (PWMduty2) in a state where there is no developing agent interposed at the nip portion.
The CPU 1000 stores the PWM signal value (PWMduty2) in the RAM 1200 in the second state where the photosensitive drum 10 is rotating, the intermediate transfer belt 24 is being driven, and the developing sleeve 8 is stopped, every 8 msec, for example. The PWM signal value in the second state (PWMduty2) corresponds to the second signal value (second information) that changes in accordance with the torque of the motor M3. Upon 36 sets of the PWM signal (PWMduty2) in a state where no developing agent is interposed at the nip portion being stored in the RAM 1200, the CPU 1000 stops storage of the PWM signal (PWMduty2).
Next, the target speed deciding unit 1002 executes target speed adjustment processing for the photosensitive drums 10 of the image forming units 5 (5y, 5m, 5c, 5bk) (S1207). The CPU 1000 then stops rotation of the photosensitive drum 10, stops driving of the intermediate transfer belt 24 (S1208), and ends image forming operations. The target speed adjustment processing in step S1207 is the same as the adjustment processing illustrated in
In a case where all images have not been formed in step S1203, the CPU 1000 determines whether or not the number of images printed consecutively without stopping the developing sleeve 8 has reached 200 (S1209). In a case where the number of images printed consecutively without stopping the developing sleeve 8 is smaller than 200 in step S1209, the CPU 1000 transitions the processing to step S1202.
On the other hand, in a case where determination is made in step S1209 that the number of images printed consecutively without stopping the developing sleeve 8 has reached 200, the CPU 1000 stops rotation of the developing sleeve 8 (S1210). The image forming apparatus 100 temporarily stops the developing sleeve 8 in order to resolve the immobile layer of developing agent that is created within the developing unit 1. In a case where the developing agent in the immobile layer within the developing unit 1 becomes cohered, image defects may occur. For example, if the cohered developing agent comes into contact with the developing sleeve 8 and the thickness of the layer of developing agent borne by the developing sleeve 8 changes, streaks may be formed on the photosensitive drum 10. Accordingly, the image forming apparatus 100 temporarily stops image forming operations and stops the developing sleeve 8 for around two seconds, for example, to resolve the immobile layer of developing agent within the developing unit 1. Thereafter, the image forming apparatus 100 rotates the developing sleeve 8 again and resumes image forming operations.
In step S1210, the CPU 1000 causes the motor driver 1300 to stop rotation of the motor M2. At this time, the photosensitive drum 10 and the drive roller 40 of the intermediate transfer belt 24 continue to rotate. After a second amount of time has elapsed after rotation of the developing sleeve 8 has stopped in step S1210, the CPU 1000 stores the PWM signal value (PWMduty2) output from the motor driver 1300 in the RAM 1200 (S1211).
In the second state where the photosensitive drums 10 is rotating, the intermediate transfer belt 24 is being driven, and the developing sleeve 8 is stopped, the PWM signal value (PWMduty2) is stored is in the RAM 1200, every 8 msec, for example. The PWM signal value in the second state (PWMduty2) corresponds to the second signal value (second information) that changes in accordance with the torque of the motor M3. Upon 36 sets of the PWM signal value (PWMduty2) in a state where no developing agent is interposed at the nip portion being stored in the RAM 1200 for example, the CPU 1000 stops storage of the PWM signal (PWMduty2).
Next, the target speed deciding unit 1002 executes target speed adjustment processing for the photosensitive drums 10 of the image forming units 5 (5y, 5m, 5c, 5bk) (S1212). The CPU 1000 then stops rotation of the photosensitive drum 10, and stops driving of the intermediate transfer belt 24, and ends the image forming processing. The target speed adjustment processing in step S1212 is the same as the target speed adjustment processing illustrated in
After the developing sleeve 8 has stopped for two seconds (S1213), the CPU 1000 resumes rotation of the developing sleeve 8 (S1214), resumes formation of images based on the image data, and the CPU 1000 transitions the processing to step S1202.
Even in a case where the image forming apparatus 100 is consecutively forming multiple images, the rotation of the developing sleeve 8 can be temporarily stopped and the PWM signal value (PWMduty2) relating to torque of the motor M3 in a state where no developing agent is interposed at the nip portion can be acquired. Further, the target rotation speed of the photosensitive drums 10 can be corrected even in a case where the image forming apparatus 100 is consecutively forming multiple images. Accordingly, the image forming apparatus 100 of the present embodiment can suppress image defects occurring due to frictional force between he photosensitive drum 10 and the intermediate transfer belt 24.
Now, the timing of stopping the developing sleeves 8 of the image forming units 5y, 5m, 5c, and 5bk will be described with reference to the timing chart in
The developing sleeves 8 then sequentially start rotating, after sampling of the PWM signal values has been completed. After the developing sleeve 8 of the image forming unit 5y that is farthest upstream in the conveyance direction of the intermediate transfer belt 24 resumes rotation, the developing sleeve 8 of the image forming unit 5m situated downstream from the image forming unit 5y in the conveyance direction resumes rotation. Further, after the developing sleeve 8 of the image forming unit 5m resumes rotation, the developing sleeve 8 of the image forming unit 5c situated downstream from the image forming unit 5m in the conveyance direction resumes rotation. In the same way, after the developing sleeve 8 of the image forming unit 5c resumes rotation, the developing sleeve 8 of the image forming unit 5bk situated downstream from the image forming unit 5c in the conveyance direction resumes rotation. Thus, the stopped time of the developing sleeves 8 can be minimized by controlling the rotation of the developing sleeves 8 and the sampling timing of PWM signal values. Sampling Timing and Load on Photosensitive Drum 10
The PWM signal value (PWMduty2) of a state where there is no developing agent interposed between the photosensitive drum 10 and intermediate transfer belt 24 is acquired with the rotation of the developing sleeve 8 stopped and the AC voltage of the power source unit 2 (
Further, the amount of change in frictional force between the photosensitive drum 10 and the intermediate transfer belt 24 depending on whether developing agent is present or absent at the nip portion is predicted based on the difference in PWM signal values of the motor M3. Accordingly, the PWM signal value in a state where developing agent is interposed at the nip portion and the PWM signal value in a state where no developing agent is interposed at the nip portion must not change due to any other influence besides whether developing agent is present or absent.
However, there is a possibility that frictional force between the photosensitive drum 10 and intermediate transfer belt 24 may change due to transfer bias supplied from the power source unit 3 (
According to the image forming apparatus 100 of the present embodiment, even in a case of consecutively forming multiple images, a timing is provided for stopping the rotation of the developing sleeve 8 during multiple images being formed, and the PWM signal value of the motor M3 is acquired at this time. Thus, the PWM signal value of the motor M3 can be acquired in a state where no developing agent is interposed between the photosensitive drum 10 and the intermediate transfer belt 24. Further, the target rotation speed of the motor M3 can be adjusted even while the image forming apparatus 100 is forming multiple images. Accordingly, the possibility of frictional force increasing between the photosensitive drum 10 and intermediate transfer belt 24 while the image forming apparatus 100 is forming multiple images, resulting in image defects, can be suppressed.
Description has been made with reference to
The stopping conditions may be the amount of time that the image forming apparatus 100 has continuously driven the image forming unit 5 to form multiple images. For example, in a case where the time over which the image forming unit 5 has been continuously driven exceeds a predetermined amount of time, the CPU 1000 temporarily stops rotation of the developing sleeve 8. The developing sleeve 8 continues to rotate as long as the image forming unit 5 is being continuously driven, so there is a high probability that an immobile layer of developing agent will be created within the developing unit 1. Accordingly, the image forming operations are temporarily stopped at a timing where the continuous rotating time of the developing sleeve 8 reaches a predetermined amount of time, and the rotation of the developing sleeve 8 is stopped, to resolve the immobile layer of developing agent that is created within the developing unit 1.
The stopping conditions may be the amount of developing agent consumed while the image forming apparatus 100 consecutively forms multiple images. For example, an arrangement may be made where the amount of consumption of developing agent is predicted based on the image data, and in a case where the amount of developing agent consumed for images formed on a predetermined number of sheets is smaller than a predetermined amount, the CPU 1000 temporarily stops rotation of the developing sleeve 8. It is known that there is a high probability of an immobile layer of developing agent being created within the developing unit 1 when the amount of developing agent consumed is small. Accordingly, when the amount of developing agent being consumed is smaller than the predetermined amount, the image forming operations are temporarily stopped at an optional timing during consecutive forming of multiple images, and the rotation of the developing sleeve 8 is stopped, to resolve the immobile layer of developing agent that is created within the developing unit 1.
According to the image forming apparatus 100 of the present embodiment, downtime to decide the target speed of the photosensitive drum 10 can be reduced. Further, according to the image forming apparatus 100 of the present embodiment, even if multiple images are being consecutively formed, a timing to stop rotation of the developing sleeve 8 is provided during the multiple images being consecutively formed, and the PWM signal value of the motor M3 is acquired at this timing. Accordingly, the PWM signal value of the motor M3 can be acquired in a state where no developing agent is interposed between the photosensitive drum 10 and the intermediate transfer belt 24. Thus, the target rotation speed of the motor M3 can be adjusted even if the image forming apparatus 100 is consecutively forming multiple images. Consequently, the possibility of frictional force increasing between the photosensitive drum 10 and intermediate transfer belt 24 while the image forming apparatus 100 is consecutively forming multiple images, resulting in image defects, can be suppressed.
The image forming apparatus 100 according to a third embodiment will be described below with reference to
when the image forming apparatus 100 consecutively forms images on a great number of sheets P, the temperature in the apparatus rises. When the temperature in the apparatus rises, the friction coefficient μb at the surface of the intermediate transfer belt 24 also rises. Consequently, when the temperature in the apparatus rises, the rotation torque necessary to drive the photosensitive drum 10 also rises.
When a load where the PWM duty exceeds 60% is placed on the motor M3 that drives the photosensitive drum 10, there is a possibility of color misregistration or banding occurring. Accordingly, the image forming apparatus 100 must appropriately control the rotation speed of the motor M3 driving the photosensitive drum 10, so that color misregistration or banding occurring does not occur.
As described above, downtime can be reduced by adjusting the rotation speed of the motor M3 driving the photosensitive drum 10 at the timing when color registration adjustment is executed. However, intervals between execution of color registration adjustment are relatively long. Accordingly, there is the possibility that color misregistration or banding will occur in a case where rotation torque suddenly rises. The image forming apparatus 100 according to the present embodiment adjusts the rotation speed of the motor M3 driving the photosensitive drum 10 as necessary, without waiting for execution of color registration adjustment. The configuration of the image forming apparatus 100 according to the third embodiment is the same as that of the image forming apparatus 100 according to the first embodiment. Accordingly, description of the configuration of the image forming apparatus 100 according to the third embodiment will be omitted.
A motor driver 830 drives the motors M1, M2, M3, and M4 in accordance with instructions and setting values (target speed) from the CPU 800. The motor driver 830 executes feedback control based on speed information obtained from the speed sensors 32, 33, 37, and 38.
A load measuring unit 801 is a unit that detects (measures) information relating to rotation torque of the motor M3 by acquiring the duty of PWM signals supplied to the motor M3. Rotation torque may be referred to as load torque. The object of measurement may be the motor M4 that drives the intermediate transfer belt 24, instead of the motor M3. A difference calculating unit 802 calculates the difference between two PWM duties measured by the load measuring unit 801. The first is the PWM duty (PWMduty1) measured by the load measuring unit 801 in the driving state where the developing sleeve 8 is being driven by the motor M2 (first state). The second is the PWM duty (PWMduty2) measured by the load measuring unit 801 in the non-driving state where the developing sleeve 8 is not being driven by the motor M2 (second state). Toner is supplied to the photosensitive drum 10 in the driving state, but no toner is supplied to the photosensitive drum 10 in the non-driving state. That is to say, the difference calculating unit 802 acquires the difference between PWM duty in a state where there is toner at the nip portion and PWM duty in a state where there is no toner at the nip portion.
The storage device 850 stores differences acquired by the difference calculating unit 802. A first statistics unit 803 obtains an average value of the N newest difference data out of the difference data 852 stored in the storage device 850, as a statistics value. A second statistics unit 804 an average value of M difference data 852 stored in the storage device 850, as a statistics value. Note that M>N. For example, M is 30 and N is 5. When the statistics value (e.g., average value) obtained by the first statistics unit 803 reaches or exceeds a first threshold value (e.g., 10%), a target speed deciding unit 805 decides a setting value for the rotation speed of the motor M3 (target speed) so that the difference will be reduced. An image formation control unit 806 controls the exposing devices 22, developing units 1, power source units 2, and power source units 3, of the image forming units 5y, 5m, 5c, and 5bk.
A trigger unit 810 manages timing for executing color registration adjustment, and timing for executing adjustment processing (
A color registration adjustment unit 820 corrects the image formation positions (write timings) of each color, so that the image forming positions among Y, M, C, and Bk are aligned. A second adjustment unit 822 forms color patterns 48y, 48m, 48c, and 48bk, controls the sensor 14 to detect the color patterns 48y, 48m, 48c, and 48bk, and adjusts the write timing for each color based on the detection results. A first adjustment unit 821 adjusts the write timings for the colors based on the target speed decided by the target speed deciding unit 805. That is to say, the first adjustment unit 821 adjusts the write timing without forming the color patterns 48y, 48m, 48c, and 48bk. Accordingly, the adjustment time by the first adjustment unit 821 is shorter than the adjustment time by the second adjustment unit 822. This is useful in reducing downtime. Color registration adjustment that the second adjustment unit 822 performs using color patterns is more precise as compared to the prediction color registration adjustment that the first adjustment unit 821 performs.
The image forming apparatus 100 according to the present embodiment executes rotation speed adjustment processing for the photosensitive drums 10 in a case where color registration adjustment is executed. Further, the image forming apparatus 100 according to the present embodiment executes rotation speed adjustment processing for the photosensitive drums 10 in a case where the rotation torque of the motor M3 changes greatly, even if not the timing for executing color registration adjustment. Accordingly, the circumferential speed of the photosensitive drums 10 as to the intermediate transfer belt 24 can be adjusted at a more appropriate timing.
In step S1803, the CPU 800 (load measuring unit 801) determines whether or not rotation torque measurement conditions are satisfied. The CPU 800 (load measuring unit 801) determines that measurement conditions have been satisfied in a case where, for example, the number of sheets on which images have been formed (number of formed images) after the previous measurement timing has reached a predetermined number. The predetermined number here is 200 sheets, for example. Note that the predetermined number may differ for each model of the image forming apparatus 100. Accordingly, the predetermined number may be decided by simulation or experimentation or the like, and be stored in the storage device 850 of the image forming apparatus 100 beforehand. If measurement conditions are not satisfied, the CPU 800 advances the processing to step S1804.
In step S1804, the CPU 800 (image formation control unit 806) determines whether or not image formation has ended. For example, in a case where images are to be formed on X sheets, the CPU 800 (image formation control unit 806) determines whether or not images have been formed on all X sheets. If image formation has not been completed, the CPU 800 transitions the processing to step S1803. On the other hand, if image formation has been completed, the CPU 800 transitions the processing to step S1805.
In step S1805, the CPU 800 (load measuring unit 801) measures rotation torque in a state while the developing sleeve 8 is being driven by the motor M2, while post rotation is being executed. The load measuring unit 801 detects the duty of PWM signals supplied to the motor M3 as rotation torque, as described above. Post rotation is an operation where the photosensitive drum 10 and intermediate transfer belt 24 are rotated for a certain period even after image formation is ended. Note that during post rotation, driving is stopped in the order of exposing device 22, developing sleeve 8, power source unit 2, power source unit 3, charger 21, photosensitive drum 10, and intermediate transfer belt 24. Measurement processing is executed during the period from driving of the exposing device 22 being stopped to driving of the power source unit 2 being stopped. If the developing sleeve 8 is rotating, toner in the developing unit 1 is being borne by the developing sleeve 8. Accordingly, minute amounts of toner are being supplied to the photosensitive drum 10 even if the photosensitive drum 10 is not being exposed. Toner adhering to an unexposed region of the surface of the photosensitive drum 10 is referred to as “development-fogged toner”. Note that the power source unit 2 may be stopped or may be running. The amount of development-fogged toner in a state where the power source unit 2 is supplying developing bias is greater than the amount of development-fogged toner in a state where the power source unit 2 is not supplying developing bias. However, supply of developing bias is not indispensable. In the same way, supply of charging bias and transfer bias may be stopped.
The CPU 800 (load measuring unit 801) stops rotation of the developing sleeve 8 in step S1806. That is to say, rotation of the motor M2 is stopped. In step S1807, the CPU 800 (load measuring unit 801) measures the rotation torque in the non-driven state (second state) where the developing sleeve 8 is not rotating. The load measuring unit 801 detects the duty of PWM signals supplied to the motor M3, as rotation torque. The difference calculating unit 802 calculates the difference between the PWM duty (PWMduty1) in the driven state (first state) and the PWM duty (PWMduty2) in the non-driven state (second state). The load measuring unit 801 may store the difference in the storage device 850 as difference data 852. Alternatively, the load measuring unit 801 may store the PWM duty (PWMduty1 and PWMduty2) in the storage device 850 as it is. The difference calculating unit 802 may read the PWM duty (PWMduty1 and PWMduty2) out from the storage device 850 and calculate the difference. The CPU 800 stores the number of images formed at the time of having measured the PWM duty in the storage device 850. The number of images formed may be used to determine whether or not the measurement conditions are satisfied in step S1803. The CPU 800 may determine whether the difference between the current number of images formed and the number of images formed stored in the storage device 850 is a predetermined number of greater.
If measurement conditions are not satisfied in step S1803, the CPU 800 transitions the processing to step S1810. In step S1810, the CPU 800 (image formation control unit 806) interrupts image forming operations. In step S1811, the CPU 800 (load measuring unit 801) measures rotation torque (PWM duty) in a state where the developing sleeve 8 is being rotated. In step S1812, the CPU 800 (load measuring unit 801) stops rotation of the developing sleeve 8. In step S1813, the CPU 800 (load measuring unit 801) measures rotation torque (PWM duty) in a non-driven state. The difference calculating unit 802 may calculate the difference between the PWM duty (PWMduty1) in the driven state (first state) and the PWM duty (PWMduty2) in the non-driven state (second state) at this stage. The difference may be stored in the storage device 850 as difference data 852. The PWM duty (PWMduty1 and PWMduty2) may be stored in the storage device 850 as it is. The CPU 800 (image formation control unit 806) resumes image forming operations in step S1814.
In step S1901, the CPU 800 (third determining unit 813) determines whether or not execution conditions for color registration adjustment are satisfied. If execution conditions for color registration adjustment are satisfied, the CPU 800 transitions the processing to step S1902. An example of execution conditions for color registration adjustment being satisfied is a case where the operator instructs execution of color registration adjustment, or a case where the number of images formed has reached a predetermined number (e.g., 1000).
In step S1902, the CPU 800 (second determining unit 812) determines whether or not second adjustment conditions, which are conditions for executing rotation speed adjustment processing of the photosensitive drum 10, are satisfied. The CPU 800 (second determining unit 812) determines that second adjustment conditions are satisfied in a case where the average value of M sets of difference data saved in the storage device 850 is equal to or exceeds a second threshold value. The second threshold value is, for example, 2%. This is to facilitate execution of adjustment processing when color registration adjustment is being performed. If the second adjustment conditions are not satisfied, the CPU 800 transitions the processing to step S1905, to perform only color registration adjustment. Note that the CPU 800 transitions the processing to step S1905 if the number of difference data 852 stored in the storage device 850 has not reached M.
In step S1905, the CPU 800 (second adjustment unit 822) forms color patterns on the intermediate transfer belt 24, and corrects the write timing for images of each color based on the color pattern detection results. The second adjustment unit 822 controls the image forming units 5y, 5m, 5c, and 5bk, via the image formation control unit 806, and forms color patterns on the intermediate transfer belt 24. The second adjustment unit 822 controls the sensor 14 to detect the color patterns, and obtains the amount of positional deviation (color misregistration amount) in the main scan direction and the amount of positional deviation (color misregistration amount) in the sub-scan direction. The second adjustment unit 822 decides the write timing of the images of each color so that the amount of positional deviation is zero, and sets the write timing to the image formation control unit 806. The image formation control unit 806 controls the exposing device 22 based on the write timing. The CPU 800 then ends the color registration adjustment and adjustment processing.
On the other hand, if the second adjustment conditions are satisfied, the CPU 800 advances the processing to step S1903. In step S1903 the CPU 800 (target speed deciding unit 805) decides the rotation speed of the photosensitive drum 10 (speed setting value of the motor M3), based on the rotation torque difference data 852. For example, the target speed deciding unit 805 decides the speed setting value based on the following Expression
Sd2=Sd1−g×ΔPWMduty (1)
where Sd2 represents a newly-decided speed setting value, Sd1 represents the speed setting value used up till now, g represents gain (coefficient) that is decided when shipping from the factory, and ΔPWMduty is rotation torque difference data. The average value of M sets of difference data is substituted into ΔPWMduty here.
In step S1904, the CPU 800 (load measuring unit 801) deletes the M sets of difference data 852 stored in the storage device 850. The M sets of difference data 852 stored in the storage device 850 are data acquired based on the speed setting value before changing (previous speed setting value). Accordingly, the M sets of difference data stored in the storage device 850 are deleted. Thereafter, in step S1905 the CPU 800 executes color registration adjustment (prediction) based on the speed setting value decided in step S1903. This reduces color misregistration in addition to reducing banding.
If execution conditions for color registration adjustment are not satisfied in step S1901, the CPU 800 advances the processing to step S1910. The CPU 800 (first determining unit 811) determines whether or not first adjustment conditions are satisfied in step S1910. First adjustment conditions are conditions for executing rotation speed adjustment processing. The first adjustment conditions are less readily satisfied as compared to the second adjustment conditions. The reason is that the first adjustment conditions are for determining whether or not emergency speed adjustment has become necessary due to sudden rise in the temperature in the apparatus. If the average value of the newest N sets of difference data, out of the M sets of difference data stored in the storage device 850, is equal to or exceeds the first threshold value, the CPU 800 (first determining unit 811) determines that the first adjustment conditions have been satisfied. The first threshold value is, for example, 10%. The first threshold value (e.g., 10%) is set to a larger value than the second threshold value (e.g., 2%). If the first adjustment conditions are not satisfied, the CPU 800 advances the processing to step S1901. The CPU 800 also advances the processing to step S1901 in a case where the number of difference data 852 stored in the storage device 850 has not reached N. On the other hand, the CPU 800 advances the processing to step S1911 if the first adjustment conditions are satisfied.
In step S1911, the CPU 800 (target speed deciding unit 805) decides the rotation speed of the photosensitive drum 10 (speed setting value for the motor M3) based on the rotation torque difference data 852. This deciding processing is the same as the processing in step S1903. In step S1912, the CPU 800 (load measuring unit 801) deletes the M sets of difference data stored in the storage device 850.
In step S1913, the CPU 800 (first adjustment unit 821) decides the write timing based on the newly-decided rotation speed (speed setting value). The image formation position in the sub-scanning direction shifts in accordance in the amount of change to the rotation speed. Accordingly, the write timing is corrected in accordance with the amount of change in rotation speed. The correction amount dt for the write timing can be calculated from, for example, the following Expression
dt=X/(ω2×D)−X/(ω1×D) (2)
where X represents the distance from the exposure position on the surface (circumferential surface) of the photosensitive drum 10 to the nip portion, D represents the diameter of the photosensitive drum 10, ω1 represents the angular velocity corresponding to the speed setting value Sd1 before correction, and ω2 represents the angular velocity corresponding to the speed setting value Sd2 after correction. The CPU 800 then ends the color registration adjustment and adjustment processing.
The image forming apparatus 100 according to the third embodiment adjusts the rotation speed of the photosensitive drum 10 not only at the timing of executing color registration adjustment, but also when the rotation torque difference has suddenly increased. Accordingly, the image forming apparatus 100 appropriately adjusts the rotation speed of the photosensitive drum 10 even in cases where temperature in the apparatus suddenly rises. Thus, according to the image forming apparatus 100, occurrence of banding can be reduced even in a case where temperature in the apparatus suddenly rises.
Although description has been made in the above embodiment that the rotational torque of the motor M3 is detected, the rotational torque of the motor M4 of the intermediate transfer belt 24 may be detected. The photosensitive drum 10 and intermediate transfer belt 24 rotate in contact with each other. Accordingly, rise in frictional force of the photosensitive drum 10 is reflected in the rotation torque of the motor M4 as well. In this case, the first adjustment conditions and second adjustment conditions are changed into conditions using the rotation torque of the motor M4. Note that the rotation speed of the motors M3 for each color may be changed in accordance with the rotation torque of the motor M4 measured by the load measuring unit 801. Alternatively, the rotation speed of the motor M4 may be changed in accordance with the rotation torque of the motor M4 measured by the load measuring unit 801. This is because occurrence of image defects can be suppressed by the difference between the circumferential speed of the photosensitive drum 10 and the circumferential speed of the intermediate transfer belt 24 ultimately coming to a predetermined value.
The first determining unit 811 is an example of a determination unit that determines whether or not a statistics value (e.g., moving mean, etc.) of differences stored in the storage device 850 (or differences obtained from first information and second information that are stored) is equal to or exceeds the first threshold value (e.g., 10%). When the statistics value reaches or exceeds the first threshold value, the target speed deciding unit 805 decides a setting value for the rotation speed of the motor M3 in accordance with the statistics value of the difference, so that the difference is reduced, which has been described with regard to steps S1910 and S1911.
According to the present embodiment, the circumferential speed of the photosensitive drum 10 as to the circumferential speed of the intermediate transfer belt 24 can be adjusted at a more appropriate timing. Accordingly, rotation speed is adjusted at a more appropriate timing.
The target speed deciding unit 805 changes the rotation speed setting value in a case where the operation conditions of the second adjustment unit 822 have been satisfied, and also the statistics value of the load parameter is equal to or exceeds the second threshold value. Even if the operation conditions of the second adjustment unit 822 are not satisfied, the target speed deciding unit 805 changes the setting value if the statistics value of the load parameter is equal to or exceeds the first threshold value that is greater than the second threshold value. Accordingly, the circumferential speed of the photosensitive drum 10 as to the circumferential speed of the intermediate transfer belt 24 can be adjusted at a more appropriate timing.
The load measuring unit 801 may store difference data in the storage device 850 each time the number of sheets on which the image forming apparatus 100 has formed toner images reaches a predetermined number. The image forming apparatus 100 according to the present embodiment execute measurement and acquisition of rotation torque in post rotation as well, so sudden rise in rotation torque is readily detected.
The first statistics unit 803 may obtain the newest N differences from the newest N sets of first information and the newest N sets of second information stored in the storage device 850. The first determining unit 811 determines whether or not the average value of the newest N sets of difference data 852 is equal to or exceeds the first threshold value. Statistical process such as a moving mean or the like is effective in reducing the influence of variance in measurement results. The average value of the newest N differences is used in the present embodiment, thereby enabling reduction in variance in measurement results and detection of sudden rise in rotation torque to be realized.
In a case where execution conditions are satisfied, the second adjustment unit 822 executes color registration adjustment. That is to say, the second adjustment unit 822 controls the image forming units 5y, 5m, 5c, and 5bk, to form color patterns 48y, 48m, 48c, and 48bk. The second adjustment unit 822 then controls the sensor 14 to detect the color patterns, and adjusts the write timing based on the color misregistration amount. In a case where execution conditions are satisfied, the first adjustment unit 812 determines whether or not the average value of M differences is equal to or exceeds the second threshold value. In a case where the average value of M differences is equal to or exceeds the second threshold value, the target speed deciding unit 805 decides the setting value of rotation speed of the motor M3, based on the average value of M differences, so that the difference is reduced.
Note that after the setting value for the rotation speed of the motor M3 has been changed to the setting value decided by the target speed deciding unit 805, the second adjustment unit 822 adjusts the write timing based on the color misregistration amount of the color patterns. The color misregistration amount changes when the rotation speed is changed. Accordingly, the image forming apparatus 100 can correct color misregistration more accurately by executing color registration adjustment after the rotation speed has been changed.
According to the image forming apparatus 100 of the present embodiment, downtime generated by deciding the target speed of the photosensitive drums 10 can be suppressed. Further, according to the image forming apparatus 100 of the present embodiment, occurrence of image defects can be suppressed even in a case where frictional force between the photosensitive drum 10 and the intermediate transfer belt 24 suddenly rises.
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. 2016-137955 filed Jul. 12, 2016, Japanese Patent Application No. 2016-138748 filed Jul. 13, 2016, and Japanese Patent Application No. 2016-138754 filed Jul. 13, 2016, which are hereby incorporated by reference herein in their entirety.
Number | Date | Country | Kind |
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2016-137955 | Jul 2016 | JP | national |
2016-138748 | Jul 2016 | JP | national |
2016-138754 | Jul 2016 | JP | national |