Patent Application
20090263159
This application is related to Japanese Patent Application No. 2008-107930 filed on Apr. 17, 2008, whose priority is claimed and the disclosure of which is incorporated by reference in its entirety.
1. Field of the Invention
The present invention relates to an image forming apparatus having plural photoconductors.
2. Description of the Related Art
There has been known an image forming apparatus, i.e., a so-called tandem type image forming apparatus, in which plural toner images are formed by means of plural photoconductors, each corresponding to each toner image, with an electrophotographic process, and these toner images are superimposed. In a tandem type image forming apparatus that forms a full-color image, toner images of respective color components, such as yellow (Y), magenta (M), cyan (C), and black (K), are formed by means of different photoconductors, and each of the toner images is superimposed (see, for example, Japanese Unexamined Patent Application No. 11-91205).
In the tandem type image forming apparatus, it is necessary to drive the plural photoconductors, each corresponding to each toner image, and an image forming section for forming toner images onto the corresponding photoconductors. The number of components can be reduced by driving the photoconductors of Y, M, and C, which are simultaneously driven, and the corresponding image forming sections (including a developing unit) with a single motor in order to reduce the number of components in a drive section so as to downsize the apparatus. On the other hand, as for the black color, the K photoconductor and the K image forming section (including a K developing unit) are driven with a motor different from the motor used for the YMC, since the sections involved with the black color solely form an image during the formation of a monochromatic image. A stepping motor can be used, for example, as a motor for driving the photoconductors of the respective colors and the corresponding image forming sections. However, it is preferable to use a DC motor, which has a driving force per volume greater than that of the stepping motor, in order to drive a great number of loads, such as the loads for the YMC, with a single motor.
In a structure in which each of the photoconductors of the respective colors and the corresponding image forming sections are independently driven, there may be a case in which a capacity of the K developing unit is set to be greater than the capacities of the developing units for the other colors in order to make a frequency of an exchange of the K developing unit equal to that of the developing units for the other colors, since the K developing unit is more frequently used for the monochromatic printing than the other colors. In this case, a DC motor having a great driving force is preferable. A DC motor may sometimes be used for the other colors in order to share a control circuit and a control program with K. However, the problems described below arise when the DC motor is used for the drive.
Specifically, each of the photoconductors has a very small eccentricity due to a processing precision or assembling precision of components. This eccentricity produces a speed irregularity, which agrees with the rotating cycle, in a peripheral speed. A banding (periodic occurrence of coarse portions and fine portions) is produced due to the speed irregularity. When the high-density portions (fine portions) and the low-density portions (coarse portions) in the respective toner images are different in case where the toner images having the banding are superimposed, a color misregistration occurs, and this color misregistration is noticeable. In view of this, in order to match the high-density portions and the low-density portions in the respective toner images, the photoconductors are assembled with the rotational phase thereof adjusted. Further, the drive of each of the photoconductors is controlled so as to keep the adjusted rotational phase.
The control of the rotational phase is easy, if a stepping motor is used. However, when a DC motor is used, an increase curve of the speed of each of the YMC photoconductors and an increase curve of the speed of the K photoconductor during the period from when the respective photoconductors are started to when they reach a predetermined process speed might not be matched. This causes either the YMC photoconductors or the K photoconductor to rotate faster. Accordingly, a misregistration occurs in the rotational phases of the YMC photoconductors and the K photoconductor, before the YMC photoconductors or the K photoconductor reach the process speed.
This will be described in more detail.
On the other hand, a transition state of an actual drive speed of the motor is as described below. The motor keeps stopped for a short while after the start of the motor. During this period, an output of a set comparing circuit 33 changes so as to gradually supply high current to the motor, since a misregistration from the target speed increases. Since the time has elapsed from the starting time ts to the time t0 when the motor starts to rotate, the target speed increases more than Vi. Thereafter, the driving force of the motor overcomes a static friction force, so that each motor starts to rotate at the time t0. The rotational speed sharply increases in order to follow the target speed. The drive speed of the K photoconductor reaches the target speed at the time t1. The target speed at this point is Vi that is greater than the initial drive speed Vi. On the other hand, the drive speeds of the YMC photoconductors reach the target speed at a time t2 because a load is heavier than that of the K photoconductor. The target speed at this point is V2. Because of a difference in a drive load between the YMC photoconductors and the K photoconductor, the K photoconductor increases more sharply than the YMC photoconductors. Therefore, the time taken to reach the target speed is different between the K photoconductor and the YMC photoconductors. In
In the Japanese Unexamined Patent Application No. 11-91205, the current value applied to each motor upon the starting is set to be lower than the constant current value applied to each motor upon the steady-state operation of the photoconductors and a transporting belt in order to reduce a load exerted to the drive source upon the starting. However, this control does not aim to reduce the misregistration in the rotational phase upon the starting.
According to the finding of the inventors, the misregistration amount in the rotational phase caused upon the start of the motor increases as a difference of a load between the motors is great. This is considered that the inconsistency between an increase curve of the speed of the YMC motors and an increase curve of the speed of the K motor upon the starting increases. When the YMC photoconductors and the corresponding image forming sections are driven by a single motor, a difference in a load between the motor for the YMC photoconductors and the corresponding image forming sections and the motor for the K photoconductor and the K image forming section increases compared to a case of driving each color of YMC with a separate motor, whereby the misregistration in the rotational phase is likely to occur upon the start. This is non-preferable from the viewpoint of preventing the color misregistration.
The present invention is accomplished in view of the circumstance described above, and aims to provide an image forming apparatus including plural photoconductors, each having an image to be superimposed formed thereon, wherein a misregistration in a rotational phase, which is caused upon starting a photoconductor driven by a first drive section and a photoconductor driven by a second drive section after they are stopped, can be prevented.
The present invention provides an image forming apparatus including: a first photoconductor group constituted of one or more photoconductors which is/are used for forming a mono-color image; a second photoconductor group constituted of one or more photoconductors which is/are used for forming a full-color image with the first photoconductor group; a first drive section for driving the first photoconductor group to rotate the photoconductor(s) thereof; a second drive section for driving second photoconductor group to rotate the photoconductor(s) thereof; a first drive control section for controlling of the first drive section; and a second drive control section for controlling of the second drive section, wherein each photoconductor constituting the first and the second photoconductor groups is engaged to the corresponding drive section thereto with rotational phases being matched with one another; the rotational phases of the first photoconductor group and the second photoconductor group are adjusted to be matched therebetween; and the first and the second drive control sections control so that the first and the second photoconductor groups are driven simultaneously with an equal target speed during the formation of a full-color image, wherein an initial drive speed which is the target speed upon starting is set at a speed which is lower than a predetermined speed for image-formation, and after the speed of the first and the second photoconductor groups reaches the initial drive speed, the target speed is changed from the initial drive speed to the speed for image-formation.
The image forming apparatus according to the present invention controls the drive of each photoconductor in which an initial drive speed lower than an image forming speed determined beforehand for an image formation is defined as a target speed upon the starting, and changes the target speed to the image forming speed from the initial drive speed to control the drive of each photoconductor after the speed of each of the photoconductors reaches the initial drive speed. Accordingly, the misregistration in the rotational phase caused upon starting the photoconductor driven by the first drive section and the photoconductor driven by the second drive section can be prevented.
In the present invention, a mono-color image is formed by using one or more color components, and further, formed by using color components less than those for a full-color image. When the mono-color image is formed by plural color components, a color phase of the image is substantially uniform in each region.
The first and the second drive sections drive the photoconductors. The specific embodiment thereof includes, for example, a mechanism for transmitting a drive from a drive source by means of a DC motor, a gear, a timing belt, or the like serving as the drive source.
The first drive section controls the start, stop and drive speed of the photoconductor driven by the first drive section. The second drive section controls the start, stop and drive speed of the photoconductor driven by the second drive section. The specific embodiment thereof includes, for example, a control circuit of a motor and a CPU that gives an instruction to the control circuit.
The image forming apparatus further includes known mechanisms such as an image forming section, a superimposing section, a sheet feeding tray that stores print sheets, a second transfer section that transfers a toner image onto an intermediate transfer belt to the print sheet fed from the sheet feeding tray, a fixing section that fixes the toner image transferred onto the print sheet to the print sheet, etc.
The image forming section is arranged for forming the toner image onto a surface of the photoconductor. The image forming section includes each of a station involved with a charging, exposure, development, cleaning, and discharge, those of which are steps in an electrophotographic process.
The superimposing section transfers and superimposes the toner images onto the respective photoconductors. The specific embodiment thereof includes, for example, an endless intermediate transfer belt that moves as successively being contact with the respective photoconductors, and a drive mechanism that drives the intermediate transfer belt.
In the present invention, in case where the locations of periodic fine portions and the coarse portions in respective toner image correspond each other on a printout, it means the rotational phases of the photoconductors corresponding to the toner images are matched.
Preferable embodiments of the present invention will be described below.
The first drive control section may control so that the first photoconductor group stops at a position where the rotational phase thereof is matched with the rotational phase before the starting, when a mono-color image is formed. With this configuration, it is controlled such that a state in which the rotational phases of the respective photoconductors are adjusted is maintained, even after a mono-color image is formed.
The first photoconductor group may be constituted of a single photoconductor, while the second photoconductor group is constituted of a plurality of photoconductors. With this configuration, the plural photoconductors are driven by a common drive section. Accordingly, the number of components of the drive section can be reduced, whereby the apparatus can be downsized and the cost can be reduced. Furthermore, the present invention can prevent the misregistration in the rotational phases of the respective photoconductors upon starting the photoconductors.
Each of the photoconductors may be used for forming a toner image of a different color component, the first photoconductor group is used for forming a black toner image, and the second photoconductor group is constituted of three photoconductors used for forming a yellow toner image, a cyan toner image, and a magenta toner image, respectively. With this configuration, the drive section is respectively provided to the YMC photoconductors that are simultaneously driven during the formation of a color image and the K photoconductor that is solely driven during the formation of a monochromatic image. Therefore, only the photoconductor used for forming a monochromatic image is solely driven, and the photoconductors that are simultaneously driven can be driven with the common drive section. The unnecessary sections can be stopped during the formation of a monochromatic image, whereby unnecessary power consumption can be suppressed, and the deterioration of consumable components can be suppressed. Moreover, the present invention can prevent the misregistration in the rotational phases caused when the photoconductors are started.
Alternatively, as a different embodiment, a second photoconductor group may be any one of a yellow photoconductor, a magenta photoconductor, or a cyan photoconductor. Specifically, in a structure in which the yellow photoconductor, the magenta photoconductor, and the cyan photoconductor are driven by the independent drive sections, any one of the photoconductors corresponds to the second photoconductor group, and the black photoconductor corresponds to the first photoconductor group.
Each of the first and the second drive sections may include a DC motor for driving the corresponding photoconductor group, respectively. With this configuration, the photoconductors can efficiently be driven by means of a DC motor that has a driving force per volume greater than that of a stepping motor. Further, the present invention can prevent the misregistration in the rotational phases caused when the photoconductors are started.
The image forming apparatus of the present invention may further comprise a plurality of image forming sections for forming toner images on the photoconductors, each of the image forming sections forming an toner image on different photoconductors, wherein the first drive section may drive image forming section(s) which forms/form the toner image(s) on the photoconductor(s) of the first photoconductor group and the second drive section may drive image forming section(s) which forms/form the toner image(s) on the photoconductor(s) of the second photoconductor group, and each of the image forming sections may include at least a developing section. With this configuration, the image forming section, particularly a developing section having a heavy load, is driven by the common drive section. Accordingly, the number of components of the drive section can be reduced, whereby the apparatus can be downsized and the cost can be reduced. Furthermore, the present invention can prevent the misregistration in the rotational phases of the respective photoconductors upon starting the photoconductors.
The image forming apparatus of the present invention may further comprise: a phase detecting section for detecting the rotational phases of the first photoconductor group and the second photoconductor group; and a rotational phase correcting section for determining whether the matched rotational phases of the first and the second photoconductor groups are maintained or not based on the results of the detections of the phase detecting section, and corrects the rotational phases of the first and/or the second photoconductor groups/group according to the results of the determination of the rotational phase correcting section, wherein the rotational phase correcting section may detect whether the matched rotational phases are maintained or not at a predetermined timing, and may allow the first and/or the second drive control sections/section to correct the rotational phase of the first and/or the second photoconductor groups/group when the rotational phase correcting section determines that the matched rotational phases are not maintained. With this configuration, when the misregistration occurs in the rotational phases of the photoconductors with the repeated operation of the start, rotation, and stop of the photoconductors, and the misregistration amount exceeds a predetermined allowable range and deviates from the allowable range from the state after the misregistration amount is adjusted, the misregistration is detected so as to allow the first and/or the second drive control section to correct the rotational phases. Consequently, the rotational phases can be returned to the state after the adjustment, at least in the allowable range. Moreover, the present invention can prevent the misregistration in the rotational phases caused when the photoconductors are started. Accordingly, the frequency of the correction can be reduced more than in the conventional case.
The rotational phase correcting section may ignore the results of the detections of the phase detecting section in the period from startup of the first and the second photoconductor groups to a time of their reaching the speed for image-formation and may determine whether the matched rotational phases are maintained or not based on the results of the detections of the phase detecting sections after the reaching. With this configuration, the rotational phases can be detected in a state in which the photoconductors are driven with the image forming speed and the rotational phases of the photoconductors are stable. Accordingly, a correct determination can be done.
Various preferred embodiments described herein may be used in combination with one another.
The present invention will be described in detail below with reference to the drawings. It should be understood that the following description is illustrative of the invention in all aspects, but not limitative of the invention.
The overall structure of an image forming apparatus according to the present invention will be described first. Particularly, a photoconductor, an image forming section, and a superimposing section will be described.
A document platen 92 made of a transparent glass on which a document is placed is mounted at an upper portion of the body 110. The document placed onto the document platen 92 is scanned and read by the document reading section 90. The automatic document feeder 120 transports the document onto the document platen 92. The automatic document feeder 120 is configured so as to be pivotable in a direction of an arrow M, whereby a document can manually be placed thereon by opening the document platen 92.
The body 110 includes an exposure unit 1, developing devices [developing units] 2 (2Y, 2M, 2C, 2K), photoconductor drums 3 (3Y, 3M, 3C, 3K), cleaner units 4 (4Y, 4M, 4C, 4K), chargers 5 (5Y, 5M, 5C, 5K), an intermediate transfer belt unit [intermediate-transfer-belt unit] 6, a fuser unit 7, a sheet feeding tray 81, a manual sheet-feeding tray 82, a sheet exit tray 92, and the like.
The image date handled by the image forming apparatus corresponds to a color image using colors of black (K), cyan (C), magenta (M), and yellow (Y). Therefore, four developing devices 2, four photoconductor drums 3, four charging devices 5, and four cleaner units 4 are provided so as to form four types of latent images corresponding to four colors. Each of these devices is set respectively to black, cyan, magenta, and yellow, whereby four image stations are formed. Any one of alphabets of Y, M, C, and K is attached at an end of the numerals in the figure.
The photoconductor drums 3 for the respective colors correspond to the photoconductor in the present invention. The charging devices 5, the developing devices 2 and the cleaner units 4 for the respective colors correspond to the image forming section in the present invention.
Each of the charging devices 5 is means for uniformly charging a surface of each of the photoconductor drums 3 with a predetermined potential. The illustrated charger type charging device, a contact roller type charging device or a brush type charging device may be employed.
The exposure unit 1 is configured as a laser scanning unit (LSU) including a laser emitting section and a reflection mirror. The LSU includes laser light-emitting elements, each of which emits a laser beam of Y, M, C, and K independently, a polygon mirror that reflects the laser beam emitted from each of the laser emitting elements to deflect the same, and an optical element (lens or mirror) for guiding the laser beam reflected by the polygon mirror to the photoconductor drums 3 of the respective colors. Instead of the LSU, the exposure unit 1 may be configured as an optical writing head having light-emitting elements such as EL or LED arranged in an array.
A peripheral surface of each of the photoconductor drums 3 charged by each of the charging devices 5 is scanned and exposed by the exposure unit 1 with patterns of the respective colors according to the inputted image data. With this exposure, an electrostatic latent image in accordance with the image data of each color is formed on the surface of each of the photoconductor drums 3. Each of the developing devices 2 makes the electrostatic latent image formed on the peripheral surface of each of the photoconductor drums 3 visible with toner. Each of the toner images, which are made visible, is transferred onto the later-described intermediate transfer belt 61 and superimposed with one another. Each of the cleaner units 4 removes and collects residual toner on the surface of each of the photoconductor drums 3 after the development and the image transfer.
The intermediate transfer belt unit 6 is arranged above the photoconductor drums 3. The intermediate transfer belt unit 6 includes an intermediate transfer belt 61, an intermediate-transfer-belt drive roller 62, an intermediate-transfer-belt driven roller 63, intermediate transfer rollers 64 (64Y, 64M, 64C, 64K), and an intermediate-transfer-belt cleaning unit 65. An intermediate transfer bias voltage is applied to each of the intermediate transfer rollers 64 for transferring the toner image onto the photoconductor drum 3.
The intermediate transfer belt unit corresponds to the superimposing section in the present invention.
The intermediate transfer belt 61 is driven by the intermediate-transfer-belt drive roller 62 during the image formation, and is brought into contact with the photoconductor drums 3Y, 3M, 3C, and 3K, which simultaneously rotate, successively along a rotating direction. The toner images of the respective color components formed on the peripheral surfaces of the photoconductor drums 3 are superimposed and transferred, one by one, on the intermediate transfer belt 61. As a result, a color toner image (multi-color toner image) is transferred onto the intermediate transfer belt 61. The intermediate transfer belt 61 is an endless belt using a resinous film having conductivity with a thickness of about 100 to 150 μm, for example. The toner image that is superimposed and transferred onto the intermediate transfer belt 61 moves to a second transfer section where the intermediate-transfer-belt drive roller 62 and the transfer roller 10 are brought into contact with each other, and then, is transferred onto a print sheet, which is fed from the sheet feeding tray, at the second transfer section. A transfer bias voltage is applied to the transfer roller 10 for transferring the toner to the sheet.
The intermediate-transfer-belt cleaning unit 65 having a cleaning blade is provided for removing and collecting residual toner on a surface of the intermediate transfer belt 61 after the toner image is transferred at the second transfer section.
The sheet feeding tray 81 is provided below the exposure unit 1. The sheet feeding tray 81 stores sheets (print sheets) used for the image formation. The print sheet can be fed from the manual sheet feeding tray 82. The sheet fed from the sheet feeding tray 81 and the manual sheet feeding tray 82 passes through a sheet transporting path S having substantially a vertical shape to be discharged onto the sheet exit tray 91 provided at the upper portion of the body 110 through the transfer roller 10 and the fuser unit 7. Pickup rollers 11a, 11b, a transport roller 12a, a registration roller 13, the transfer roller 10, the fuser unit 7, and the transport roller 12b are arranged on a path from the sheet feeding tray 81 and the manual sheet feeding tray 82 to the sheet exit tray 91 through the sheet transporting path S. Transport rollers 12c and 12d are arranged on a reverse path for a duplex printing that is parallel with the sheet transporting path S.
The pickup roller 11a picks up the sheet from the sheet feeding tray 81 one by one, and supplies the sheet to the sheet transporting path S. Similarly, the pickup roller 11b picks up the sheet from the manual sheet feeding tray 82 one by one, and supplies the sheet to the sheet transporting path S. The registration roller 13 temporarily stops the sheet, which is transported through the sheet transporting path S, with the leading end thereof being in contact with the roller. Then, the registration roller 13 transports the sheet at a timing when the toner images formed on the photoconductor drums 3 and a position of the sheet are synchronized, and allows the sheet to pass through the transfer roller 10.
The fuser unit 7 includes a heat roller 71 and a pressure roller 72. The heat roller 71 and the pressure roller 72 transport the sheet transported from the transfer roller 10 as nipping the sheet. A temperature detector is arranged on a surface of the heat roller 71. Further, an external heating belt 73 for externally heating the heat roller 71 is provided. A control section, not shown, for controlling the operation of the image forming apparatus 100 controls a heater provided to heat the external heating belt 73 based on a signal from the temperature detector, in order to control the surface of the heat roller 71 to be a predetermined temperature. When the print sheet passes through the fuser unit 7, the multi-color toner image transferred onto the sheet is fused, mixed, and pressed to be fixed onto the sheet through an application of heat and pressure from the heat roller 71 and the pressure roller 72.
Next, a drive section and a drive control section for driving the photoconductor drums 3 of the respective colors and the developing devices 2 of the respective colors in the image forming apparatus 110 will be described.
The CL motor drive control circuit 23 controls the start, stop, and drive speed of the CL motor 21. The CL motor drive control circuit 23 is a servo control circuit that controls to agree the drive speed of the CL motor 21 with the target speed instructed from the drive control section 25. A K motor drive control circuit 24 controls the start, stop, and drive speed of a K motor 22. The K motor drive control circuit 24 is a servo control circuit that controls to agree the drive speed of the K motor 22 with the target speed instructed from the drive control section 25.
The drive control section 25 gives an instruction of start/stop of the CL motor 21 to the CL motor drive control circuit 23. During the image formation, the drive control section 25 gives an instruction to the CL motor drive control circuit 23 to drive the CL motor 21 with a predetermined process speed (a drive speed for the image formation). The drive control section 25 also gives an instruction of start/stop of the K motor 22 to the K motor drive control circuit 24. During the image formation, the drive control section 25 gives an instruction to the K motor drive control circuit 24 to drive the K motor 22 with the process speed.
The functions of the CL motor drive control circuit 23 and the drive control section 25 that gives an instruction to the CL motor drive control circuit 23 correspond to the first drive control section in the present invention. The functions of the K motor drive control circuit 24 and the drive control section 25 that gives an instruction to the K motor drive control circuit 24 correspond to the second drive control section in the present invention.
A C photoconductor phase sensor 27 detects the rotational phases of the photoconductor drums 3Y, 3M, and 3C. A K photoconductor phase sensor 28 detects the rotational phase of the photoconductor drum 3K.
The power circuit 31 is a bridge circuit that controls the current flowing through the winding of the motor. The power circuit 31 includes six switching transistors, i.e., two for one phase.
The logic circuit 32 receives a signal from a hall element arranged to the CL motor 21 in order to detect a rotating position of the rotor of the CL motor 21, and determines the order of the excitation of a motor winding, i.e., a pattern of on/off (switching) and a switching timing of the switching transistors in the power circuit 31. The logic circuit 32 also receives the instruction of the start and stop from the CL motor drive control circuit 23. It controls the switching of each of the transistors in accordance with the instruction. The logic circuit 32 also has a function of detecting the rotating speed of the CL motor 21. The CL motor 21 has incorporated therein a frequency generator (FG) for detecting the rotating speed. The logic circuit 32 detects the rotating speed based on a signal (FG signal) from the frequency generator.
The set comparing circuit 33 compares the target speed instructed from the drive control section and the FG signal indicating the rotating speed of the CL motor 21. Specifically, the set comparing circuit 33 compares whether the rotating speed of the CL motor 21 is faster than the target rotating speed or not. When the rotating speed of the CL motor 21 is higher than the target speed, the set comparing circuit 33 gives an instruction to the current control circuit 34 to reduce the input to the CL motor 21. When the rotating speed of the CL motor 21 is lower than the target speed, the set comparing circuit 33 gives an instruction to the current control circuit 34 to increase the input to the CL motor 21. When the rotating speed of the CL motor 21 agrees with the instructed target speed, the set comparing circuit 33 outputs a speed lock signal to the drive control section 25. The drive control section recognizes that the CL motor 21 rotates with the target speed from the speed lock signal.
The current control circuit 34 receives the instruction from the set comparing circuit 33, and controls the current flowing through the winding of the CL motor 21 by the power circuit 31.
The K motor drive control circuit 24 has the configuration same as that of the CL motor drive control circuit 23.
Next, a configuration of the drive mechanism that transmits the drive to the photoconductor drums 3Y, 3M, 3C, and 3K, which are loads, from the CL motor 21 and the K motor 22 serving as the drive source will be described. The drive mechanism constitutes the drive section in the present invention together with the motor serving as the drive source. The photoconductor-drum drive gears 41Y, 41M, 41C, and 41K belong to the photoconductors, since they rotate integral with the photoconductor drums 3Y, 3M, 3C, and 3K.
The C photoconductor phase sensor 27 is a photo interrupter type sensor for detecting the rotational phase of the photoconductor drum 3C. The photoconductor-drum drive gear 41C is provided with a projecting portion 45C at a position corresponding to the C photoconductor phase sensor 27. The projecting portion 45C shields light of the C photoconductor phase sensor 27 per one rotation. In response to this, the C photoconductor phase sensor 27 outputs a C rotational phase signal. The K photoconductor phase sensor 28 is a photo interrupter type sensor for detecting the rotational phase of the photoconductor drum 3K. The photoconductor-drum drive gear 41K is provided with a projecting portion 45K at a position corresponding to the K photoconductor phase sensor 28. The projecting portion 45 K shields light of the K photoconductor phase sensor 28 per one rotation. In response to this, the K photoconductor phase sensor 28 outputs a K rotational phase signal.
In the present embodiment, the photoconductor drums 3Y, 3M and 3C are driven as coupled with one another with gears, so that the rotational phases are not misregistered during the drive. The eccentricity of each of the photoconductor-drum drive gears 41Y, 41M, and 41C greatly affects a banding in the toner image. However, the rotational phases of the gears are adjusted when the apparatus is shipped from a factory. Therefore, the rotational phase of the photoconductor drum 3C is detected as the representative of three photoconductor drums 3Y, 3M, and 3C. Then, the rotational phase is corrected between the photoconductor drum 3C and the photoconductor drum 3K. According to the present embodiment, the rotational phases of the photoconductor drums correspond to the rotational phases of the photoconductor-drum drive gears 41Y, 41M, and 41C.
A photoconductor-drum drive gear 54 is arranged at the first end of each of the photoconductor drums 3. The photoconductor drum 3 is made into a process unit 53 including the cleaner unit 4 and the charging device 5.
The drive unit 40 also includes a cleaner drive coupling 48 that transmits drive to the cleaner unit 4, a developing drive coupling 49 that transmits drive to the developing device 2, and a transfer drive coupling 50 that transmits drive to the transfer roller 10. A cleaner driven coupling 55 that is engaged with the cleaner drive coupling 48 is provided to the process unit 53. The rotational drive transmitted to the cleaner driven coupling 55 rotates a waste toner transport screw provided in the cleaner unit 4.
As illustrated in
If the photoconductor drums 3Y, 3M, 3C, and 3K are driven by respective independent drive sources, and a photoconductor rotational phase sensor is provided for the respective colors in the configuration described above, the rotational phase of each of the photoconductor drums is detected after they are mounted, and the rotational phases thereof can be adjusted.
Since the control section autonomously executes a procedure described below, the rotational phases of the photoconductor drums 3 after the exchange can be adjusted without troubling a user. After the photoconductor drums 3 are exchanged, the control section forms a pattern for adjusting the rotation, and transfers the formed pattern on the intermediate transfer belt 61. A reflection-type photo sensor used for the detection is arranged so as to be opposite to the intermediate transfer belt 61.
The control section allows the photo sensor to detect the pattern transferred onto the intermediate transfer belt 61, and compares a detection timing of each line with each of reference timings so as to acquire a delay time or advance time of each line. When the acquired delay time or the advance time is plotted with respect to the time, the waveform having a sine wave caused by the eccentricity of the photoconductor drum 3 is ideally obtained (see
The control section determines a line corresponding to the maximum delay time dmax− and a line corresponding to the maximum advance time dmax+, and determines a line closest to the middle of the respective lines as a reference phase line. This process is performed for the respective colors of Y, M, C, and K.
After the reference phase lines for the respective colors are determined, the control section determines the misregistration amount of the other reference phase lines (the reference phase lines of Y, M, and C) from the reference phase line of the reference color (e.g., K). The control section corrects the rotational phases of the photoconductor drums 3Y, 3M, and 3C based on the determined misregistration amount. The rotational phases are corrected when the photoconductor drums 3 are stopped. The correction of the rotational phase will be described in detail below.
The speed control, which is the greatest feature of the present invention, will be described next.
According to this embodiment, the target value of the drive speed is set to the initial drive speed Vi upon the starting (time ts), when the CL motor 21 and the K motor 22 are started, like the conventional waveform shown in
In a case of
A difference in loads for the respective motors will be described below. For example, load torque for the K motor, i.e., drive torque needed for the K motor is 60 mN·m, while the load torque for the YMC motor, i.e., the drive torque needed for the YMC motor is 100 mN·m.
According to the present invention, during when the target speed is kept to be the initial drive speed Vi, the output from the set comparing circuit 33 gives an instruction to the current limitation circuit 33 so as to supply the current, according to the misregistration with respect to the target speed, to the motor. Thereafter, the driving force of the motor overcomes the static friction force, so that the motors start to rotate at the time t0. Then, the rotating speed of each motor sharply increases to the initial drive speed Vi. The drive speed of the K photoconductor drum reaches the target speed at the time t1. On the other hand, the drive speeds of the YMC photoconductors reach the target speed at the time t2, which is slightly later than the time t1, since a load is heavier than the K photoconductor. As described above, the K photoconductor slightly sharply accelerates compared to the YMC photoconductors, because of a difference in a drive load between the YMC photoconductors and the K photoconductor.
However, a time difference between the K photoconductor and the YMC photoconductors is small. Because the target speed is lower than the speeds V1 and V2 in
When the CL motor 21 reaches the target speed, the speed lock signal is outputted from the CL motor drive control circuit 23 to the drive control section 25. When the K motor 22 reaches the target speed, the speed lock signal is outputted from the K motor drive control circuit 24 to the drive control section 25. When the drive control section 25 recognizes that these speed lock signals are outputted (time t3), the drive control section 25 sequentially increases the target speed to the process speed Vf.
According to the study of the present inventors, after the CL motor 21 and the K motor 22 reach the target speed (after the times t1 and t2), the speeds of both motors are controlled along the target speed. In the conventional speed control shown in
According to the present embodiment, the motors are started as the target speed is kept to be the initial drive speed Vi by which the motors can be started. Even if the target speed is increased after the drive speed of each motor temporarily reaches the initial drive speed Vi, the motors correctly follow the target speed, compared to the period (the period from the time ts to the times t1 and t2) before the drive speed reaches the initial drive speed Vi. Therefore, the misregistration in the rotational phases is suppressed, compared to the conventional technique.
The procedure of the drive control section when the motors are started will be described according to the present embodiment.
The drive control section 25 starts a process in
The initial drive speed Vi is the value by which each motor can be started, and within a settable range in the circuit specification. The drive control section 25 starts the CL motor 21 and the K motor 22 at a same time in order to prevent the misregistration in the rotational phases of both motors.
The CL motor drive control circuit 23 and the K motor drive control circuit 24 start both motors with the initial speed Vi in response to the instruction at step S100. When the drive speed of each motor follows the target speed, the CL motor drive control circuit 23 and the K motor drive control circuit 24 output the speed lock signal respectively. The drive control section 25 waits for the output of these speed lock signals (step S110). After the speed lock signals are outputted (Yes at step S110), the drive control section 25 starts a ramp-up process for increasing the target speed to the process speed Vf from the initial drive speed Vi. This corresponds to the time t3 in
The drive control section 25 firstly increases the target speed in predetermined increments to the CL motor drive control circuit 23 and the K motor (step S120). Then, the drive control section 25 determines whether or not the target speed reaches the process speed Vf that is the final target value (step S130). When the target speed does not reach the final target, the drive control section 25 proceeds to step S120 after waiting for a predetermined time (step S135). The waiting time is set beforehand as the time that each motor can follow the change in the target speed. The drive control section 25 further increases the target speed in predetermined increments at step S120. Thereafter, a process loop of steps S S135, S120, and S130 is repeated until the target speed reaches the process speed Vf. The target speed increases by a repeated process. This corresponds to the period from the time t3 to the time t4 in
The drive control section 25 waits for the output of the speed lock signal from each of the motor drive control sections (step S140), and allows the control section, which controls the entire operation of the image forming apparatus 100, to start the image formation (step S150). The drive control section and the control section may be realized by a separate hardware resource (a CPU, a ROM that stores a control program executed by the CPU, a RAM that provides a work area, etc.), or may be realized by a common hardware resource.
The drive control section 25 measures a time difference Tpx between the rotational phase signal for the cyan photoconductor drum 3C and the rotational phase signal for the black photoconductor drum 3K during the image forming process. The measurement of the time difference Tpx of the rotational phase signal will be described later.
After the image formation is completed, the control section gives an instruction to the drive control section 25 to stop the motors. The drive control section 25 executes a process of stopping both motors in response to the instruction for the stop (step S170). Specifically, the drive control section 25 sends a stop signal to the CL motor drive control circuit 23 and the K motor drive control circuit 24. Further, the drive control section 25 corrects the rotational phases of the photoconductor drums during the stopping process. The correction of the rotational phases will be described later.
In step S110, the ramp-up process of the target speed is started after the speed lock signal of each motor is outputted. However, instead of monitoring the speed lock signal, a period (a period from the time ts to the time t3 in
The method of detecting the rotational phases of the photoconductor drums will next be described.
The detection of the rotational phase of the black photoconductor drum 3K is performed in the same manner.
In the present embodiment, the YMC photoconductors are adjusted in order not to produce the misregistration in the rotational phases thereof upon the manufacture. After the adjustment, the YMC photoconductors are engaged with the input gears and the idle gears, so that there is no chance that the misregistration in the phases occurs during the operation. Accordingly, only the projecting portions formed at an end of the cyan (C) photoconductor and at an end of the black (BK) photoconductor are detected by the phase sensors, and the misregistration is corrected based on a time difference in the rotational phase signals of both phase sensors.
The procedure of correcting the rotational phases of the photoconductor drums will be described.
Firstly, the rotational phases of the photoconductor drums 3C and 3K are adjusted to be matched during the manufacture of the apparatus. A time difference Tp0 of the rotational phase signals of the photoconductor drums 3C and 3K with the phases being matched after the adjustment is measured, and stored. In the present embodiment, the delay and the advance of the photoconductor drum 3C are stored with the photoconductor drum 3K defined as a reference.
On the other hand, as described in the explanation of step S165 in the flowchart in
When the phases of the photoconductor drums are matched, i.e., when a difference between the time Tpx and the time Tp0 is within a predetermined range, the drive control section 25 simultaneously stops the photoconductor drum 3K and the photoconductor drum 3C. During the normal use, both phases are matched, so that the drive control section 25 simultaneously stops both drums (see
When the black printing is performed, the black photoconductor drum 3K is stopped with the rotational phase n rotations (n is an integer) after the photoconductor drum 3K is started, whereby the black photoconductor drum 3K can be stopped without changing the relationship between the phases of the black photoconductor drum 3K and the cyan photoconductor drum 3C.
If the phase of the photoconductor drum 3C advances more than the phase of the photoconductor drum 3K from the reference by the time σ, the photoconductor drum 3C is stopped earlier than the photoconductor drum 3K by the time a, whereby the misregistration in the rotational phases of both photoconductor drums can be corrected (
On the contrary, if the phase of the photoconductor drum 3C delays more than the phase of the photoconductor drum 3K from the reference by the time σ, the photoconductor drum 3C is stopped later than the photoconductor drum 3K by the time a (the photoconductor drum 3C is driven too much), whereby the misregistration in the rotational phases of both photoconductor drums can be corrected (
Any one of the photoconductor drums is stopped by performing the correction of σ in the same manner n rotations (n is an integer) after it is stopped, whereby the rotational phases can be corrected.
The rotational phases are corrected in the same manner in case where the photoconductor drums 3Y, 3M, 3C, and 3K are driven by the respective independent drive sources.
Various modifications are possible for the present invention other than the aforesaid embodiment. It should not be construed that the modifications do not belong to the scope of the present invention. The present invention should include the meaning equivalent to the claims and all modifications within the scope of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2008-107930 | Apr 2008 | JP | national |
