Patent Application
20230127053
The present invention relates to an image forming system including an image forming apparatus for forming an image on a recording material and a varnish application apparatus for applying varnish to the recording material on which the image has been formed.
There has been proposed an image forming system including an image forming apparatus for forming an image on a recording material and a varnish application apparatus for applying varnish to the recording material on which the image has been formed (Japanese Patent Application Laid-Open Publication No. 2018-69669). The image forming system according to Japanese Patent Application Laid-Open Publication No. 2018-69669 is an inline system capable of performing an image forming process and a varnish application process to the recording material consistently when an image forming job is entered, by automatically conveying the recording material on which the image has been formed from the image forming apparatus to the varnish application apparatus.
Hitherto, in the conventional image forming system, if failure of the image forming apparatus or the varnish application apparatus is detected, failure of the apparatus is notified to a user by displaying a notice on a liquid crystal monitor or ringing an alarm, and the job will not be executed even if an image forming job is entered. If failure of the varnish application apparatus has occurred, not only the varnish application process to the recording material by the varnish application apparatus but also the image forming process to the recording material by the image forming apparatus, whose failure has not been detected, will not be executed. That is, the user could not use the image forming system until the varnish application apparatus has been repaired, such that there was a drawback that the productivity of the image forming system was deteriorated.
The present invention aims at providing an image forming system capable of suppressing deterioration of productivity of an image forming system in a case where failure of the varnish application apparatus has been detected.
According to a first aspect of the present invention, an image forming system includes an image forming apparatus configured to form an image on a recording material, a varnish application apparatus configured to apply varnish to the recording material on which an image is formed by the image forming apparatus, and a controller configured to execute a first image forming job in which varnish is applied by the varnish application apparatus to a recording material on which an image is formed by the image forming apparatus and a second image forming job in which vanish is not applied by the varnish application apparatus to a recording material on which an image has been formed by the image forming apparatus. The varnish application apparatus includes a varnish application unit configured to apply varnish to a recording material, a first conveyance unit configured to convey a recording material in a first conveyance path that passes through the varnish application unit, and a second conveyance unit configured to convey a recording material in a second conveyance path that does not pass through the varnish application unit. In a case where failure is occurred to one or both of the varnish application unit and the first conveyance unit and failure is not occurred to the second conveyance unit, the controller is configured to permit execution of the second image forming job and to convey a recording material by the second conveyance unit in the varnish application apparatus.
According to a second aspect of the present invention, an image forming system includes an image forming apparatus configured to form an image on a recording material, a varnish application apparatus configured to apply varnish to the recording material on which an image is formed by the image forming apparatus, and a controller configured to execute a first image forming job in which varnish is applied by the varnish application apparatus to a recording material on which an image is formed by the image forming apparatus and a second image forming job in which varnish is not applied by the varnish application apparatus to a recording material on which an image is formed by the image forming apparatus. The varnish application apparatus includes a varnish application unit configured to apply varnish to a recording material, a first conveyance unit configured to convey a recording material in a first conveyance path that passes through the varnish application unit, and a second conveyance unit configured to convey a recording material in a second conveyance path that does not pass through the varnish application unit. In a case where failure is occurred to the second conveyance unit and failure is not occurred to the varnish application unit and the first conveyance unit, the controller is configured to permit execution of the first image forming job and to convey a recording material by the first conveyance unit in the varnish application apparatus.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
An image forming system according to the present embodiment will be described with reference to
The image forming apparatus 100 is a tandem-type full-color printer adopting an electrophotographic system. The image forming apparatus 100 includes image forming units Pa, Pb, Pc, and Pd respectively forming color images of yellow, magenta, cyan, and black. The image forming apparatus 100 forms a toner image on the recording material S based on an image signal from a document reading apparatus (not shown) connected to the apparatus body 100A or an external apparatus 91 such as a personal computer that is connected to the apparatus body 100A in a manner capable of communicating signals therewith.
According to the present embodiment, an image forming unit 300 for forming a toner image on a recording material S is composed of image forming units Pa to Pd, primary transfer rollers 24a to 24d, an intermediate transfer belt 130, a plurality of rollers 13 to 15, and a secondary transfer outer roller 11. Further, various types of sheet materials, such as paper material including plain paper, thick paper, rough paper, uneven paper, and coated paper, plastic films, and cloth, can be used as the recording material S.
As illustrated in
A cassette 10 storing the recording material S is arranged in a lower part of the image forming apparatus 100. The recording material S is conveyed by a conveyance roller 16 from the cassette 10 toward a registration roller 12. Thereafter, the registration roller 12 is started to be rotated in synchronization with the toner image formed on the intermediate transfer belt 130 as described below, by which the recording material S is conveyed to the secondary transfer portion T2. Only one cassette 10 is illustrated, but a plurality of cassettes 10 capable of storing different types of recording materials S having various sizes and thicknesses can be provided, in which case the recording material S is conveyed selectively from one of the plurality of cassettes 10. Further, not only the recording material S stored in the cassette 10 but also the recording material S supported on a manual sheet feed portion (not shown) can be conveyed.
The four image forming units Pa, Pb, Pc, and Pd arranged in the image forming apparatus 100 have substantially the same configuration except for the difference in the colors being developed. In the following description, an image forming unit Pa for developing a yellow image is described as an example, and the descriptions of other image forming units Pb. Pc, and Pd are omitted.
A cylindrical photosensitive drum 3a serving as a photosensitive member is arranged in the image forming unit Pa. The photosensitive drum 3a is driven to rotate in an arrow R1 direction. A charging unit 2a, an exposing unit La, a developing unit 1a, a primary transfer roller 24a, and a drum cleaning device 4a are arranged in a circumference of the photosensitive drum 3a.
A process for forming a full-color image by the image forming apparatus 100 will be described as an example. At first, in a state where an image forming operation is started, a surface of the rotating photosensitive drum 3a is charged uniformly by the charging unit 2a The charging unit 2a is, for example, a corona charger that irradiates charged particles by corona discharge to charge the photosensitive drum 3a to a uniform negative dark potential. Next, the photosensitive drum 3a is scanned and exposed by laser light emitted from the exposing unit La corresponding to image signals. Thereby, an electrostatic latent image corresponding to image signals is formed on the photosensitive drum 3a. The electrostatic latent image formed on the photosensitive drum 3a is developed as a toner image, which is a visible image, using developer containing toner and carrier stored in the developing unit 1a. According to the present embodiment, the developing units 1a to 1d respectively use two-component developer containing nonmagnetic toner and magnetic carrier. Toner having a low melting point and containing binding resin, coloring agent, and wax as a releasing agent is used.
The toner image formed on the photosensitive drum 3a is primarily transferred to the intermediate transfer belt 130 at a primary transfer portion T1 formed between the intermediate transfer belt 130 and the primary transfer roller 24a arranged in a manner interposing the intermediate transfer belt 130. In this state, a primary transfer voltage is applied to the primary transfer roller 24a The toner remaining on the surface of the photosensitive drum 3a after primary transfer is removed by the drum cleaning device 4a.
The above-described operation is performed sequentially in each of the image forming units Pa to Pd corresponding to yellow, magenta, cyan, and black, and the toner images of four colors are superposed on the intermediate transfer belt 130. Thereafter, at a matched timing with the formation of toner images, the recording material S stored in the cassette 10 is conveyed to the secondary transfer portion T2. Then, by applying a secondary transfer voltage to the secondary transfer outer roller 11, a full-color toner image formed on the intermediate transfer belt 130 is collectively secondarily transferred to the recording material S. The toner remaining on the intermediate transfer belt 130 after secondary transfer is removed by a belt cleaning device 22.
Next, the recording material S to which the toner image has been transferred is conveyed to the fixing apparatus 8. In the fixing apparatus 8, the recording material S bearing the toner image is nipped and conveyed at a fixing nip portion T3 composed of a fixing belt 40 and a pressing belt 41, and heat and pressure is applied to the recording material S. The toner of the toner image borne on the recording material S is melted and mixed by the heat and pressure applied in this manner, and the toner image is fixed on the recording material S as a full-color image. A series of image forming processes is completed in this manner.
The image forming system 1X according to the present embodiment includes the image forming apparatus 100 and the varnish coater 200 connected thereto so as to enable an image forming process of forming a toner image on the recording material S by the image forming apparatus 100 and a varnish coating process of applying varnish by the varnish coater 200 to be processed consecutively. In other words, the image forming system 1X is an in-line system capable of automatically conveying the recording material S on which the toner image has been formed from the image forming apparatus 100 to the varnish coater 200 to thereby consistently perform the image forming process and the varnish coating process to the recording material S when an image forming job is entered.
The varnish coater 200 is configured connectably to the image forming apparatus 100 as one of peripheral devices, also referred to as optional units, that can be retrofitted to the image forming apparatus 100 to expand the functions thereof. The varnish coater 200 is capable of applying varnish as surface processing to the recording material S discharged from the apparatus body 100A with the aim to apply glossiness and provide surface protection as added value to the recording material S, for example. The varnish coater 200 is, for example, an apparatus having a maximum sheet passing size of 330 mm×482 mm, an applicable varnish thickness, i.e., coating thickness, of 6 to 14 μm, and a maximum conveyance speed of the recording material S of 35 m/min.
Next, the varnish coater 200 will be described. An example of using an ultraviolet-curing type UV varnish, which is a varnish cured by ultraviolet radiation is described. As illustrated in
The varnish application roller 201 is formed to have a dimension capable of applying varnish supplied from the varnish storage tank 208 across the entire area of the recording material S in a longitudinal width direction that is orthogonal to the conveyance direction. The ultraviolet radiation lamp 203 irradiates the recording material S on which varnish is applied by the varnish application roller 201 with UV light having a wavelength corresponding to varnish, to thereby cure the varnish. The ultraviolet radiation lamp 203 is disposed to irradiate ultraviolet radiation, i.e. UV light, to approximately the entire area of the recording material S in the longitudinal width direction, similar to the varnish application roller 201.
Further, the varnish coater 200 includes a first conveyance unit 220 and a second conveyance unit 225 for conveying the recording material S. The interior of the varnish coater 200 is divided into a varnish application route 205 (a first conveyance path) through which the recording material S is conveyed through the varnish application unit 210, and a varnish bypath route 204 (a second conveyance path) through which the recording material S is conveyed without passing through the varnish application unit 210. A switching unit 206 is provided to switch the conveyance path of the recording material S between the varnish application route 205 and the varnish bypath route 204. In a case where the path is switched to the varnish application route 205 by the switching unit 206, the recording material S is conveyed to the varnish application unit 210 by the first conveyance unit 220, such that varnish is applied to the recording material S before the recording material S is discharged. Meanwhile, in a case where the path is switched to the varnish bypath route 204 by the switching unit 206, the recording material S will not be conveyed to the varnish application unit 210 by the second conveyance unit 225, such that the recording material S will be discharged without having varnish applied thereto.
The application unit for applying varnish to the recording material S is not limited to the use of a roller method using the varnish application roller 201 and the counter roller 202, and the use of an inkjet method using line heads is also possible. When using line heads, the varnish is not only applied to the entire surface of the recording material S but also used to form a varnish image such as characters and figures on an arbitrary position on the recording material S. Further, a UV-curing type varnish is illustrated as an example of varnish, but other types of varnish such as oil varnish and aqueous varnish can also be used. However, when oil varnish or aqueous varnish is used, infrared (IR) lamp is preferably used as a drying unit for drying the varnish, instead of using the ultraviolet radiation lamp 203. Further, varnish can be dried by hot air, or varnish can be dried using both the IR lamp and hot air.
As illustrated in
The control unit 80 performs various controls such as the image forming operation of the image forming apparatus 100. The control unit 80 includes a Central Processing Unit (CPU) 81, a Random Access Memory (RAM) 82, and a Read Only Memory (ROM) 83. The ROM 83 stores various programs and various data, such as an image forming job or a varnish coater failure processing (refer to
The CPU 81 has, in addition to the RAM 82 and the ROM 83, an input/output interface unit (I/F unit) 85, a varnish application apparatus control unit 86, an input reception unit 87, a temperature detection unit 88, and a motor control unit 90 connected thereto via a bus 84. An operation unit 95 is connected to the input/output interface unit (I/F unit) 85. The operation unit 95 includes an input unit 93 and a display unit 94, wherein the input unit 93 is an operation panel and the like through which instructions to execute various programs such as the image forming job or input of various data by the user are received. The display unit 94 is, for example, a liquid crystal monitor on which various screens including a varnish coater stop screen (refer to
According to the present embodiment, the user can enter through the input unit 93 an instruction to start a first image forming job in which varnish application is performed after image formation and a second image forming job in which varnish application is not performed after image formation, together with information on whether to perform color printing or monochrome printing and the type of the recording material S to be used. Further, the user can enter an instruction to stop the heater 209 through the input unit 93. It is possible to display a virtual operator that resembles switches of the operation unit 95 on the display unit 94, and to enable the user to enter execution operations of various programs and input operations of various data through use of the virtual operator In other words, the operation unit 95 can be a so-called touch panel. Further, the operation unit 95 can also serve as a display unit of the external apparatus 91, such as a personal computer connected via a wired or wireless communication network.
The CPU 81 can acquire image data and various data from the external apparatus 91 such as a personal computer via the input reception unit 87. Further, according to the present embodiment, an instruction to start the first image forming job in which varnish application is performed after image formation and the second image forming job in which varnish application is not performed after image formation can be acquired from the external apparatus 91.
The temperature detection unit 88 detects the temperatures of the fixing roller 40 and the pressing roller 41 based on detection results of thermistors 42a and 42b. The CPU 81 controls a heater control unit 89 based on a temperature detected by the temperature detection unit 88. The heater control unit 89 controls a heater 40a for heating the fixing roller 40 and a heater 41a for heating the pressing roller 41 such that the temperatures of the fixing roller 40 and the pressing roller 41 become the target temperatures. According to the present embodiment, the CPU 81 can control the heater 40a by the heater control unit 89 such that the surface temperature of the fixing roller 40 is set to a desirable temperature within the range of 140 to 190° C., for example, as a target temperature capable of fixing the toner image to the recording material S. The target temperature of the fixing roller 40 is set to a predetermined temperature according to a grammage of the recording material S to realize both fixity of toner to the recording material S and glossiness of the toner image after fixing. Meanwhile, the CPU 81 can control the heater 41a by the heater control unit 89 such that the surface temperature of the pressing roller 41 is maintained to 100° C., for example.
The motor control unit 90 controls the rotation of a motor 92. The CPU 81 controls a rotational speed of the fixing roller 40 via the motor control unit 90 to thereby control a conveyance speed of the recording material S at the fixing apparatus 8 during fixing of toner image.
The varnish application apparatus control unit 86 controls the varnish coater 200 connected to the image forming apparatus 100. For example, the varnish application apparatus control unit 86 controls the varnish application unit 210, the first conveyance unit 220, and the second conveyance unit 230. The CPU 81 controls the varnish coater 200 by transmitting and receiving electric signals via the bus 84. Therefore, if transmission and reception of electric signals via the bus 84 between the image forming apparatus 100 and the varnish coater 200 is not possible, the CPU 81 determines that the image forming apparatus 100 and the varnish coater 200 are not connected.
Next, the varnish coater failure processing according to the present embodiment will be described based on
As illustrated in
In the present embodiment, the control unit 80 determines whether failure has occurred to the varnish application unit 210 in S1, but it is also possible to have the control unit 80 determine whether failure has occurred to at least one of the varnish application unit 210 and the first conveyance unit 220. The processes that follow are similar for both cases where the control unit 80 determines whether failure has occurred to the varnish application unit 210 and determines whether failure has occurred to at least one of the varnish application unit 210 and the first conveyance unit 220, such that in the present embodiment, the case where the control unit 80 determines whether failure has occurred to the varnish application unit 210 will be described.
In a state where failure has not occurred to the varnish application unit 210 (S1: No), the control unit 80 ends the processing. In this case, although not shown, if a second image forming job is entered, the control unit 80 executes an image forming process by the image forming apparatus 100, and simply forms a toner image on the recording material S without performing varnish application thereto. That is, the control unit 80 permits execution of the second image forming job. In this state, the control unit 80 causes the recording material S to be conveyed through the varnish bypath route 204 by the second conveyance unit 230 in the varnish coater 200, and will not perform varnish application. Meanwhile, if a first image forming job is entered, the control unit 80 executes the image forming process by the image forming apparatus 100 and the varnish application process by the varnish coater 200, and forms a toner image on the recording material S and also applies varnish thereto. That is, the control unit 80 permits execution of the first image forming job. In this state, the control unit 80 causes the recording material S to be conveyed through the varnish application route 205 by the first conveyance unit 220 in the varnish coater 200, and performs varnish application.
In a case where failure of the varnish application unit 210 has occurred (S1: Yes), the control unit 80 determines whether the image forming job is a first image forming job in which varnish application is performed after image formation (S2). If the job is a first image forming job (S2: Yes), the control unit 80 will not permit execution of the first image forming job and will execute neither the image forming process by the image forming apparatus 100 nor the varnish application process by the varnish coater 200 (S3). That is, if the job is a first image forming job in which varnish application is performed, the image forming process as a previous process thereof will not be performed by the image forming apparatus 100, such that the recording material S will not be conveyed from the image forming apparatus 100 to the vanish coater 200 that has failed. Then, the control unit 80 outputs a notice to the user by displaying a varnish coater failure and job interruption screen (refer to
Meanwhile, in a case where the job is a second image forming job in which varnish application is not performed after image formation (S2: No), the control unit 80 performs switching to the varnish bypath route 204 by the switching unit 206 (S5). Then, the control unit 80 permits execution of the second image forming job, and executes the image forming process by the image forming apparatus 100 (S6). In this case, the recording material S on which the toner image has been formed is conveyed from the image forming apparatus 100 to the varnish coater 200, and conveyed through the varnish bypath route 204 by the second conveyance unit 230 in the varnish coater 200. That is, in a state where the job is a second image forming job in which varnish application is not performed, even if the recording material S is conveyed to the varnish coater 200 from the image forming apparatus 100, the recording material S is conveyed through the varnish bypath route 204 that does not pass through the varnish application unit 210. Therefore, in the case of the second image forming job, the image forming process by the image forming apparatus 100 will be performed even if failure has occurred to the varnish application unit 210. Then, the control unit 80 notifies the user by displaying a varnish coater failure screen (refer to
Since the second image forming job is executed even if failure has occurred to the varnish coater 200, if failure of the varnish coater 200 is not notified to the user, there may be a possibility that the user will recognize that failure has occurred to the varnish coater 200 only when the user attempts to perform the first image forming job. In that case, the first image forming job cannot be executed until the repairment of the varnish coater 200 is completed, and the user will not be able to obtain the recording material S subjected to varnish application, such that the operation efficiency of the image forming system 1X is deteriorated. Therefore, the user is urged to repair the vanish coater 200 by being notified that failure of the varnish coater 200 has occurred even if the second image forming job is executed and a desired recording material S can be acquired.
As described, according to the present embodiment, even if failure has occurred to the varnish application unit 210, if failure of the second conveyance unit 230 has not occurred, execution of the second image forming job is permitted. If the job is a second image forming job that does not execute varnish application, the recording material S conveyed from the image forming apparatus 100 is conveyed by the second conveyance unit 230 in the varnish coater 200. That is, the recording material S will be conveyed through the varnish bypath route 204 by the second conveyance unit 230, and will not pass through the varnish application unit 210. In other words, since the recording material S will not pass through the varnish application unit 210 that has failed, such that even if failure has occurred to the varnish application unit 210, the recording material S on which image has been formed by the image forming apparatus 100 can be passed through. As descried, by conveying the recording material S using the second conveyance unit 230 that has not failed, the user can perform the image forming process by the image forming apparatus 100 even if failure has occurred to the varnish application unit 210, such that the operation efficiency of the image forming system is improved.
Next, a varnish coater failure processing according to a second embodiment will be described based on
If failure has not occurred to the second conveyance unit 230 (S11: No), the control unit 80 ends the processing. In this case, similar to the first embodiment described above, if a second image forming job is entered, the control unit 80 executes the image forming process by the image forming apparatus 100, and if a first image forming job is entered, the control unit 80 executes the image forming process by the image forming apparatus 100 and the varnish application process by the varnish coater 200.
If failure has occurred to the second conveyance unit 230 (S11: Yes), the control unit 80 determines whether the image forming job is a first image forming job in which varnish application is performed after image formation (S12). If the job is a first image forming job (S12: Yes), the control unit 80 performs switching to the varnish application route 205 by the switching unit 206 (S13). Then, the control unit 80 permits execution of the first image forming job and executes the image forming process by the image forming apparatus 100 and the varnish application process by the varnish coater 200 (S14). In that case, the recording material S on which the toner image has been formed is conveyed from the image forming apparatus 100 to the varnish coater 200, and in the varnish coater 200, conveyed through the varnish application route 205 by the first conveyance unit 220. That is, if the job is a first image forming job in which vanish application is performed, the recording material S is conveyed by the first conveyance unit 220 instead of being conveyed by the second conveyance unit 230. Therefore, even if failure has occurred to the second conveyance unit 230, the recording material S can be conveyed through the varnish coater 200 by the first conveyance unit 220 that has not failed. Therefore, in the case of a first image forming job, even if failure has occurred to the second conveyance unit 230, the image forming process by the image forming apparatus 100 and the varnish application process by the varnish coater 200 can be performed. Then, the control unit 80 outputs a notice to the user by displaying a second conveyance unit failure screen (refer to
Meanwhile, if the job is a second image forming job in which varnish application is not performed (S12: No), the control unit 80 will not permit execution of the second image forming job and will execute neither the image forming process by the image forming apparatus 100 nor the varnish application process by the varnish coater 200 (S16). That is, if the job is a second image forming job in which varnish application is not performed, the recording material S is conveyed by the second conveyance unit 230 in the varnish coater 200. Therefore, the recording material S cannot be conveyed if failure has occurred to the second conveyance unit 230, such that execution of the second image forming job using the second conveyance unit 230 will not be permitted. In contrast, if the job is a first image forming job in which varnish application is performed, the recording material S is conveyed by the first conveyance unit 220 in the varnish coater 200, and the second conveyance unit 230 is not used. Therefore, even if failure has occurred to the second conveyance unit 230, the recording material S can still be conveyed by the first conveyance unit 220, such that the execution of the first image forming job using the first conveyance unit 220 is permitted. In that case, the control unit 80 notifies the user by displaying a second conveyance unit failure and job interruption screen (refer to
As illustrated in
As described, according to the present embodiment, in a state where failure has occurred to the second conveyance unit 230, the execution of the first image forming job is permitted Since according to the second image forming job in ich varnish application is not performed, the recording material S is conveyed using the second conveyance unit 230, such that the recording material S cannot be conveyed by the second conveyance unit 230 that has failed, so the execution of the second image forming job is not permitted. In contrast, in the case of a first image forming job in which varnish application is performed, the recording material S is conveyed using the first conveyance unit 220, and the recording material S will not be conveyed using the second conveyance unit 230 that has failed. Therefore, in the case of the first image forming job, the recording material S can be conveyed using the first conveyance unit 220 that has not failed and have varnish applied by the varnish coater 200, such that execution is permitted. Thereby, the operation efficiency of the image forming system is improved.
The embodiment described above is not limited to application to an electrophotographic image forming apparatus in which the toner image is formed on the recording material using a two-component developer containing toner and carrier, and it is applicable to other types of image forming apparatuses. For example, it is applicable to an inkjet-type image forming apparatus in which image is formed by discharging ink onto the recording material.
According to the present invention, deterioration of productivity of the image forming system in a case where failure has occurred to the varnish application apparatus can be suppressed.
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. 2021-173230, filed Oct. 22, 2021, which is hereby incorporated by reference herein in its entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2021-173230 | Oct 2021 | JP | national |
