Patent Application
20060083530
The present invention relates generally to image forming equipment and is particularly directed to electrophotographic printers of the type which use heated fusers to fix toner onto print media. The invention is specifically disclosed as a laser printer that runs its belt fuser in a standby mode at a slightly raised temperature to operate more quickly when a print job arrives at the printer. The standby temperature of the fuser is low enough so that the movable components are not required to cycle to otherwise avoid thermal problems, but at the same time the standby temperature is raised to a temperature that allows the printer to begin printing the first page more quickly. If possible, it is preferred for the time required to raise the fuser temperature from the standby temperature to the fusing {or fixing} temperature to be short enough so that other printer operations become the determining factor in the time to first print parameter. (In past printers, the time needed to raise the belt fuser temperature from ambient to operating {or fixing} temperature was the controlling factor.)
The electrical energy to keep the belt fuser at its standby temperature can be provided in a form that prevents light flicker, by use of AC waveform phase control or by use of integer half cycle control, in two exemplary modes of the invention. Such types of control can also be used when heating the belt fuser from its standby to fusing temperatures, especially to prevent large overshoots when approaching the fusing temperature. In one mode of the present invention, the control system uses closed-loop feedback control, and the type of controller is a PID (proportional-integral-derivative controller).
Belt fusers are popular for laser printers because of their nearly “instant on” characteristic, i.e., they are heated and prepared to fix toner onto media within a few seconds. The present operation of a conventional belt fuser is to be have the fuser turned off unless toner is being fixed. This mode of operation minimizes the energy used by the printer when it is not printing.
A belt fuser has a finite warm up time that is constrained by the physics (such as thermal capacitance and thermal impedance) of the fuser, the amount of power supplied to the fuser, the desired (target) temperature of the fuser, and the initial conditions of the fuser. Because of improvements in the time at which modern laser printers can generate an image, this finite warm up time has become the limiting factor in time to first print (TTFP). Since there is an interest in improving the time to first print in order to satisfy the user's expectations, a need exists for an improved method. However, any improvement in the time to first print still must meet the important power consumption requirements (such as the USA Environmental Protection Agency ENERGY STAR and German Blue Angel), as well as European flicker and harmonic requirements (IEC 61000-3-2 and 61000-3-3, respectively).
It would be an improvement to minimize the warm-up time of belt fusers in EP printers, while still meeting other important power operating parameters.
Accordingly, it is an advantage of the present invention to provide an electrophotographic (EP) printer, such as a laser printer, which uses a belt fuser that minimizes the warm-up time required in printing the first sheet of a new print job.
It is another advantage of the present invention to minimize the warm-up time of the belt fuser of an EP printer by applying a small amount of power to the fuser, to keep the fuser at an initial condition between the ambient machine (or room) temperature and the fixing temperature of the fuser of the EP printer.
It is yet another advantage of the present invention to provide an EP printer that minimizes the warm-up time of a belt fuser while also reducing voltage transients that can otherwise result in light flicker that might be created by current supplied to the fuser's heating element.
It is still another advantage of the present invention to reduce the warm-up time of the belt fuser of an EP printer while also reducing voltage and current transients by use of several possible control modes, including integer half-cycle control, or percent duty cycle control using a phase-controlled AC power circuit.
It is a further advantage of the present invention to provide an EP printer that minimizes the warm-up time of a fuser apparatus by use of a PID controller that operates in more than one control mode, including standby, ramping, and printing control modes.
It is yet a further advantage of the present invention to provide an EP printer that minimizes the warm-up time of a fuser apparatus by use of a PID controller that operates in more than one control mode, including standby, ramping, and printing control modes, and in which the PID control parameters exhibit different numeric gain values for some of the different control modes.
Additional advantages and other novel features of the invention will be set forth in part in the description that follows and in part will become apparent to those skilled in the art upon examination of the following or may be learned with the practice of the invention.
To achieve the foregoing and other advantages, and in accordance with one aspect of the present invention, a method for controlling a temperature of a printing material fixing apparatus in an image forming apparatus is provided, in which the method comprises the following steps: (a) providing an image forming apparatus having a memory circuit for storage of data, a print engine, and a processing circuit, the print engine including a belt fuser and a heater driver circuit, and the print engine including a supply of printing material to be applied to print media; (b) under the control of the processing circuit, energizing the belt fuser with electrical power from the heater driver circuit in a standby mode, to raise a temperature of the belt fuser to a first temperature that is greater than an ambient temperature of the image forming apparatus; and (c) upon receiving a print job, and under the control of the processing circuit, energizing the belt fuser with electrical power from the heater driver circuit in one of a ramping mode and a printing mode, to quickly raise a temperature of the belt fuser to a second temperature that allows the belt fuser to fix the printer material to the print media, such that a time to first print parameter is reduced as compared to raising the belt fuser temperature from an ambient temperature to the second temperature.
In accordance with another aspect of the present invention, an image forming apparatus is provided, which comprises: a memory circuit for storage of data; a processing circuit; a print engine that produces a physical output upon a print media, the print engine including a belt fuser and a heater driver circuit, and the print engine including a supply of printing material to be applied to the print media; wherein the processing circuit is configured: (a) to energize the belt fuser with electrical power from the heater driver circuit in a standby mode, and thereby raise a temperature of the belt fuser to a first temperature that is greater than an ambient temperature of the image forming apparatus; and (b) upon receiving a print job, to energize the belt fuser with electrical power from the heater driver circuit in one of a ramping mode and a printing mode, and quickly raise a temperature of the belt fuser to a second temperature that allows the belt fuser to fix the printer material to the print media, such that a time to first print operating characteristic is reduced as compared to raising the belt fuser temperature from an ambient temperature to the second temperature.
In accordance with yet another aspect of the present invention, a method for controlling a temperature of a printing material fixing apparatus in an image forming apparatus is provided, in which the method comprises the following steps: (a) providing an image forming apparatus having a memory circuit for storage of data, a print engine, and a processing circuit, the print engine including a heater device and a heater driver circuit, and the print engine including a supply of printing material to be applied to print media; (b) under the control of the processing circuit, energizing the heater device with electrical power from the heater driver circuit in at least one of (i) a standby mode, (ii) a ramping mode, and (iii) a printing mode; (c) the processing circuit being configured to act as a proportional-integral-derivative (PID) controller for energizing the heater device, wherein the PID controller exhibits at least one predetermined PID control parameter when acting in a first of the standby, ramping, and printing modes, and wherein the PID controller varies the at least one of the predetermined PID control parameters when acting in a second of the standby, ramping, and printing modes.
Still other advantages of the present invention will become apparent to those skilled in this art from the following description and drawings wherein there is described and shown a preferred embodiment of this invention in one of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of other different embodiments, and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.
The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description and claims serve to explain the principles of the invention. In the drawings:
Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings, wherein like numerals indicate the same elements throughout the views.
Electrophotographic (EP) printers such as laser printers typically use a fuser apparatus to fix a toner image to some type of print media, such as paper. Belt fusers are popular for laser printers, as noted above, because of their nearly “instant on” characteristic. However, they have a predetermined warm-up time, so they are not truly ready to print in an “instant.” In the present invention, the fuser is kept at an initial condition that maintains the fuser's temperature above the ambient machine temperature. Since this temperature is greater than the room temperature, the time required to reach the target (fixing) temperature is less than the time that otherwise would be required for heating from room temperature to the target (fixing) temperature.
Therefore, it is preferred to keep the initial condition of the belt temperature between the ambient temperature of the machine (typically room temperature) and the target (fixing) temperature. However, it is also preferred to use an initial condition that does not require the printer to periodically rotate the drive train to prevent deleterious effects on the drive train components, and for example, does not need to rotate the drive train to prevent rubber compression set in the back-up roller of the fuser; moreover it is preferred for the initial condition to not require a fan to run in the printer to cool the printer.
In the present invention, the initial condition temperature may be chosen so that the time required to raise the fuser temperature from this initial condition temperature to the target (fixing) temperature is equal to or less than the time needed for the rest of the printing system to be ready to print the first page of the print job. In this way, the rest of the printer becomes the limiting factor for time to first print (TTFP), rather than the fuser being the limiting factor. However, it should be noted that the “goal” of having the remainder of the printer become the limiting factor for TTFP is by no means the only useful feature of the present invention. A “smoother” electrical power characteristic, with regard to the printer's effect on other electrical equipment, is another important feature of the present invention, which reduces light flicker, etc. This other characteristic is discussed below in greater detail.
In one exemplary mode of the present invention, the initial condition temperature is selected as 10° C. However, the initial condition temperature could be selected for a higher or lower value than this 110° C. temperature, for other implementations. In a particular laser printer manufactured by Lexmark International, Inc., the 110° C. initial condition temperature provides about a 1.5 to 2.0 seconds of improvement in warm-up time (e.g., from about six (6) seconds to about 4.0-4.5 seconds). Other configurations could be selected to provide a somewhat greater or lesser improvement in the warm-up time, if desired.
In order to maintain the initial condition temperature, a small amount of electrical power is applied to the fuser heating element. In the present invention, the electrical power is provided to the fuser as phase-controlled AC power, which can be used to minimize the amount of light flicker created by the current flow through the heating element of the fuser. In an alternative embodiment, instead of using phase-controlled power, integer half-cycle control can be used, or even ON-OFF control in situations where the instantaneous voltage and current characteristics are less critical. Such control concepts are discussed in greater detail below.
Referring now to the drawings,
Such a laser printer 10 would also contain memory elements, such as read only memory (ROM) 16 and random access memory (RAM) 18, which also would typically be in communication with an address bus and data bus, and typically connected through the buses 20 to the microprocessor or microcontroller 14.
Most printers receive print jobs from an external source, and in printer 10 there typically would be an input buffer 22 to receive print data, usually through at least one input port, such as the ports 30 and 32. In modern printers, a typical input port could be a USB port or a network ETHERNET port, but also other types of ports can be used, such as parallel ports and serial ports. The input buffer 22 can be part of the overall system RAM 18, or it can be a separate set of memory elements or data registers, if desired.
The print job data will leave the input buffer 22 and in many modern printers, the data is sent to an application specific integrated circuit (ASIC), generally designated by the reference numeral 40 on
The print engine portion of the laser printer 10 will control the fuser's electrical interface circuit, and on
Referring now to
In one exemplary mode of the present invention, a “safety relay” is provided to monitor the thermistor temperature, to ensure that the thermistor has not overheated; if it has, the safety relay will open an electrical contact to prevent the AC heating element 120 from being energized any further. This safety relay is generally designated by the symbol “RY1”, which includes an electromechanical contact 130, and an inductive coil 132. The coil 132 is energized by a relatively low voltage circuit 105, which will become de-energized if the thermistor reads a temperature that is greater than desired for the printer's operation. In one mode of the present invention, this low-voltage circuit 105 is a twenty-four volt circuit. In
The current through the AC heater element 120 continues through the contact 130 to a triac 134 (e.g., a part number BTB 24) and a biasing resistor 136, which in turn supplies current through a second triac element 144 that is part of an opto-coupler 140 (e.g., a part number TLP665). The driver side of opto-coupler 140 is an LED 142, which receives a signal at a signal line 148. The signal 148 is a command from the printer's controller, which typically would be a signal that is derived at the ASIC 40. When this signal becomes at a predetermined voltage level (referred to as Logic 1), then a sufficient current will drive through the LED 142 to turn on the triac 144. This will then allow current to flow through the AC heater element 120. Triac 144 is biased or gated by the other triac 134, as well as resistors 136 and 138. A current-limiting resistor 146 can be included, if desired, although in an exemplary mode of the present invention, the resistor 146 is set to zero Ohms, and the current through the LED 142 is controlled by the ASIC 40 on the controller card.
The control signal at 148 will typically be a phase-firing control signal, in one exemplary mode of the present invention. As noted above, the current supplied to the fuser heating element can be in the form of phase-controlled AC power, or it could be in the form of integer half-cycle control, or some other control scheme, if desired. In the most rudimentary form, the control can be simple on-off control, sometimes referred to as “bang-bang” control, since there would be no attempt to control the timing of the on and off transitions with respect to the single phase AC power that enters the circuit at 110.
With regard to integer half-cycle control, one simple way to implement that type of control scheme is to select certain half-cycles of the AC current that are to be supplied to the fuser heating element 120. For example, three (3) consecutive half-cycles of AC power can be selected as being a single overall “control period,” and the power levels will be controlled in a fairly coarse manner as either being 0/3 for 0% duty cycle, ⅓ for 33% duty cycle, ⅔ for 66% duty cycle, or 3/3 for 100% duty cycle (which is full power). The control circuit will provide the signal 148 at the appropriate times to turn on the AC power at a zero-crossing point of the sine wave for the line power at 110 on
A much finer control can be utilized by using phase-controlled AC power. The signal 148 can be used to turn on the LED 142 at a certain phase angle after a zero crossing of the incoming AC line voltage at 110. This can be controlled in whatever precision is desired, but typically 8-bit precision is quite sufficient, which provides 256 possible duty cycle percentages. In many phase-controlled circuits, the timing of the “start” mark of a particular AC half-cycle is controlled to not be at a zero crossing, but the termination of this half-cycle can be implemented to always occur at such a zero crossing, to reduce the transient voltage and current when the inductive heating element 120 is de-energized. This is not necessary, but it is often desired in many types of equipment.
Finer control can also be implemented strictly using integer half-cycle control, if desired. It will be understood that any number of half-cycles can be chosen to act as the “control period.” If four half-cycles are chosen, then the possible power levels are 0%, 25%, 50%, 75%, and 100% (i.e., 0/4, ¼, 2/4, ¾, and 4/4 of full power). The “control interval” can be many more half-cycles than three or four, and, for example could be ten (10), in which case the duty cycle would be in intervals of 10%, in the range from 0% through 100% inclusive. The “fuser ON” signal 148 can be controlled to merely select the starting zero-crossing and the ending zero-crossing for each of the control intervals, at times when the fuser is to be energized.
If the printer is beginning to print for the first time after not operating for a fairly long time period, then it may be likely that the duty cycle would be 100% for this fuser ON signal 148, to bring the heater assembly 50 up to temperature as quickly as possible. On the other hand, if a closed loop control system is used, which is an exemplary mode of the present invention, then a controller will typically change the duty cycle to reduce the amount of temperature overshoot as the fuser assembly 50 nears its nominal operating temperature. This will be discussed below in greater detail.
Referring now to
The overall operation of this circuit 150 uses the signal 56 to act more or less as a threshold voltage at the negative input terminal of the comparator chip 64, while the other input voltage 54 represents the actual fuser temperature. The output signal 58 will turn on for a particular duty cycle if the actual fuser temperature is below the threshold level indicated by the signal 56. This output signal 58 can be in the form of a DC signal, or in the form of a pulse-width modulated signal that can be used to control a phase-fired AC signal, such as the signal running through the triac 144 and the heating element 120 of
It should be noted that the control scheme used in the present invention is not limited to strictly a feedback control mode. Alternative control modes could be used, if desired, also without departing from the principles of the present invention. For example, the control system may be envisioned to run in some type of feed-forward control if desired. In a similar way, the control system can be envisioned as running in an open loop mode. An example of open loop control is to turn on the fuser heater for a selected amount of time (for example, 1 second) at a selected power (for example, ⅓ power) any time the fuser temperature falls below a certain threshold (for example, below 110 degrees C.).
If PID control is selected as the control scheme, the PID gains (Kp=proportional gain, Ki=integral gain, and Kd=derivative gain) may be chosen to give the best compromise between temperature swing and speed of response. In one exemplary implementation, the Kp, Ki, and Kd variable values were chosen as 12, 13/32, and 11 respectively for printing mode, and 3, 2/32, and 1 respectively for standby mode. This change of gains gave better performance with respect to light flicker. However, other implementations may be envisioned with only one set of Kp, Ki, and Kd gains for printing and standby, and in a similar way, other implementations may be envisioned with much different numeric values selected for these PID control parameters. See below for further details on implementing the invention using a PID control scheme.
The average power consumption is a function of the “initial condition temperature.” The power consumption will decrease when the “initial condition temperature” selected is closer to room ambient temperature; alternatively, the power consumption will increase when the “initial condition temperature” selected is closer to the target (fixing) temperature. In one example printing system, the power supplied to the fuser heater was approximately 15-20 watts to hold the “initial condition temperature” at a value between 100-110 degrees C. A machine total power consumption of approximately 25-30 watts was measured for this example printing system; of course, other implementations are possible while falling within the principles of the present invention.
In an exemplary mode of the present invention, the “initial condition temperature” may be maintained indefinitely. It can be readjusted, if necessary, to meet the ENERGY STAR and Blue Angel requirements, and for example, it may be set to lower and lower levels as time passes, in order to meet those requirements.
The “filtered” temperature reading is then directed to a fuser control state machine 200. There is also a “page supervisor” function 300, which is also referred to as the “fuser manager” state machine. This function 300 is the calling function that requests operation of the fuser when it is time to print a sheet of print media. Fuser manager 300 not only requests the fuser to operate, but requests a certain fuser temperature and control type. These requests are entered to the fuser control state machine 200. These functions 200 and 300 are described in greater detail below.
The fuser control state machine 200 outputs a duty cycle to the controlling triac at signal 148. This is the “fuser ON” signal that is also seen on
In one mode of the present invention, the software control elements of
Referring now to
From the closed loop ramping state 220, the logic flow can travel down a pathway 222 if the current fuser temperature is greater than or equal to the desired temperature −5° C. When that occurs, the control state known as “steady state” is entered at 230. During this transition of states, the gain mode is set to either printing or standby, the integral error value is set to the initial error value. Now that the steady state 230 has been achieved, the fuser will be energized under the appropriate duty cycle until it is time to turn the fuser off. The fuser can be turned off at a state 250 from the steady state, via an arrow 232. The fuser off state 250 requests the main controller to set the fuser mode to “OFF,” and this request applies to all arrows pointing to the fuser off state 250. When in the steady state 230, the control mode will pass back to the transition to belt control state 210 from the steady state 230, via an arrow 234 if the fuser is not to be turned off at this time.
If at the closed loop ramping state 220, and if a different fuser control or temperature is requested, then the control mode is passed either along arrow 224 or 226, back to the transition to belt control state 210. If arrow 226 is used, the fuser is turned off at state 250. The arrow from the fuser off state to the transition state 210 is the arrow 254, which calls forth the requested control as being either the belt control mode or the standby control mode.
If the control state currently is waiting for the fuser to cool at 240, and if the fuser's current temperature is less than or equal to the desired temperature +5° C., then the fuser is turned on through an arrow 242 to the steady state 230. While this occurs, the gain mode is set to either printing or standby, the integral error mode is set equal to the initial error (in the gain mode function).
When in the wait for cool state 240, if a different fuser control or temperature is requested, then the control mode is passed back to the transition to belt control state 210, either along an arrow 244, or an arrow 246 that first turns the fuser off at the fuser off state 250.
When in the transition state 210, if the fuser temperature is not greater than or equal to the desired temperature +10° C., or if it is not less than or equal to the desired temperature −10° C., then the control state is set directly to the steady state 230, via an arrow 216. In this transition to steady state 230, if the fuser is not already on, then the fuser is to be turned on. The gain mode is set equal to either printing or standby, and if the integral error is greater than zero (0), then the integral error is set to zero (0). On the other hand, if the integral error is greater than 638, then the integral error value is set to 638. Finally, if the integral error is already at any other value than that described above, then the integral error value is not changed.
The numeric values for the variables integral error and initial error, are control concepts used in proportional-integral-derivative mode controllers, also commonly referred to as PID controllers. In an exemplary mode of the present invention, the PID controller is implemented within the print engine code that runs in the print engine ASIC, and uses a processing circuit, either within the ASIC, or perhaps a separate microprocessor or microcontroller device. This is an exemplary mode of the present invention, but as discussed above, other control schemes are envisioned by the present inventors, such as proportional-integral modes only, or proportional mode only, or even “bang bang” ON/OFF mode control, without departing from the principles of the present invention. The PID controller will be discussed in greater detail below.
In an exemplary mode of the present invention, the belt fuser control state machine logic of
Referring now to
If this is a cold start condition, then the logic flow travels down an arrow 312 to a state 330 that is referred to as the “wait for media in fuser” state. The control logic turns on the fuser to the printing temperature during the transition from the spin state 310 to this wait state 330. Once the printer realizes that the first page of the print job has reached the fuser nip, then an arrow 332 transfers the logic control to a state 340 referred to as a “wait for media clear fuser” state, where it remains until the media clears the fuser.
If at the spin state 310, and alternatively the control logic determines that the first page of a print job has not occurred during a cold start condition, then a “just in time ramping” flag is set and the logic flow travels down an arrow 314 to a state 320 that is referred to as the “wait for fuser ramp start” state. Once at state 320, the logic stays here until it is realized that the next page is approaching the fuser nip. When that occurs, the temperature begins ramping so that the fuser temperature is set to the printing temperature when the ramp time is greater than or equal to the remaining time for the page to reach the fuser nip. This occurs along an arrow 322, and that changes the logic state to the wait for media in fuser state 330.
When the printer realizes that the first page of the print job has reached the fuser nip, then the arrow 332 transfers the logic control to the “wait for media clear fuser” state 340, where it remains until the media clears the fuser. Once at state 340, if the trailing edge of the page passes the fuser and other pages need to be printed, and if the next page is past the input sensor, then the fuser is set to the next page's printing temperature along an arrow 342, and the logic is sent back to the wait for media in fuser state 330. In other words, the temperature should stay approximately where it already is at, at least for the same type of sheet media.
On the other hand, at state 340 if another page needs to be printed and the next page has not yet reached the input sensor, then the fuser temperature is set to its standby temperature, and a “just in time ramping” flag is set. This occurs along an arrow 344, and changes the state to the wait for fuser ramp start state 320. Finally, at state 340 if the trailing edge of the media has passed through the fuser and all pages are finished for this print job, then the logic travels along an arrow 346 to the spin state 310, and the fuser is set to its standby temperature.
Referring now to
The target clicks in the temperature control block diagram 400 represent the desired temperature that the fuser assembly 50 is to be set to. This numeric value is directed down an arrow 412 to a difference function 420, in which the actual temperature of the fuser (also in units of “clicks”—a different numeric value in the range of 0-255) is subtracted from the target temperature (in clicks), resulting in a difference value, which is referred to as the “error” (also in units of clicks), at an arrow 422. This difference function 420 is a standard function used by many PID controllers. Using the error value 422, a PID calculation occurs at a calculation block 424, and the computed error result is directed down an arrow 426 to an error calculation lookup table 430. (Some type of transfer function could be used instead of a lookup table, as is understood in the art.)
The result of this lookup table is a duty cycle value, which is directed down an arrow 432 to a power calculation at a block 440. The heating element of the fuser is sometimes referred to as a “slab resistor,” and its resistance value is typically in the range of 7.2 Ohms through 43 Ohms. The AC voltage in RMS volts is designated by an arrow 434. The power output from the calculation block 440 is equal to the RMS voltage squared divided by the resistance value of the heating element, times the duty cycle of the signal 432. This output power in watts is a result, and is directed down an arrow 442 to another difference calculation at 446.
If a sheet of print media is passing through the fuser at this time, then some of the fuser's power will be delivered to that media as the toner is fixed to that media. The power delivered to the media is represented by an arrow 444, and this is subtracted from the power generated by the slab resistor, represented by the arrow 442. The difference is the net power being delivered to the fuser assembly, represented by an arrow 448. The fuser assembly 50 receives this power, and the controller calculates the resulting desired slab temperature in degrees C, at an arrow 452.
The fuser temperature is also directed down an arrow 454 to a mathematic model of the thermistor 52. A calculation that determines the expected resistance value of the thermistor for a given temperature is provided on
Referring now to
The reference temperature 510 is directed down an arrow 512 to a difference function 520, in which the actual temperature of the fuser 570 (in degrees C.) is subtracted from the target temperature, resulting in a difference value, which is referred to as the “error” (also in units of degrees C.), at an arrow 522. This difference function 520 is a standard function used by many PID controllers. Using the error value 522, a PID calculation occurs at a calculation block or step 524, and the computed error result is directed down an arrow 526 to a function that will use this computed error.
As discussed above, the present invention can be used with more than one type of output circuit control mode, including a “phase control delay” mode and an “integer half-cycle” (IHC) mode. In
If IHC control is selected, then the computed error 526 is directed to a block 530 in which the output control value 532 will essentially comprise an integer value of AC sine wave half-cycles as a voltage waveform or signal which exhibits a “longer” interval “total duty cycle” that is appropriate for the computed error signal 526. (In IHC control, the duty cycle for a given half-cycle will either be 100% or 0%, but the “overall” or “total” duty cycle for a predetermined number of half-cycles will be at some fraction between 0% and 100%, inclusive, as discussed above.) The numeric values to be used in these calculations for function blocks 528 and 530 could be stored as an error calculation lookup table, or provided by use of some type of transfer function.
The control value 532 is directed down an arrow 532 to a “slab resistor” power calculation at a function block 540. (As noted above, the heating element of the fuser is sometimes referred to as a “slab resistor.”) The AC voltage supply in RMS volts is designated by an arrow 534. The power generated by slab resistor in calculation block 540 is equal to the RMS voltage squared divided by the resistance value of the heating element, times the duty cycle of the signal 532. This output power in watts is a result, and is directed down an arrow 542 to another difference calculation at 546.
If a sheet of print media is passing through the fuser at this time, then some of the fuser's power will be delivered to (or absorbed by) that media as the toner is fixed to that media. The power absorbed by the media is represented by an arrow 544, and this is subtracted from the power generated by the slab resistor, represented by the arrow 542. The difference is the net power being delivered to the fuser assembly which is available to raise the fuser temperature, represented by an arrow 548. The fuser assembly 50 receives this power, and the controller calculates the resulting desired slab temperature in degrees C., at an arrow 552.
The fuser temperature (in C) is also directed down an arrow 554 to a mathematic model of the thermistor 52 which, as a thermistor, exhibits a non-linear temperature-to-resistance characteristic. The thermistor's resistance (in units of Ohms) is passed along an arrow 556 to a thermistor circuit block 560. This circuit block receives a DC power supply voltage of 5 volts +5% at 558, and converts the thermistor's resistance in Ohms into an output voltage, which is directed along an arrow 562 to an A/D converter, such as the A/D converter 150.
The A/D converter 150 receives a DC power supply voltage of 5 volts +5% along an arrow 564, and the thermistor voltage 562 is then converted into clicks. (As noted above, the term “clicks” refers to a numeric value, typically in the range of zero (0) through 255 for a control system having an 8-bit precision, for example. The number of clicks could be zero (0) for a minimum value and 255 for a maximum value, representing the numeric integer values using this 8-bit precision.) A software function at a block or step 566 then converts this numeric value in clicks to a temperature value in degrees C., which is output from block 566 along an arrow 570. This arrow 570 represents the present actual temperature of the fuser (or more specifically, the fuser's thermistor 52), and this value is fed back to the difference function 520, and then used in the calculation of the current “error,” along with the desired temperature 512.
One benefit of using a PID control scheme for controlling the temperature of the fuser is that some of the electrical power requirements can be reduced, particularly for transient “turn-on” voltage and current characteristics. For example, if simple ON-OFF control is used for a “large” laser printer (e.g., for a heavy-duty office color laser printer) that includes a rather powerful fuser, then the operating characteristics of the printer using ON-OFF control may not be optimal, because there can be significant inrush current that may cause light flicker in other electrical equipment on the same branch line circuit. In one “large” printer, the fuser draws current on the order of 9-11 Amperes for a 120 VAC printer when full on. A “bang-bang” ON-OFF control may well result in light flicker at this magnitude of abrupt current switching.
The more refined output signal control available in some control modes (e.g., phase control or IHC control) of the present invention can indeed reduce the power transients induced in other electrical equipment that is nearby to the printer 10, to an extent that the light flicker of that other equipment becomes virtually undetectable to the human eye. This is true for electrical equipment running on 120 VAC power lines and for that running on 230 VAC power lines. Thus, in the United States, the EPA's ENERGY STAR power consumption standards can be met (e.g., at 120 VAC); in Europe, the European flicker and harmonic requirements (IEC 61000-3-2 and 61000-3-3) can be met (e.g., at 230 VAC).
On the other hand, if the rather “coarse” control afforded by ON-OFF output signal control is used, it may result in fairly large temperature swings in some of the operating modes, due, for example, to lag time between the resistor heating element (e.g., positioned on one side of the slab element) and the thermistor (which may be positioned on the opposite side of the slab element). In one prototypical test of this configuration, the lag time was on the order of 200 ms, such that when the resistor heating element was energized with electrical current, it took about 200 ms before the thermistor was able to detect a change in temperature. This effect could perhaps be minimized by altering the physical layout of the circuit components, but another way to improve this characteristic is to use a different control mode, such as a PID controller, for example. The PID controller allows a more continuous (and perhaps “finer”) energy flow to the fuser load. For example, the use of a PID controller with integer half-cycle control should work well for printers using 50 Hz electrical power in Europe and Japan; the use of a PID controller with phase control should work well for printers using 60 Hz electrical power in the United States.
In many conventional PID controllers, it is normal practice to set the PID control parameters to values that provide optimum performance for the operating extremes of the system being controlled. For a laser printer having a belt fuser, for example, selecting certain values for some of the control parameters (e.g., for “P gain”, “I gain”, and “D gain”) may work well in one mode of operation, such as the ramping mode, but may not work so well in a different mode, such as the warm-up (standby) mode. In other words, the standby mode. may exhibit substantial temperature swings using the same control parameters that would work very well in the ramping mode (or perhaps also in the printing, full-power mode).
With this in mind, another improvement provided by the present invention is the use of more than a single set of PID control parameters—the Kp, Ki, and Kd gains—for different modes of operation. As noted above, different Kp, Ki, and Kd variable values may be used for the printing and standby modes. In a similar manner, a different set of Kp, Ki, and Kd variable values also can be used for the ramping mode.
In one embodiment of the invention, the operating computer software code utilizes a lookup table to decide which PID control parameters should be used during the present stage of the printer's operation. (Note that a transfer function, or some other method for calculating and storing numeric values, could be used instead of a lookup table.) A reasonable set of gains was found to include six possible modes, but there can be more or fewer than six modes for various types of printers when using the present invention. Using this embodiment of the present invention, the six modes are:
(1) Integer half cycle, standby.
(2) Integer half cycle, ramping.
(3) Integer half cycle, printing.
(4) Phase control, standby.
(5) Phase control, ramping.
(6) Phase control, printing.
The PID control variables can be set to many different values by the system designer. A set of tables is presented below showing some example values that are appropriate for certain laser printers manufactured by Lexmark International, Inc. The variable Kp represents the proportional gain factor, the variable Ki represents the integral variable factor, and the variable Kd represents the differential variable factor for the PID controller. In the tabular data below, the integral value is listed as both a numerator value and a denominator value, as well as a denominator shift value.
Within each control mode of these tables, a 5-tuple describes the gain specifics. For example, in the “integer half cycle, standby” case, the 5-tuple of gains is set as (Kp, Ki num/Ki den, Kd, and InitialIntegralError)=(P, I, D, initial error)=(8, 9/16, 20, 5). In this particular example, the proportional gain is “8”, the derivative gain is “20”, and the integral gain is 9/16, in which the values “9” and “16” are stored as separate values. Note that the variable “InitialIntegralError” may typically be set to a value of zero as it is loaded into the software code. However, this value can be modified and later stored as a non-zero updated value for later generations of a specific printer product, since such a non-zero value might work better in certain printers.
One advantage of the above type of lookup table methodology is that integral gains of less than one ( 1 ) can be achieved, which may provide better temperature control, particularly in the standby mode of operation. As can be seen from inspecting the tables below, one optimum integral gain for standby mode was 9/16 using integer half-cycle control. In this manner, integer values can be used in the lookup table for gain factors less than one, rather than floating point numbers. However, if desired by the system designer, floating point numbers could be stored in a lookup table and used for some or all of the PID control parameters.
The example numeric values for these control variables are listed in two different types of control mode. The “phase control” mode values are listed along the right portion of the table, while the “integer half-cycle” mode values are listed on the left side of the table. It will be understood that different numeric values can be used for these PID control variables, without departing from the principles of the present invention. The above values are provided as examples of an exemplary mode of the present invention.
In the above tabular information, the Ki denominator typically has a numeric value that is a power of 2.
It will be understood that the term “print media” herein refers to a sheet or roll of material that has toner or some other “printable” material applied thereto by a print engine, such as that found in a laser printer, or other type of electrophotographic printer. Alternatively, the print media represents a sheet or roll of material that has ink or some other “printable” material applied thereto by a print engine or printhead, such as that found in an ink jet printer, or which is applied by another type of printing apparatus that projects a solid or liquified substance of one or more colors from nozzles or the like onto the sheet or roll of material. Print media is sometimes referred to as “print medium,” and both terms have the same meaning with regard to the present invention, although the term print media is typically used in this patent document. Print media can represent a sheet or roll of plain paper, bond paper, transparent film (often used to make overhead slides, for example), or any other type of printable sheet or roll material. In the present invention, the print media is typically in the form of sheets or “pages,” for documents being output by the printer.
It will also be understood that the logical operations described in relation to the logic diagrams of
It will be further understood that the precise logical operations depicted in the logic diagrams of
It will also be understood that some of the principles of the present invention are applicable to other types of heating devices besides belt fusers. For example, the use of different PID control parameters for various modes of operation can be readily applied to roller-type fusers in EP printers, or in other types of printers that require various components to be quickly heated by use of electrical energy.
All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.
The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Any examples described or illustrated herein are intended as non-limiting examples, and many modifications or variations of the examples, or of the preferred embodiment(s), are possible in light of the above teachings, without departing from the spirit and scope of the present invention. The embodiment(s) was chosen and described in order to illustrate the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to particular uses contemplated. It is intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
