Patent Application
20100142977
This invention relates in general to electrographic printing, and more particularly to reducing downtime of a multi-toner printing apparatus.
One method for printing images on a receiver member is referred to as electrophotography. In one example, an electrophotographic printing device may create multi-color toner images using a plurality of color imaging printing modules coupled within the printing device. The printing modules may be arranged in tandem such that the toner images are successively electrostatically transferred to the receiver member.
Known examples of printing devices may deposit toner at specific locations on the receiver member and/or on top of other previously deposited toner using the plurality of printing modules. Once the receiver member has received the appropriate toner images the final print image may be permanently fixed to the receiver member typically using heat, and/or pressure. Multiple layers or marking materials can be overlaid on one receiver, for example, layers of different color particles can be overlaid on one receiver member to form a multi-color print image on the receiver member after fixing.
In the event one of the printing modules experiences a failure, the performance of the printing device and/or the quality of the final printed image may be decreased. Generally, there are at least two types of printing module failures that may occur: (1) hard failures and (2) soft failures. During a hard failure, for example, at least one of the components of the printing module may become non-functional. As a result, during a hard failure, the affected printing module may be non-functional. In a soft failure, however, the failing printing module may still function albeit at a lower performance level or the printing module may print toner images that may contain artifacts therein.
Print providers have been looking for ways to reduce the downtime of a printing device that experiences failures.
In one exemplary embodiment, a method for interchanging components between a failing printing module and a functioning printing module may be provided. The method may include the steps of providing a printing assembly that includes a plurality of printing modules that each include a specific toner color, wherein a first printing module is failing and at least one second printing module is functioning; determining a toner use demand for the plurality of printing modules; and swapping the first printing module with the at least one second printing module to facilitate reducing a downtime of the printing apparatus, wherein the first printing module has a toner use demand that is substantially greater than the toner use demand of the at least one second printing module.
In another exemplary embodiment, a method of preventing downtime of a printer assembly may be provided. The method may include providing a printer assembly that includes a plurality of printing modules that each include a first toner color coupled therein; determining a toner use demand for each toner color of each printing module, wherein a primary printing module has the greatest toner use demand; and adding a redundant printing module that includes a redundant toner color that is substantially identical to the first toner color of the primary printing module.
In yet another exemplary embodiment, a means of decreasing a downtime of a printing apparatus may be provided. The means may include means for determining a failure of one of a plurality of printing modules; means for determining a toner use demand of each of the plurality of printing modules; and means for swapping the failing printing module with a functioning printing module, wherein the failing printing module has a toner use demand that is substantially greater than the toner use demand of the functioning printing module.
The invention, and its objects and advantages, will become more apparent in the detailed description of the exemplary embodiments described herein.
In the detailed description of the preferred embodiments of the invention presented below, reference is made to the accompanying drawings, in; which:
a is a schematic cross-sectional side view of an electrographic reproduction apparatus suitable for use with this invention;
b is a schematic cross-sectional side view of the electrographic reproduction apparatus shown in
a is a schematic cross-sectional side view of another embodiment of an electrographic reproduction apparatus;
b is a schematic cross-sectional side view of the electrographic reproduction apparatus shown in
Referring now to the accompanying drawings,
In one embodiment, printing modules M1-M4 may be rotatably coupled to a transport device, such as endless belt web 112. A plurality of receiver members 110 may be coupled to belt web 112, wherein each receiver member 110 may receive the print image. Receiver members 110 may be removably electrostatically coupled to belt web 112 via corona tack-down chargers (not shown) or by mechanical devices such as grippers (not shown).
Similarly, as described above, in one embodiment, printing modules M1-M5 may be rotatably coupled to belt web 112. The plurality of receiver members 110 may be coupled to belt web 112, wherein each receiver member 110 may receive the print image. Receiver members 110 may be removably electrostatically coupled to belt web 112 via the corona tack-down chargers or the grippers.
Printing module M1 may also include a plurality of electrographic imaging subsystems for producing one or more multilayered images or patterns. For example, in one embodiment, printing module M1 may include a cleaner system 122 that may be operatively coupled to surface 118. Printing module M1 may also include a primary charging system 124 that is operatively coupled to surface 118 of photoconductive imaging roller 114, wherein primary charging system 124 may facilitate uniformly electrostatically charging surface 118. Moreover, printing module M1 may include an exposure subsystem 126 that may be operatively coupled to surface 118, wherein exposure subsystem 126 may facilitate image-wise modulating the uniform electrostatic charge by exposing photoconductive imaging roller 114 to form a latent electrostatic multi-layer (separation) image of the respective layers. Printing module M1 may also include a dry ink, or toner, station 128 that may be operatively coupled to surface 118, wherein toner station 128 may facilitate depositing a color toner image 130 on surface 118 of photoconductive imaging roller 114.
A logic and control unit (LCU) 132 may be provided and may include a microprocessor incorporating suitable look-up tables and control software, which may be executable by LCU 132. The control software may be stored in a memory associated with LCU 132. The control software may include image processing algorithms that facilitate sending the correct image data, or plane, to the appropriate printing module. Moreover, each printing module M1-M5 may have unique calibrations that are color specific and/or module specific. In one embodiment, LCU 132 may facilitate reassigning the unique calibrations to another printing module, as described in more detail below. In another embodiment, LCU 132 may facilitate repeating, or copying, the unique calibrations for a specific color to a different printing module, as described in more detail below. Each toner station 128 may include a toner color identifier (not shown) that may be detected by a plurality of sensors (not shown) coupled within printing modules M1-M5. In a non-limiting example, LCU 132 may automatically reprogram printing module M1 in response to the sensors in the event toner station 128 is swapped out of one of the other printing modules M2-M5 and coupled within printing module M1. Furthermore, LCU 132 may generally nominalize and/or optimize the operating parameters and reduce errors which are attributable to the printing process.
A power supply unit 134 may provide individual transfer currents to the transfer backup rollers 116. LCU 132 may provide control of the various components and process control parameters of the apparatus in response to signals from various sensors (not shown) associated with the electrophotographic printer apparatus. LCU 132 may also provide timing and control signals to the respective components to provide control of the printing apparatus in accordance with well understood and known employments.
During operation, receiver members 110 may be channeled from a paper supply unit (not shown) and transported through the printing modules M1-M5 in a direction as indicated in
In the exemplary embodiment, printing module M1 may deposit black (K) toner color separation images; printing module M2 may deposit yellow (Y) toner color separation images; printing module M3 may deposit magenta (M) toner color separation images; and printing module M4 may deposit cyan (C) toner color separation images. An optional printing module M5, as shown in printing assembly 200 in
In one embodiment, as shown in
Turning back to printing assemblies 100 and 200, in the event one of the printing modules experiences a failure, the uptime and/or performance of the printing apparatus may be substantially reduced. In the event a printing module experiences a soft failure, a customer and/or field engineer may reconfigure the printing apparatus to enable the printing module to continue performing. Such reconfiguration may facilitate reducing downtime of the printing assembly, as described in more detail below. One such solution to prevent downtime, for example, is to swap the failing component of the affected printing module with a substantially similar component of a functional printing module coupled within the printing apparatus. In another embodiment, the entire printing module may be failing. In such an event, the entire failing printing module may be swapped out with a function printing module that may also be contained within the printing apparatus.
Regarding printing apparatus 100, in the event one of printing modules M1-M4, as shown in
In the exemplary embodiment, the user may first determine which printing module is experiencing the soft failure. In this non-limiting example, printing module M2 may be experiencing the soft failure. More specifically, the user may determine what toner color is associated with printing module M2. Once the failing toner color is determined, the user may then determine what the respective demands of toner use are for the other functioning color toner printing modules M1, M3 and M4 based on the final printed image printing apparatus 100 may be printing. For example, in the event printing apparatus 100 is printing a green book cover, printing module M4, which has C-colored toner, and printing module M2, which has Y-colored toner, will be substantially used to create the final green printed image for the green book cover. As a result, in this non-limiting example, a toner use demand for C-colored toner and Y-colored toner will be substantially higher than the K-colored toner and the M-colored toner. In such an example, if the Y-colored toner printing module, printing module M2, experiences a soft failure the performance of printing apparatus 100 may decrease. In another embodiment, printing module M2 may include other soft failures such as, but not limited to, printing artifacts in the Y-colored toner image. In such an embodiment, the quality of the final green book cover image will be substantially decreased.
After the user has determined the respective toner use demands for each toner color printing module, the user may determine which component or which components of printing module M2 may be causing the soft failure. For example, one of printing module M2 components, such as, transfer backup roller 116, photoconductive imaging roller 114, cleaner station 122, charging system 124, exposure subsystem 126 and toner station 128 may be the source of the soft failure. In another example, the entire printing module M2 may need to be swapped with a functioning printing module. In a non-limiting example, exposure subsystem 126 may be the source of the soft failure. In such an example, the user may remove exposure subsystem 126 from printing module M2 and replace it with a functioning exposure subsystem 126 from either printing module M1 or printing module M3. In the exemplary non-limiting example, exposure subsystem 126 from printing module M2 may be swapped with the functioning exposure subsystem 126 of printing module M1, as shown by the dotted lines in
In this non-limiting example, once the failing component (exposure subsystem 126) has been removed from printing module M2 and swapped with the functional exposure subsystem 126 of printing module M1, the effect of the failing component on the performance or quality of the final printed image may be substantially reduced. For example, the lower performance of a printing module that includes a toner color in low demand may not affect the overall performance of printing assembly 100 in printing the final print image. Moreover, a printing module that may print an artifact using a toner color that is in low demand may not be apparent in the final print image. As a result, the quality of the final print image may not be decreased. Therefore, the uptime of printing assembly 100 during a soft failure may be substantially increased.
In the non-limiting example, once the failing component or failing components of printing module M2 have been swapped with functioning components from printing module M1, the unique component calibrations and/or color specific calibrations may be reassigned in LCU 132 from the previous printing module M2 to printing module M1. For example, the functional exposure subsystem 126 may have unique component calibrations that need to be reassigned from the previous printing module M1 to printing module M2. In one embodiment, the unique component calibrations may be pre-programmed calibrations that are uniquely customized for the specific component. In another embodiment, each printing module M1-M4 may have toner color specific calibrations that are pre-programmed for that specific toner color. Therefore, in the event that the entire printing module is swapped or the toner stations are swapped, the toner color specific calibration must also be reassigned in LCU 132 to the appropriate printing module.
Turning to
In the exemplary embodiment, the user may first determine which printing module is experiencing the soft failure. In this non-limiting example, printing module M2 may be experiencing the soft failure. Moreover, printing module M5 may include a clear toner. Next, the user may determine what the respective demands of use are for the other functioning color toner printing modules M1-M5 based on the final printed image printing apparatus 200 may be printing.
For example, in the event printing apparatus 200 is also printing a green book cover, printing module M4, which has C-colored toner, and printing module M2, which has Y-colored toner, will be used to create the final green printed image for the green book cover. As a result, in this non-limiting example, a demand of use for C-colored toner and Y-colored toner will be substantially higher than the K-colored toner, M-colored toner and the clear-colored toner of printing module M5. In such an example, if the Y-colored toner printing module M2 experiences a soft failure, the performance of printing module M2 may decrease. In another embodiment, printing module M2 may include other soft failures such as, but not limited to, printing artifacts in the Y-colored toner image. In such an embodiment, the quality of the final green book cover image will be substantially decreased.
There are other ways to determine demand. There are qualitative methods that can be as simple as a subjective judgment by the operator and also quantitative methods that can be precisely calculated by a controller looking at the image content data of the image files in the job queue that is to be printed. This could involve pixel counting to determine toner demand data. One such method is described in U.S. application Ser. No. 11/321,246 entitled PRINT JOB COST ESTIMATE METHOD AND SYSTEM 91589 having a priority date of 29 Dec. 2005.
There are also other ways to determine a probability of failure. There are existing diagnostics (NexPert is an example) available to get the operator/FE down to the root cause component of failure. Alternatively printer historic performance data can be stored and a diagnostic data source created and/or stored in memory. The idea is to identify one or more components and to use the above described methods to create an alternative option to re-locate/reposition the component so it does not need to be replaced at that time and the system can continue to operate.
After the user has determined the respective demands of use for each toner color printing module, the user may determine which component or which components of printing module M2 may be causing the soft failure. For example, one of the components of printing module M2, such as transfer backup roller 116, photoconductive imaging roller 114, cleaner station 122, charging system 124, exposure subsystem 126 and toner station 128 may be the source of the soft failure. In another example, the entire printing module M2 may need to be swapped with a functioning printing module. In this non-limiting example, printing module M5 has a low demand for clear toner in printing the green image book cover. As a result, tie user may swap printing module M2 with printing module M5, swap the failing components of printing module M5 with the functioning components of printing module M5 or remove the Y-color toner station 128 and insert the Y-colored toner station 128 into printing module M5. As a result, the effect of the failing component on the performance of printing apparatus 200 or the effect on the quality of the final printed image may be substantially reduced. As such the uptime of printing apparatus 200 during a soft failure may be substantially increased.
Similarly, as described above, once the failing component or components have been swapped with functioning components, the unique calibrations and/or color specific calibrations may be reassigned to the appropriate printing modules in the LCU 132.
Turing to
In the event one of the redundant printing modules M1 or M5 experiences a failure, the user may program LCU 132 to enable 100% of the K-colored toner demand to be reassigned to the functioning printing module. As a result, the downtime of printing apparatus 300 during a failure is substantially reduced.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
