Patent Application
20070071475
1. Field of the Invention
The present invention relates to a method of controlling the throughput of media in a printer and, more particularly, to a method including a control algorithm for controlling the interpage gap of media conveyed through a heat fixing device in a printer.
2. Related Prior Art
In an electrophotographic image forming apparatus, such as a printer or copier, a latent image is formed on a light sensitive drum and developed with toner. The toner image is then transferred onto media, such as sheets of paper, and is subsequently passed through a fuser where heat and pressure are applied to melt and adhere the unfused toner to the surface of the media. There are a variety of devices to apply heat and pressure to the media such as radiant fusing, convection fusing, and contact fusing. Contact fusing typically comprises cooperating nip forming members such as cooperating rollers capable of delivering heat and pressure to the media, a single fuser roller in contact with a rotating belt or a belt backup roller fusing system. The fuser roller may be provided with an internal heater, such as a halogen lamp, and the temperature of the fuser roller may be monitored by a temperature control sensor providing a temperature signal for controlling the temperature of the fusing operation to a predetermined target temperature. Generally, the temperature control sensor may be located in a media path traversed by all media sizes, i.e., including full width and narrow width media. For example, the temperature control sensor may be located adjacent a media reference edge or similar location that may be traversed by all media sizes processed by the fuser.
As media is processed through the fuser, heat is transferred from the fuser to the media in a media passing region traversed by the media, and the fuser is energized to maintain or control the fuser temperature to the predetermined temperature in the media passing region, as sensed by the temperature control sensor. When processing media having a width less than full width media for the printer, a non-media passing region of the fuser, i.e., a region outside of the area traversed by media having a size less than full width media, may exhibit increased temperatures. In order to avoid the non-media passing region overheating to temperatures that may cause damage to cooperating nip forming members, narrow media may be detected at the media tray or by a narrow media sensor in the media path to cause a control algorithm to be implemented for avoiding an overheat condition of the fuser.
Typically, algorithms for controlling media flow through a fuser generally classify media into two categories, namely full width and narrow width media. Further, the narrow media algorithm may generally be triggered not only for narrow width media, but also for other media having a width intermediate narrow and full width media.
Accordingly, there continues to be a need for a method of processing media in a printer, where the media throughput for narrow width media and media of widths intermediate full width and narrow width media may be maximized.
The invention relates to a method of processing media in a printer that may vary the media throughput based on a variable related to media width to optimize the throughput of media as it is processed through a heat fixing device for the printer.
In accordance with one aspect of the invention, a method of controlling throughput of media passing through a heat fixing device is provided comprising the steps of: conveying media to the heat fixing device at a nominal interpage gap; counting a number of substrates conveyed through the heat fixing device; obtaining a temperature related measurement at the heat fixing device; and after a predetermined number of substrates have been conveyed through the heat fixing device, increasing the interpage gap when the temperature related measurement is a predetermined value.
In accordance with another aspect of the invention, a method of controlling throughput of media passing through a heat fixing device is provided comprising the steps of: conveying media to the heat fixing device; obtaining a temperature measurement from a first temperature sensor located in a portion of a media passing region where media of all widths may pass through the heat fixing device, said temperature sensor providing a temperature signal for effecting control of a heater for the heat fixing device; obtaining a temperature related measurement at the heat fixing device from a second temperature sensor for measuring a temperature of said heat fixing device in a portion of a media passing region where media having widths less than full width media may not pass through the heat fixing device; and adjusting an interpage gap between the media with reference to the temperature related measurement.
A fuser assembly within an image forming apparatus having a paper path along which substrates travel through the image forming apparatus is provided, the fuser assembly comprising a heating member, and a backup member cooperating with the heating member to form a nip therebetween for fusing images onto substrates passing through the nip. Structure is provided for conveying substrates along the paper path to the nip. Processing structure is provided for determining a temperature measurement from a first temperature sensor located at a portion of a media passing region where media of all widths may pass through the nip, and for determining a temperature related measurement from a second temperature sensor located at a portion of a media passing region where media having widths less than full width media may not pass through the nip; and the processing structure adjusts an interpage gap between the media with reference to the temperature related measurement.
While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the present invention will be better understood from the following description in conjunction with the accompanying Drawing Figures, in which like reference numerals identify like elements, and wherein:
Referring to
At a second image transfer station 34, a composite toner image, i.e., the yellow (Y), cyan (C), magenta (M) and black (K) toner images combined, is transferred from the ITM belt 28 to a substrate 36. The second image transfer station 34 includes a backup roller 38, on the inside of the ITM belt 28, and a transfer roller 40, positioned opposite the backup roller 38. Substrates 36, such as paper, cardstock, labels, envelopes or transparencies, are fed from a substrate supply 42 to the second image transfer station 34 so as to be in registration with the composite toner image on the ITM belt 28. Structure for conveying substrates from the supply 42 to the second image transfer station 34 may comprise a pick mechanism 42A that draws a top sheet from the supply 42 and a speed compensation assembly 43, see U.S. patent application Ser. No. ______, entitled Electrophotographic Device Capable of Performing an Imaging Operation and a Fusing. Operation at Different Speeds, filed concurrently herewith, assigned attorney docket no. 2004-0406.02, as well as U.S. Pat. No. 6,370,354 B1, the disclosures of which are incorporated herein by reference. The composite image is then transferred from the ITM belt 28 to the substrate 36. Thereafter, the toned substrate 36 passes through a fuser assembly 48, where the toner image is fused to the substrate 36. The substrate 36 including the fused toner image continues along a paper path 50 until it exits the printer 10 into an exit tray 51.
The paper path 50 taken by the substrates 36 in the printer 10 is illustrated schematically by a dot-dashed line in
The fuser assembly 48 in the illustrated embodiment includes a fuser hot roller 70 or fusing roller defining a heating member, and a backup member 72 cooperating with the hot roller 70 to define a nip for conveying substrates 36 therebetween. The hot roller 70 may comprise a hollow metal core member 74 covered with a thermally conductive elastomeric material layer 76. The hot roller 70 may also include a PFA (polyperfluoroalkoxy-tetrafluoroethylene) sleeve (not shown) around its elastomeric material layer 76. A heater element 78, such as a halogen tungsten-filament heater, may be located inside the core 74 of the hot roller 70 for providing heat energy to the hot roller 70 under control of a print engine controller or processor 102. The heater element 78 may comprise a filament that provides an end boost along a predetermined portion adjacent at each end of the heater element 78 to provide a greater heat output adjacent the ends than at a central portion of the heater element 78. It should be understood that the illustrated embodiment is not limited to a particular mechanism or structure for heating the hot roller 70 and that any known means of heating a roller may be implemented within the scope of this invention. In addition, first and second temperature sensors 80, 82, see
The backup member 72 may comprise any structure for cooperating with the hot roller 70 to create a nip whereby a substrate passing through the fuser 48 is pressed into engagement with the hot roller 70. The illustrated backup member 72 comprises a belt backup member. However, it should be understood that the backup member 72 may comprise other nip forming structures including, without limitation, a cooperating backup roller.
The printer 10 is capable of printing different widths of media, including normal or full width media, narrow width media and nearly narrow width media. Normal or full width media for a particular printer may comprise, for example, letter size media or A4 size media. Narrow width media may be generally classified for the purposes of the present description as media having a width less than approximately 6.5 inches, and may comprise A5 size paper and envelopes. Nearly narrow media may be classified for the purposes of the present description as media having a width approximately within the range of 6.5-8 inches, and may comprise B5 size paper and executive size paper. It should be understood that the categories of media described herein are provided for the purposes of illustrating the operation of the present invention and are not intended to be limiting to the broad concepts that comprise the invention.
Referring to
The first temperature sensor 80 may be connected to the print engine controller or processor 102 for providing a temperature feedback for controlling power to the heater element 78. The second temperature sensor 82 is also connected to the processor 102 and is located to provide a temperature of the hot roller 70 at a longitudinally distal location from the first temperature sensor 80, see
The first and second temperature sensors 80, 82 may comprise any means for measuring the temperature of the hot roller 70 including, without limitation, thermistors located in contact with the hot roller 70. It should be understood that the present invention is not limited to a particular form of temperature sensing for determining a temperature of the hot roller 70 at the locations depicted by temperature sensors 80, 82, and may comprise, without limitation, contact or non-contact temperature sensors.
If the page count has exceeded the predetermined number in step S106, the process flow continues to step S108 where a temperature reading, T2, is taken from the second temperature sensor 82. The process then proceeds to step S110 where T2 is compared to a lower limit temperature, i.e., 180° C. in the present example. If T2 is greater than or equal to the lower limit temperature, the process proceeds to step S112 and the throughput is reduced to an intermediate throughput value by increasing the interpage gap by a small increment. In the present embodiment, the intermediate throughput value is approximately ⅔ of the throughput provided by the nominal interpage gap and may generally correspond to adding approximately 2-5 inches to the nominal interpage gap. The throughput is reduced, i.e., the interpage gap is increased, by increasing the time period between when successive substrates are picked from the substrate supply 42.
The process continues to step S114 where T2 is compared to an upper limit temperature, i.e., 190° C. in the present example. If T2 is greater than or equal to the upper limit temperature, corresponding to a condition indicative of narrow media, the process proceeds to step S116 where the throughput is reduced to a low throughput value by further increasing the interpage gap by a large increment. In the present embodiment, the low throughput value is approximately ⅓ of the throughput provided by the nominal interpage gap and may generally correspond to adding approximately 6-11 inches to the nominal interpage gap.
If T2 is less than 180° C. at step S110, corresponding to a condition indicative of full width media, the throughput remains at the initial throughput value, and the process proceeds to step S118 where a determination is made as to whether the printing of all print jobs received by the printer have been completed. That is, a determination is made as to whether the current print job has been completed and whether any further print jobs are waiting to be printed. If no further print jobs are to be performed, the process returns to step S100 and the printer goes to the standby mode, otherwise the process returns to step S108 to again obtain a temperature measurement from the second temperature sensor 82.
If T2 is less than 190° C. at step S114, i.e., 180° C.≦T2<190° C., corresponding to a condition indicative of nearly narrow media, the throughput remains at the intermediate throughput value. That is, the throughput remains at approximately ⅔ of the throughput provided by the nominal interpage gap, and the process proceeds to step S120 where a determination is made as to whether the current print job has been completed and whether any further print jobs are waiting to be printed. If no further print jobs are to be performed, the printer goes to the standby mode and the process goes to step S122 where a determination is made whether T2 is less than 180° C. and, if so, the process returns to step S100, otherwise the process continues to perform a check at step S122 until T2 drops below 180° C. During the time that the process remains at step S122, the interpage gap setting remains the same as for the last print job. If a print job is received subsequent to step S120 and prior to T2 dropping below 180° C., the process exits the standby mode and begins the new print job at step S108. If additional printing is to be performed at step S120, the process returns to step S108 to again obtain a temperature measurement from the second temperature sensor 82.
If T2 is greater than or equal to the upper limit temperature at step S114 and the process proceeds to step S116 to set the throughput to the low throughput value, i.e., approximately ⅓ of the throughput provided by the nominal interpage gap, the process further proceeds to step S120. Subsequently, the process continues as described above in relation to the steps S120, S122, S100 and S108.
In addition, if a further print job is waiting to be performed before the process described above returns to the idle state at step S100, the process for controlling the throughput of the subsequent print job will proceed directly from step S101 to step S108. That is, if a subsequent print job is initiated without the printer returning to a standby condition, the process will bypass the initialization step S102 and the steps S104 and S106 of processing the predetermined number of pages at the nominal throughput.
It should be noted that the algorithm described above may operate to control an increase in the interpage gap for all media types processed through the printer without direct reference to the particular media type being processed. However, if a predetermined number of pages of full width media, i.e., letter size media, such as 10 pages, is processed consecutively through the printer, the control for the interpage gap may return the interpage gap to the nominal value in order to optimize throughput of the media. In such a case, it is anticipated that the full width media will absorb heat across the substantially the full width of the hot roll 70, such that the temperature of the portion of the hot roll 70 adjacent the second temperature sensor T2 will substantially approach the temperature measured by the first temperature sensor T1.
It may be noted that the process, as illustrated by the first embodiment, permits control of media throughput without requiring input of a media width to optimize the throughput, while also providing protection of the fuser components against overheating when processing narrow and nearly narrow width media.
It should also be understood that the process, as described with reference to the first embodiment, is not limited to the particular temperatures and throughput speeds or incremental changes to interpage gaps described above. For example, although the above-described process has been described with reference to throughput values corresponding to a nominal interpage gap, approximately ⅔ of the nominal interpage gap and approximately ⅓ of the nominal interpage gap, other throughput values than those described may be provided. Further, a greater number of smaller incremental increases in the interpage gap may be made, where each incremental increase may be made with respect to a corresponding predetermined increase in T2.
Referring to
Beginning at step S200, the printer is initially at an idle state, i.e., in the standby mode or the power saver mode. Upon initiation of a print job at the idle state, as determined at step S201, the process proceeds to step S202 where a page counter is initialized to zero and the interpage gap is initialized to zero corresponding to a standard or nominal interpage gap. All substrates, regardless of the media type, are processed through the printer at a nominal throughput, corresponding to a nominal interpage gap, until a predetermined page count is reached. At step S204, the page counter is incremented by one each time a substrate is processed and the page count is compared to a predetermined number in step S206. If the page count has not exceeded the predetermined number, the process returns to step S204 to process a further substrate.
After a predetermined number of substrates have initially been processed at the nominal throughput, a temperature increase gradient or rate of temperature increase at the second temperature sensor 82 may be determined, see step S208. Subsequently, the throughput is maintained at the nominal throughput, i.e., the nominal interpage gap, if the temperature gradient, ΔT, is less than a lower limit temperature increase gradient, i.e., ΔT<0.9° C./sec, see step S210; the interpage gap is increased by a small increment to decrease the throughput to approximately ⅔ of the nominal throughput if the temperature gradient, ΔT, is greater than or equal to the lower limit temperature gradient and is less than an upper temperature increase gradient, i.e., 0.9° C./sec≦ΔT<1° C./sec, see steps S212 and S214; and the interpage gap is increased a large amount to decrease the throughput to approximately ⅓ of the nominal throughput if the temperature gradient, ΔT, is greater than or equal to an upper limit temperature increase gradient, i.e., 1° C./sec≦ΔT, see step S216.
The remaining steps for the process of the second embodiment are performed in a manner substantially similar to the corresponding steps described for the first embodiment.
Referring to
Beginning at step S300, the printer is initially at an idle state, i.e., in the standby mode or the power saver mode. Upon initiation of a print job at the idle state, as determined at step S301, the process proceeds to step S302 where a page counter is initialized to zero, a narrow media flag is initialized to zero corresponding to full width media, and the interpage gap is initialized to zero corresponding to a standard or nominal interpage gap. All substrates, regardless of the media type, are processed through the printer at a nominal throughput, corresponding to a nominal interpage gap, until a predetermined page count is reached. At step S304, the page counter is incremented by one each time a substrate is processed and the page count is compared to a predetermined number in step S306. If the page count has not exceeded the predetermined number, the process returns to step S304 to process a further substrate.
If the page count has exceeded the predetermined number in step S306, the process flow proceeds to step S307 where a determination is made as to whether the narrow media sensor 92 has detected narrow media in the paper path 50. If narrow media has been detected, the process proceeds to step S309 and the interpage gap is increased by a large increment to decrease the throughput to a low throughput value, such as approximately ⅓ of the nominal throughput, for the remainder of the print job, as indicated at step S311. It should be noted that the interpage gap provided when narrow media is detected may correspond to a maximum interpage gap for the process.
If narrow media is not detected at step S307, the process of the third embodiment proceeds to step S308 and follows the same processing steps as described above for step S108 and the subsequent steps of the first embodiment. With regard to the third embodiment, it may be noted that if narrow media is not sensed at step S307, the throughput may still be reduced to a low throughput value that may correspond to the throughput for narrow media if the temperature T2 equals or exceeds the upper limit temperature, i.e., 190° C., as indicated at steps S314 and S316.
It is noted that the third embodiment may distinguish between full width media, narrow media and nearly narrow media, where step S307 identifies narrow media by means of a narrow media sensor and may then reduce the throughput by increasing the interpage gap by a large amount to decrease the throughput to approximately ⅓ of the nominal throughput. Nearly narrow media may be identified if the second temperature, T2, meets the condition 180° C.≦T2≦190° C., resulting in a small increase in the interpage gap to reduce the throughput to approximately ⅔ of the nominal throughput; and full width media may be identified if the second temperature, T2, meets the condition T2<180° C. resulting in the throughput remaining unchanged to convey the media at the nominal throughput.
It should be noted that the process described for the third embodiment may additionally be implemented using a temperature related measurement as described for the second embodiment. That is, the temperature values described for the third embodiment may be replaced with temperature gradient values to control increases in the interpage gap in the process of the third embodiment.
In each of the described embodiments it may be seen that the throughput of media is optimized by providing an initial processing of a predetermined number of pages at a nominal throughput corresponding to a full speed conveyance rate for the particular print job. The throughput is additionally optimized during further processing of the media by incrementally increasing the interpage gap values corresponding to narrow and nearly narrow media.
For all embodiments, the described temperatures and throughput changes are provided for the purpose of illustrating the invention and are not intended to be limiting to the invention.
The operation of the above-described embodiments is not limited to implementation in the particular electrophotographic printer described herein. In particular, the described process may be implemented in any electrophotographic printer that provides a heat fixing device including temperature sensing of a media passing region where media of all widths may pass and temperature sensing where generally only full width media will pass. Accordingly, the process is not limited to printers in which media is aligned to a reference edge located to one side of the paper path, and may include other media alignment configurations including those in which media is aligned to the center of the paper path.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
