Patent Grant
9042755
Systems and methods herein generally relate to controlling printer operations and more particularly to using electrostatic sensors, potentially in combination with optical sensors, to control printer settings.
Printers deal with many different input items and adjust for changes in printing operations over time. One process of adjusting the settings of the printer is referred to as adjusting the tone reproduction curve (TRC). The TRC calls for different amounts of different colors to be used in different situations.
Many printers use optical sensors to test printing and adjust the TRC. These optical sensors, commonly called automatic density sensors (ADC), work by shining light on a toner patch on a photoreceptor or intermediate transfer belt (ITB) and recording the specular and diffuse reflections. Depending on the type of toner and/or sensor, either one of the reflections or a combination of both, are used to generate an optical signal. The sensitivity of the optical signal to changes of toner mass on the photoreceptor or ITB is low for solid patches of toner, but increases for less dense (e.g., halftone) patches.
Therefore, some printers use several halftone patches to adjust the TRC for halftones and interpolate the setting for the solid patch. This interpolation can lead to solid densities being out of control and can vary widely. Solid densities become dependent on several variables that can affect development, such as tribo charge of the toner, toner age, environmental conditions etc.
Exemplary printing devices herein include an intermediate transfer belt (sometimes more generically referred to herein as a “transfer surface”) operatively (meaning directly or indirectly) connected to a processor and a marking device also operatively connected to the processor. The marking device is adjacent the transfer surface and transfers test patches of marking material to the transfer surface. An electrostatic sensor is operatively connected to the processor. In addition, in some embodiments herein, an optical sensor can be used and also placed adjacent the transfer surface to optically measure the density of the test patches on the transfer surface.
The electrostatic sensor (which can be used alone or in combination with the optical sensor) is adjacent the transfer surface and measures electrostatic voltage of the transfer surface as the test patches on the transfer surface move past the electrostatic sensor (by, for example, detecting an electrostatic voltage difference between the transfer surface with and without a test patch to determine an electrostatic value of each of the test patches). The electrostatic sensor can be any form of sensor that detects the electrostatic voltage of the transfer surface, such as a non-contact electrostatic voltmeter (ESV) and is therefore referred to as an ESV at some points in the following description.
When the ESV is used in combination with the optical sensor, the processor develops an “ESV sensor response ratio” between the ESV sensor response for a relatively more dense patch and a relatively less dense patch combined with a response of the optical sensor for the relatively less dense patch (e.g., a halftone test patch). The processor tests relatively less dense test patches using output from the optical sensor, but tests relatively more dense test patches using output from the ESV sensor. The test patches comprise various densities of halftone test patches and solid test patches, and the output from the electrostatic sensor is used to test the solid and dense halftone test patches and the output from the optical sensor is used to test the less dense halftone patches.
The processor converts the output from the ESV sensor into “converted output” using the electrostatic sensor response ratio. The processor adjusts the settings of the marking device by determining a tone reproduction curve (TRC) for the marking device. Thus, the processor adjusts settings of the marking device based on output from the ESV sensor alone or, if the ESV sensor is used in combination with the optical sensor, a combination of the output from the optical sensor and the converted output from the ESV sensor. For example, the processor adjusts settings of the marking device by changing the charge level of the latent charge, discharge light level and/or bias voltage, etc., used by the marking device during printing.
Various methods herein transfer test patches of marking material from a marking device of a printing apparatus to a transfer surface of the printing apparatus and measure the electrostatic differences in charge of the transfer surface as the test patches on the transfer surface move past the electrostatic sensor of the printing apparatus. For example, such methods measure the electrostatic charge by detecting an electrostatic voltage difference between the transfer surface with and without a test patch to determine an electrostatic value of each of the test patches.
Such methods can also optically measure the density of the test patches on the transfer surface using an optical sensor of the printing apparatus. These methods can develop a “ESV sensor response” ratio between the electrostatic sensor response for a relatively more dense patch and a relatively less dense patch combined with a response of the optical sensor for the relatively less dense patch (e.g., a halftone test patch) using a processor of the printing apparatus. Such methods test relatively less dense test patches using output from the optical sensor, and test relatively more dense test patches using output from the ESV (using the processor). The output from the optical sensor is used to test the halftone patches when testing relatively less dense test patches, and the output from the ESV is used to test the solid test patches when testing relatively more dense test patches.
Such methods then convert the output from the electrostatic sensor into converted output using the electrostatic sensor response ratio, and adjust settings of the marking device based on a combination of the output from the optical sensor and the converted output from the ESV (using the processor). When adjusting the settings of the marking device, such methods determine a tone reproduction curve (TRC) for the marking device. Thus, when adjusting such settings of the marking device, these methods can change the charge level of a latent charge, discharge light level and/or bias voltage, etc.
These and other features are described in, or are apparent from, the following detailed description.
Various exemplary systems and methods are described in detail below, with reference to the attached drawing figures, in which:
As mentioned above, the sensitivity of the optical signal to changes of toner mass on the photoreceptor or ITB is low for solid and high density halftone patches of toner, but increases for less dense (e.g., halftone) patches. Therefore, some printers use several halftone patches to adjust the TRC for halftones and interpolate the setting for the solid patch. However, this interpolation can lead to high densities being out of control and can vary widely.
For example, test patches can use 100%, 80%, 60%, 40%, and 20% halftone values. If an optical sensor becomes saturated above 60% halftone (for example) the remaining values may simply be extrapolated. However, the present toner or printer conditions may only be detrimentally affecting 80% and above halftones, and these poor printing conditions would not be detected by the optical sensor testing the 60% and below halftone patches.
Therefore, the systems and methods herein provide methods that use an electrostatic sensor (such as a non-contact electrostatic voltmeter (ESV)) to measure the difference in electrostatic voltage between a clean transfer surface and toner patch on the transfer surface. The electrostatic sensor can be used alone or in combination with an optical sensor (as discussed below). Thus, the ESV can be used alone for all test patches (including the low density halftones) without using an optical sensor. The use of an electrostatic sensor alone, provides a simplified/cost efficient way to control TRC in many situations.
Additional methods combine the use of an ESV and an optical sensor. The ratio between the electrostatic sensor response for a solid (or high density halftone) patch and a control halftone patch, combined with the response of the optical sensor for the same control halftone patch is used to determine the amount of toner present on the solid patch when both the optical and electrostatic sensors are used.
More specifically, the devices and methods herein use an electrostatic sensor (e.g., ESV) to measure the electrostatic voltage on a transfer surface (one example of which is an intermediate transfer belt (ITB)) as control patches on the transfer surface move by the electrostatic sensor (as the ITB rotates around its supporting rollers). The voltage difference between a clean belt voltage and a patch voltage is used as the voltage signal. This can use a single sensor or multiple sensors, as shown below.
Additional embodiments herein also can use the electrostatic sensor in combination with an optical sensor. This uses an optical sensor where it is most sensitive (to control the halftone test patches) and uses an electrostatic sensor where it is most sensitive, to control solid test patches. An exemplary equation is presented below to link the optical sensor response to the ESV response. This provides high precision control across the entire TRC (solids and different density halftones) independently of tribo-charge and toner type/composition.
Thus, when both an electrostatic sensor and an optical sensor are used, the electrostatic sensor response ratio is used to calculate optical density as shown in the following equation where TMA represents the test patch density and ESV represents the output of the electrostatic sensor.
In one example, the electrostatic sensor can be placed very close to the ITB (e.g., ˜1 mm) and can be positioned in a location to allow a printed patch to be first detected by the optical sensor and then, as the ITB moves, the ESV. The voltage difference between a clean transfer surface containing no patches and a transfer surface containing a patch accurately provides an electrostatic voltage independent of tribo charge of the toner layer. This difference in voltage can be due to the insulative effect of the toner. The more toner on the photoreceptor, the higher the insulation relative to the back side of the intermediate transfer belt (the side contacting the rollers) and the bigger the voltage signal. In addition, this voltage signal is independent of color (except black) and can be used for clear toner as well. Because black toner is significantly more conductive than others, the voltage signal is lower.
The printing device 204 includes at least one marking device (printing engine or marking station) 210 operatively connected to a processor 224 and positioned adjacent a transfer surface 218 (e.g., intermediate transfer belt or other device for transferring patterned toner to print media, etc.). Such marking devices 210 can pattern any form of marking material (e.g., toners, inks, etc.) whether currently known or developed in the future on the transfer surface 218. The transfer surface 218 transfers the marking material patterned by the marking devices 210 to print media (e.g., paper, cardstock, plastics, metals, alloys, glasses, woods, etc.) traveling along a media path 216 at the transfer location 238.
The media path 216 is positioned to supply continuous media or cut sheets of media from a media supply 214 to the transfer surface 218. After receiving various markings from the transfer surface 218 at the transfer location 238, the sheets of media can optionally pass to a finisher 208 which can fold, staple, sort, etc., the various printed sheets. Also, the printing device 204 can include at least one accessory functional component (such as a scanner/document handler 212, graphic user interface 236, etc.) that operates on the power supplied from an external power source 228 (through a power supply 222).
Thus, the transfer surface 218 is operatively (meaning directly or indirectly) connected to a processor 224 and a marking device 210 also operatively connected to the processor 224. The marking device 210 is adjacent the transfer surface 218 and transfers test patches of marking material to the transfer surface 218. Also, an optional optical sensor 230 and an electrostatic sensor 232 are operatively connected to the processor 224. The optical sensor 230 is adjacent the transfer surface 218 and optically measures the density of the test patches on the transfer surface 218.
The electrostatic sensor 232 may be used alone or in combination with the optical sensor 230 and is adjacent the transfer surface 218 and measures electrostatic voltage of the transfer surface as the test patches on the transfer surface 218 move past the electrostatic sensor 232 as the transfer surface 218 moves (as indicated by the arrows in the drawings). For example, the electrostatic sensor 232 detects an electrostatic voltage difference between the transfer surface with and without a test patch to determine an electrostatic value of each of the test patches.
In one example, the optical sensor can be a simple infrared light and sensor, a full width array (FWA) sensor of charge coupled devices (CCD), or any other type of optical sensor. In one example, the electrostatic sensor 232 can be an electrostatic voltmeter (ESV) sensor or any other type of electrostatic voltage sensing device. Such an electrostatic sensor 232 measures charge change as text patches on the transfer surface 218 move past the electrostatic sensor 232 (as the transfer surface 218 moves) to sense marking material density (based on the electrical insulation provided by the marking material).
As shown in greater detail in
When the electrostatic sensor 232 is used in combination with the optical sensor 230, the processor 224 develops an “electrostatic sensor response” ratio between the electrostatic sensor 232 response for a relatively more dense patch and a relatively less dense patch combined with a response of the optical sensor 230 for the relatively less dense patch (e.g., a halftone test patch)
The processor 224 tests relatively less dense test patches using output from the optical sensor 230 (if so equipped) but tests relatively more dense test patches using output from the electrostatic sensor 232. The test patches comprise various densities of halftone test patches and solid test patches, and the output from the electrostatic sensor 232 is used to test the solid test patches and more dense halftone patches and the output from the optical sensor 230 is used to test the less dense halftone patches.
The processor 224 converts the output from the electrostatic sensor 232 into converted output using the electrostatic sensor response ratio. The processor 224 adjusts the settings of the marking device 210 by determining a tone reproduction curve (TRC) for the marking device 210. Thus, the processor 224 adjusts settings of the marking device 210 based on output from the electrostatic sensor 232 alone, or based on a combination of the output from the optical sensor 230 and the converted output from the electrostatic sensor 232. For example, the processor 224 adjusts settings of the marking device 210 by changing the charge level of the latent charge used by the marking device 210 during printing.
As discussed above, different methods herein can use the electrostatic sensor alone to adjust the TRC, while other methods can use an optical sensor in combination with the electrostatic sensor (and use an electrostatic sensor response ratio when using the optical sensor). The flowchart in
Such methods develop an “electrostatic sensor response” ratio between the electrostatic sensor response for a relatively more dense patch and a relatively less dense patch combined with a response of the optical sensor for the relatively less dense patch in item 306 (e.g., a halftone test patch) using a processor of the printing apparatus. Such methods test relatively less dense test patches using output from the optical sensor in item 308, and test relatively more dense test patches using output from the electrostatic sensor in item 310 (using the processor). The test patches comprise various densities of halftone test patches and solid test patches. The output from the optical sensor is used to test the relatively less dense test patches in item 308, and the output from the electrostatic sensor is used to test the relatively more dense test patches in item 310.
Such methods can convert the output from the electrostatic sensor into converted output using the electrostatic sensor response ratio in item 312, and adjust settings of the marking device based on a combination of the output from the optical sensor and the converted output from the electrostatic sensor in item 314 (using the processor). When adjusting the settings of the marking device in item 314, such methods determine a tone reproduction curve (TRC) for the marking device. Thus, when adjusting such settings of the marking device in item 314, these methods can change the charge level of a latent charge, discharge light level and/or bias voltage, etc.
Therefore, some structures and methods herein use an electrostatic sensor alone to detect differences in the electrical insulation value of a transfer surface as test patches of marking material are applied to the transfer surface to detect the density of the marking material within each test patch. Generally, the back side of the transfer surface is conductive and grounded to rollers which support and rotate the transfer surface. The voltage difference from ground seen on the opposite side of the transfer surface (the front side (or printing side) on which the test patches of marking material are placed) by the electrostatic sensor increases as the insulation value of the transfer surface increases. Thus, by detecting a higher voltage on the front side of the transfer surface, the devices and methods herein can determine that more marking material is present on the front side of the transfer surface.
The devices and methods herein can use the electrostatic sensor alone to determine the amount of marking material of all test patches transferred to the transfer surface. However, as the electrostatic sensor is most sensitive for the more dense test patches and an optical sensor is most sensitive for the less dense test patches, when the electrostatic sensor is used in combination with the optical sensor, performance is increased for all patch densities, without the need for interpolation.
Many computerized devices are discussed above. Computerized devices that include chip-based central processing units (CPU's), input/output devices (including graphic user interfaces (GUI), memories, comparators, processors, etc. are well-known and readily available devices produced by manufacturers such as Dell Computers, Round Rock Tex., USA and Apple Computer Co., Cupertino Calif., USA. Such computerized devices commonly include input/output devices, power supplies, processors, electronic storage memories, wiring, etc., the details of which are omitted herefrom to allow the reader to focus on the salient aspects of the systems and methods described herein. Similarly, scanners and other similar peripheral equipment are available from Xerox Corporation, Norwalk, Conn., USA and the details of such devices are not discussed herein for purposes of brevity and reader focus.
The terms printer or printing device as used herein encompasses any apparatus, such as a digital copier, bookmaking machine, facsimile machine, multi-function machine, etc., which performs a print outputting function for any purpose. The details of printers, printing engines, etc., are well-known and are not described in detail herein to keep this disclosure focused on the salient features presented. The systems and methods herein can encompass systems and methods that print in color, monochrome, or handle color or monochrome image data. All foregoing systems and methods are specifically applicable to electrostatographic and/or xerographic machines and/or processes. Further, the terms automated or automatically mean that once a process is started (by a machine or a user), one or more machines perform the process without further input from any user.
It will be appreciated that the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. Unless specifically defined in a specific claim itself, steps or components of the systems and methods herein cannot be implied or imported from any above example as limitations to any particular order, number, position, size, shape, angle, color, or material.
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