Sheet feeding device and image forming apparatus incorporating same

Abstract

A sheet feeding device includes a support that detachably supports a roll, a rotation driver that rotates a spool, a guide including a facing portion and a guide portion, a support shaft that swingably supports the guide, a biasing member that presses the guide, a sensor that retractably projects from the facing portion and outputs a detection signal, a roller that contacts an outer circumferential surface of the roll, and circuitry that controls the rotation driver. The circuitry determines a passing time based on a first change rate and a second change rate, and causes the rotation driver to rotate the spool by a predetermined angle in a winding direction, from the passing time, to position a leading end of a continuous sheet at a feeding start position, and rotates the spool in the feeding direction to feed the continuous sheet from the feeding start position along the guide portion.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is based on and claims priority pursuant to 35 U.S.C. § 119(a) to Japanese Patent Application Nos. 2020-091640, filed on May 26, 2020 and 2021-082233, filed on May 14, 2021, in the Japan Patent Office, the entire disclosure of each of which is hereby incorporated by reference herein.

BACKGROUND

Technical Field

Embodiments of the present disclosure relate to a sheet feeding device and an image forming apparatus incorporating the sheet feeding device.

Description of the Related Art

There is known an image forming apparatus that forms an image on a long sheet (hereinafter, referred to as a “continuous sheet”) wound around a spool. The image forming apparatus using the continuous sheet includes a sheet feeding mechanism. A user manually inserts a leading end of the continuous sheet into a sheet feeding portion of the sheet feeding mechanism, and then the image forming apparatus performs a sheet feeding operation after detecting the leading end.

SUMMARY

Embodiments of the present disclosure describe an improved sheet feeding device that includes a support, a rotation driver, a guide, a support shaft, a biasing member, a sensor, a roller, and circuitry. The support detachably supports a roll formed of a continuous sheet wound around a spool. The rotation driver rotates the spool supported by the support in a feeding direction and a winding direction of the continuous sheet. The guide includes a facing portion that faces an outer circumferential surface of the roll and a guide portion that extends downstream from the facing portion in the feeding direction. The support shaft swingably supports the guide around a downstream end of the guide in the feeding direction, in a direction in which the facing portion contacts and separates from the roll. The biasing member presses the guide in a direction in which the facing portion approaches the roll. The sensor retractably projects from the facing portion toward the roll to contact the roll and outputs a detection signal having a signal level in response to an amount of projection of the sensor. The roller supported by the facing portion contacts the outer circumferential surface of the roll at a different position from the sensor in a circumferential direction of the roll. The circuitry controls the rotation driver based on a signal change rate that is an amount of change in the signal level of the detection signal per unit time. The circuitry causes the rotation driver to rotate the spool in the winding direction to determine a passing time at which a leading end of the continuous sheet passes through the sensor based on a first change rate that is the signal change rate when the senser retracts and a second change rate that is the signal change rate when the sensor projects. Further, the circuitry causes the rotation driver to rotate the spool by a predetermined angle in the winding direction, from the passing time, to position the leading end at a feeding start position that is upstream from the sensor and the roller in the winding direction and facing the guide portion, and causes the rotation driver to rotate the spool in the feeding direction to feed the continuous sheet from the feeding start position along the guide portion.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

A more complete appreciation of the disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

FIG. 1 is an exterior perspective view of an image forming apparatus according to an embodiment of the present disclosure;

FIG. 2 is a cross-sectional view illustrating an interior of the image forming apparatus;

FIG. 3 is a schematic view illustrating a configuration of a sheet feeding device of the image forming apparatus;

FIG. 4 is a perspective view of a guide arm of the sheet feeding device;

FIG. 5 is an enlarged view of a facing portion of the guide arm and the surrounding thereof;

FIGS. 6A to 6C are diagrams illustrating a positional relation between a leading end of a continuous sheet, a leading end sensor, and a roller in the sheet feeding device;

FIGS. 7A and 7B are diagrams illustrating change of a signal level of a detection signal of the leading end sensor;

FIG. 8 is a schematic block diagram illustrating a hardware configuration of the image forming apparatus;

FIG. 9 is a flowchart of a sheet setting process of the sheet feeding device;

FIG. 10 is a flowchart of a leading end detection process of the sheet feeding device;

FIG. 11 is a flowchart of an alternative detection process of the sheet feeding device;

FIG. 12 is a diagram illustrating the change of the signal level of the detection signal in the leading end detection process;

FIG. 13 is a schematic view illustrating an arrangement of leading end sensors according to a variation of the present disclosure;

FIG. 14 is a flowchart of a skew control process of the sheet feeding device; and

FIGS. 15A to 15E are schematic views for explaining a comparative method of setting a rolled sheet.

The accompanying drawings are intended to depict embodiments of the present disclosure and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. In addition, identical or similar reference numerals designate identical or similar components throughout the several views.

DETAILED DESCRIPTION

In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this patent specification is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that have the same function, operate in a similar manner, and achieve a similar result.

As used herein, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

It is to be noted that the suffixes y, m, c, and k attached to each reference numeral indicate only that components indicated thereby are used for forming yellow, magenta, cyan, and black images, respectively, and hereinafter may be omitted when color discrimination is not necessary.

Hereinafter, a description is given of an image forming apparatus 1 according to an embodiment of the present disclosure with reference to FIGS. 1 and 2. FIG. 1 is an exterior perspective view of the image forming apparatus 1 according to the present embodiment. FIG. 2 is a cross-sectional view illustrating an interior of the image forming apparatus 1.

As illustrated in FIG. 1, a housing of the image forming apparatus 1 has an exterior constructed of a center cover 2, a right cover 3 and a left cover 4 disposed on the left and right of the center cover 2, side plates 5 disposed at ends of the right cover 3 and the left cover 4, and an operation cover 6 that opens and closes respect to the center cover 2. An apparatus body of the image forming apparatus 1 covered with the respective covers 2 to 6 is supported by left and right legs 7 with casters.

The image forming apparatus 1 according to the present embodiment is an image forming apparatus using an inkjet method that discharges ink onto a continuous sheet P (long sheet) to form an image on the continuous sheet P. A method of image formation used by the image forming apparatus 1 is not limited to the inkjet method, and an electrophotographic method can be used. As illustrated in FIG. 2, the image forming apparatus 1 mainly includes a sheet feeding device 10, a conveyance unit 20, an image forming unit 30, a winding unit 40, and a controller 50 (see FIG. 8).

The sheet feeding device 10 feeds the continuous sheet P wound around a spool 8 to the conveyance unit 20 through a conveyance path L. The conveyance path L is a space through which the continuous sheet P passes inside the image forming apparatus 1. More specifically, the conveyance path L is a route from the sheet feeding device 10 to the winding unit 40 via the conveyance unit 20 and the image forming unit 30. Details of the sheet feeding device 10 is described later with reference to FIGS. 3 to 7.

The conveyance unit 20 conveys the continuous sheet P, which is fed from the sheet feeding device 10 through the conveyance path L, to the winding unit 40 through a position facing the image forming unit 30. The conveyance unit 20 mainly includes a conveyance roller 21, a pressure roller 22, and a conveyance motor 23. The conveyance roller 21 and the pressure roller 22 rotate while nipping the continuous sheet P from both sides in the direction of thickness of the continuous sheet P. The conveyance motor 23 transmits a driving force to rotate the conveyance roller 21. The pressure roller 22 is pressed against the conveyance roller 21 with a predetermined pressure and rotated along with the rotation of the conveyance roller 21.

The image forming unit 30 is disposed downstream from the conveyance unit 20 in the direction of conveyance of the continuous sheet P. The image forming unit 30 discharges ink onto the continuous sheet P conveyed by the conveyance unit 20 to form an image on the continuous sheet P. The image forming unit 30 mainly includes a carriage 31, a main scanning motor 32, and a platen 33.

As the main scanning motor 32 transmits a driving force, the carriage 31 reciprocates in the main scanning direction perpendicular to the direction of conveyance of the continuous sheet P. The carriage 31 includes recording heads 31k, 31c, 31m, and 31y that discharge inks of respective colors of black, cyan, magenta, and yellow. The recording heads 31k, 31c, 31m, and 31y discharge the inks of the respective colors toward the continuous sheet P supported by the platen 33 in accordance with instructions from the controller 50. The platen 33 upwardly faces the carriage 31. The platen 33 supports the continuous sheet P conveyed by the conveyance unit 20.

The winding unit 40 is disposed downstream from the conveyance unit 20 and the image forming unit 30 in the direction of conveyance of the continuous sheet P. The winding unit 40 winds the continuous sheet P on which an image has been formed by the image forming unit 30. The winding unit 40 mainly includes a winding roller 41 and a winding motor 42. As the winding motor 42 transmits a driving force, the winding roller 41 rotates to wind the continuous sheet P on which the image has been formed.

Here, a comparative method of setting a rolled sheet is described. FIGS. 15A to 15E are schematic views for explaining the comparative method of setting the rolled sheet. The rolled sheet is provided with flanges at the ends in a width direction of the rolled sheet, and a spool is set into the rolled sheet. A user sets the rolled sheet with the spool in a sheet holding portion (spool bearing mount) of an apparatus as illustrated in FIG. 15A, searches for a leading end of a continuous sheet of the rolled sheet, holds the rolled sheet with both hands as illustrated in FIG. 15B while keeping an eye on the leading end, and rotates the rolled sheet so that the leading end of the continuous sheet reaches the front side. Next, the user guides the leading end of the continuous sheet between guide plates disposed on the back side of the rolled sheet and inserts the leading end while rotating the rolled sheet as illustrated in FIG. 15C. When the user inserts the leading end of the continuous sheet into the back of the guide plates, the apparatus holds the leading end and pull the continuous sheet therein.

As illustrated in FIG. 15C, since the guide plates between which the leading end of the continuous sheet is inserted is located on the back side of the rolled sheet, the guide plates are hidden behind the rolled sheet. Accordingly, it is difficult for the user to see the guide plates and confirm whether the leading end has been inserted between the guide plates. In addition, the user is required to insert the leading end of the continuous sheet of the rolled sheet as evenly as possible, which is a delicate operation. If the leading end of the continuous sheet is not inserted evenly, the continuous sheet is fed obliquely, which may cause skew or jam of the continuous sheet, and the user may have to reset the rolled sheet.

Further, as illustrated in FIGS. 15D and 15E, when the apparatus includes two-stage rolled sheet mounts, if the rolled sheet is set on the upper stage, it is more difficult for the user to see the guide plates and insert the leading end between the guide plates because of the rolled sheet on the upper stage, which may increase the difficulty in setting the rolled sheet and the possibility of oblique insertion.

FIG. 3 is a schematic view illustrating a configuration of the sheet feeding device 10. FIG. 4 is a perspective view of a guide arm 13 of the sheet feeding device 10. As illustrated in FIGS. 2 to 4, the sheet feeding device 10 mainly includes a support 11, a feed motor 12 as a rotation driver, the guide arm 13 as a guide, a support shaft 14, a coil spring 15 as a biasing member, a leading end sensor 16, multiple rollers 17a and 17b, a cutter 18, and guide plates 19a and 19b.

The support 11 detachably supports a roll 9. The roll 9 is a rolled sheet formed by winding the continuous sheet P around the spool 8 having a shaft shape. More specifically, the support 11 rotatably supports both ends of the spool 8. The feed motor 12 rotates the spool 8 supported by the support 11 forward in the counterclockwise direction in FIG. 3, that is, in a feeding direction to feed the continuous sheet P from the roll 9, and rotates the spool 8 in reverse in the clockwise direction in FIG. 3, that is, in a winding direction to wind the continuous sheet P.

The guide arm 13 brings the leading end sensor 16 and the rollers 17a and 17b into contact with the roll 9 and guides the continuous sheet P fed from the roll 9 between the guide plates 19a and 19b. The guide arm 13 has an elongated plate shape. The guide arm 13 includes a facing portion 13a and a guide portion 13b.

The facing portion 13a has an arc shape along the outer circumferential surface of the roll 9. The facing portion 13a faces the outer circumferential surface of the roll 9 below a horizontal line passing through the center of rotation of the spool 8. More specifically, the facing portion 13a faces a region (lower region) including the lower end of the roll 9. The guide portion 13b extends downstream from the facing portion 13a in the feeding direction of the continuous sheet P. More specifically, the guide portion 13b extends from the facing portion 13a to a position between the guide plates 19a and 19b.

The support shaft 14 extends in the same direction as the longitudinal direction of the spool 8 supported by the support 11. The support shaft 14 is secured inside the covers 2 to 6. The support shaft 14 is attached to a downstream end of the guide portion 13b in the feeding direction of the continuous sheet P, and swingably supports the guide arm 13. That is, the guide arm 13 is swingable around the support shaft 14 so that the facing portion 13a contacts and separates from the roll 9. The coil spring 15 presses the guide arm 13 in a direction in which the facing portion 13a approaches the roll 9.

The leading end sensor 16 projects from the facing portion 13a toward the roll 9. The leading end sensor 16 is supported by the facing portion 13a and retractable with respect to the facing portion 13a. Further, the leading end sensor 16 is biased in a direction in which the leading end sensor 16 comes into contact with the outer circumferential surface of the roll 9, that is, in a direction in which the leading end sensor 16 projects from the facing portion 13a. The leading end sensor 16 outputs a detection signal to the controller 50. The detection signal has a signal level in response to an amount of projection of the leading end sensor 16 from the facing portion 13a. More specifically, the signal level of the detection signal increases as the amount of projection increases, and decreases as the amount of projection decreases.

The rollers 17a and 17b are rotatably supported by the facing portion 13a. The axis of rotation of the rollers 17a and 17b extends in the same direction as the longitudinal direction of the spool 8 and the support shaft 14. The rollers 17a and 17b are disposed at a different position from the leading end sensor 16 in a circumferential direction of the roll 9. More specifically, the rollers 17a and 17b are disposed upstream from the leading end sensor 16 in the winding direction. Further, the rollers 17a and 17b are disposed separately from each other in the width direction perpendicular to the circumferential direction of the roll 9. More specifically, the leading end sensor 16 is disposed between the roller 17a and the roller 17b in the width direction.

The cutter 18 cuts the leading end of the continuous sheet P over the entire region in the width direction. The cutting line by the cutter 18 extends in the direction perpendicular to the feeding direction of the continuous sheet P. That is, when the leading end of the continuous sheet P is inclined (skewed) with respect to the feeding direction, the cutter 18 cuts the leading end of the continuous sheet P to make the leading end of the continuous sheet P perpendicular to the feeding direction.

The guide plates 19a and 19b are disposed downstream from the guide arm 13 in the feeding direction of the continuous sheet P. The guide plates 19a and 19b faces each other across the conveyance path L. The continuous sheet P moves along the guide arm 13, passes between the guide plates 19a and 19b, and enters the conveyance unit 20. That is, the guide plates 19a and 19b serve as a sheet feeding portion into which the continuous sheet P fed from the roll 9 enters.

Next, a description is given of a relation between the position of the leading end of the continuous sheet P and the signal level of the detection signal when the spool 8 rotates in the winding direction with reference to FIGS. 5 to 7B. FIG. 5 is an enlarged view of the facing portion 13a and the surrounding thereof. FIGS. 6A to 6C are diagrams illustrating a positional relation between the leading end of the continuous sheet P, the leading end sensor 16, and the roller 17a. FIGS. 7A and 7B are diagrams illustrating change of the signal level of the detection signal of the leading end sensor 16.

Since the guide arm 13 is biased by the coil spring 15 in the direction in which the guide arm 13 approaches the roll 9, as illustrated in FIG. 5, the leading end sensor 16 and the rollers 17a and 17b contact the outer circumferential surface of the roll 9. As the spool 8 rotates in the winding direction indicated by arrow WD in FIG. 5, the leading end of the continuous sheet P that is in close contact with the outer circumferential surface of the roll 9 passes through the rollers 17a and 17b, and then passes through the leading end sensor 16.

As illustrated in FIGS. 6A and 6B, when the leading end of the continuous sheet P passes through the rollers 17a and 17b, the guide arm 13 swings by the thickness of the continuous sheet P, and the rollers 17a and 17b come into contact with the outer circumferential surface of the roll 9. As a result, the leading end sensor 16 is retracted in the facing portion 13a by the thickness of the continuous sheet P. That is, when the leading end of the continuous sheet P passes through the rollers 17a and 17b, the amount of projection of the leading end sensor 16 decreases.

As a result, as illustrated in FIG. 7A, the detection signal of the leading end sensor 16 is High signal before the leading end of the continuous sheet P passes through the rollers 17a and 17b (region α), and is Low signal after the leading end of the continuous sheet P passes through the rollers 17a and 17b (region β). The High signal has a higher signal level than the Low signal. That is, the signal level of the detection signal of the leading end sensor 16 decreases as the leading end of the continuous sheet P passes through the rollers 17a and 17b.

Next, as illustrated in FIGS. 6B and 6C, when the leading end of the continuous sheet P passes through the leading end sensor 16, the leading end sensor 16 projects from the facing portion 13a by the thickness of the continuous sheet P. That is, when the leading end of the continuous sheet P passes through the leading end sensor 16, the amount of projection of the leading end sensor 16 increases.

As illustrated in FIG. 7A, the detection signal of the leading end sensor 16 becomes the High signal after the leading end of the continuous sheet P passes through the leading end sensor 16 (region γ). That is, the signal level of the detection signal of the leading end sensor 16 increases as the leading end of the continuous sheet P passes through the leading end sensor 16.

Here, the change in the signal level of the detection signal is microscopically observed in FIG. 7B. When the leading end of the continuous sheet P passes through the rollers 17a and 17b, the detection signal of the leading end sensor 16 decreases by the signal level y1 during the time x1 as illustrated in FIG. 7B. When the leading end of the continuous sheet P passes through the leading end sensor 16, the detection signal of the leading end sensor 16 increases by the signal level y2 during the time x2.

Hereinafter, the amount of change in the signal level of the detection signal per unit time is referred to as a “signal change rate”. The signal change rate when the leading end sensor 16 retracts is referred to as a first change rate, and the signal change rate when the leading end sensor 16 projects is referred to as a second change rate. That is, the first change rate and the second change rate are opposite in the direction of change of the signal level.

The first change rate K1 is defined by expression of K1=|y1/x1|. The first change rate K1 exceeds a predetermined first threshold when the leading end of the continuous sheet P passes through the rollers 17a and 17b. The second change rate K2 is defined by expression of K2=|y2/x2|. The second change rate K2 exceeds a predetermined second threshold when the leading end of the continuous sheet P passes through the leading end sensor 16. The first threshold and the second threshold are thresholds for absorbing small variations in the diameter of the roll 9. The first threshold and the second threshold may be the same value or different values.

FIG. 8 is a schematic block diagram illustrating a hardware configuration of the image forming apparatus 1. As illustrated in FIG. 8, the image forming apparatus 1 includes a central processing unit (CPU) 51 as a control device, a random access memory (RAM) 52 as a storage device, a read only memory (ROM) 53 as a storage device, a hard disk drive (HDD) 54 as a storage device, and an interface (I/F) 55, which are connected via a common bus 56 as a communication device. The CPU 51, the RAM 52, the ROM 53, and the HDD 54 are examples of the controller 50 as circuitry.

The CPU 51 is an arithmetic device and controls the overall operation of the image forming apparatus 1. The RAM 52 is a volatile storage medium in which data is read and written at high speed and used as a working area when the CPU 51 processes data. The ROM 53 is a non-volatile read only storage medium and stores programs such as firmware. The HDD 54 is a non-volatile storage medium with large storage capacity, in which data is read and written, and stores an operating system (OS), various control programs, application programs, and the like.

The image forming apparatus 1 processes various programs loaded from the ROM 53 or the HDD 54 to the RAM 52 by arithmetic functions provided in the CPU 51. By this processing, a software control unit including various functional modules of the image forming apparatus 1 is configured. The software control unit thus configured and the hardware resources installed in the image forming apparatus 1, in combination, construct functional blocks that implement the function of the image forming apparatus 1.

The I/F 55 connects the sheet feeding device 10, the conveyance unit 20, the image forming unit 30, the winding unit 40, and a control panel (input unit) 57 to the common bus 56. That is, the controller 50 controls the sheet feeding device 10, the conveyance unit 20, the image forming unit 30, the winding unit 40, and the control panel 57 via the I/F 55.

The control panel 57 is a user interface including a display that displays various types of information to be indicated to an operator, and buttons, switches, dials, and the like that accept operations by the operator. The control panel 57 may include a touch panel overlaid on the display. The control panel 57 accepts the operation by the operator and outputs an operation signal corresponding to the accepted operation to the controller 50.

Next, a sheet setting process is described with reference to FIG. 9. FIG. 9 is a flowchart of the sheet setting process. In the sheet setting process, when a new roll 9 is mounted on the support 11, the continuous sheet P of the roll 9 is fed to the conveyance unit 20 through between the guide plates 19a and 19b. The controller 50 controls the feed motor 12 based on the signal change rate of the leading end sensor 16. The sheet setting process starts, for example, when a sensor detects that the roll 9 is mounted on the sheet feeding device 10 or when the control panel 57 accepts an operation indicating that the roll 9 has been replaced.

First, the controller 50 rotates the feed motor 12 in reverse to rotate the spool 8 in the winding direction (S901). In addition, the controller 50 executes a leading end detection process described later while rotating the feed motor 12 in the reverse (S902). Then, the controller 50 determines whether the detection of the leading end of the continuous sheet P is successful in the leading end detection process (S903).

When the controller 50 determines that the detection of the leading end of the continuous sheet P is successful (Yes in S903), the controller 50 causes the feed motor 12 to rotate in reverse to rotate the spool 8 in the winding direction by a predetermined rotation angle (for example, about 355 degrees) from a passing time determined in the leading end detection process (S904). Thus, the leading end of the continuous sheet P reaches a feeding start position.

The passing time indicates when the leading end of the continuous sheet P passes through the leading end sensor 16. The feeding start position indicates a position upstream from the leading end sensor 16 and the rollers 17a and 17b in the winding direction and facing the guide portion 13b. In other words, the feeding start position is a position where the continuous sheet P is fed toward the guide plates 19a and 19b along the guide portion 13b when the spool 8 rotates in the feeding direction.

Next, the controller 50 causes the feed motor 12 to rotate forward to feed the continuous sheet P from the feeding start position along the guide portion 13b (S905). Thus, the continuous sheet P passes between the guide plates 19a and 19b and is nipped by the conveyance roller 21 and the pressure roller 22.

After finishing the sheet setting process normally, the image forming apparatus 1 can execute an image forming process to form an image on the continuous sheet P. That is, the controller 50 drives the conveyance motor 23 to convey the continuous sheet P to a position facing the recording heads 31k, 31c, 31m, and 31y. Next, the controller 50 drives the main scanning motor 32 to move the carriage 31 in the main scanning direction and causes the recording heads 31k, 31c, 31m, and 31y to discharge ink. By repeating this process, an image is recorded on the continuous sheet P. Further, the controller 50 drives the winding motor 42 to wind the continuous sheet P on which the image is recorded on the winding roller 41.

On the other hand, when the controller 50 determines that the detection of the leading end of the continuous sheet P fails (No in S903), the controller 50 stops the feed motor 12 and displays an error on the control panel 57 (S906). The operator performs an appropriate operation (for example, remounting of the roll 9) according to the content of the error displayed on the control panel 57.

Next, with reference to FIGS. 10 to 12, a description is given of the leading end detection process of detecting the leading end of the continuous sheet P in step S902 illustrated in FIG. 9. FIG. 10 is a flowchart of the leading end detection process. FIG. 11 is a flowchart of an alternative detection process. FIG. 12 is a diagram illustrating the change of the signal level of the detection signal in the leading end detection process. During the leading end detection process and the alternative detection process, the spool 8 rotates in the winding direction.

In the leading end detection process illustrated in FIG. 10, the controller 50 determines the passing time based on both the first change rate K1 and the second change rate K2. On the other hand, in the alternative detection process illustrated in FIG. 11, the controller 50 determines the passing time based on only the second change rate K2. In the present embodiment, first, the controller 50 determines the passing time in the leading end detection process, and when the controller 50 fails to detect the passing time in the leading end detection process, the controller 50 executes the alternative detection process. Note that the leading end detection process and the alternative detection process may be performed independently.

First, the controller 50 initializes variables R and N stored in RAM 52 to 1 (S1001). The variable R represents the number of rotations of the spool 8 in the leading end detection process. The variable N represents the number of times the controller 50 determines the passing time in the leading end detection process.

Next, the controller 50 waits for subsequent processing until the first change rate K1 of the detection signal exceeds the first threshold (S1002) or until the second time t2 elapses (S1003). The controller 50 determines that the leading end of the continuous sheet P has passed through the rollers 17a and 17b when the first change rate K1 exceeds the first threshold during a predetermined third time range t3 (Yes in S1002) until the second time t2 elapses (No in S1003).

Next, when the controller 50 determines that the leading of the continuous sheet P has passed through the rollers 17a and 17b (Yes in S1002), the controller 50 waits for subsequent processing until the second change rate K2 of the detection signal exceeds the second threshold (S1004) or the first time t1 elapses (S1005). When the second change rate K2 exceeds the second threshold (Yes in S1004) before the first time t1 elapses (No in S1005), the controller 50 determines that the leading end of the continuous sheet P has passed the leading end sensor 16.

As illustrated in FIG. 12, the first time t1 is a predetermined time corresponding to a separation distance between the leading end sensor 16 and the rollers 17a and 17b. More specifically, the first time t1 is a time required for the roll 9 to rotate by the separation distance with a margin added. The second time t2 is a time required for the roll 9 to make one rotation with a positive margin added. The third time range t3 is a predetermined time range included in the second time t2. Specifically, the third time range t3 is a time range between the timing at which the second time t2 elapses (the end of the second time t2) and a time going back a predetermined time from the end of the second time t2. More specifically, the third time range t3 is a time range including positive and negative margins with respect to the timing at which the leading end of the continuous sheet P is assumed to pass through the leading end sensor 16 in the second time t2.

The controller 50 determines the timing at which the second change rate K2 exceeds the second threshold (Yes in S1004) as the passing time until the first time t1 elapses (No in S1005) after the first change rate K1 exceeds the first threshold (Yes in S1002). When the controller 50 determines the passing time, the controller 50 compares the variable N with a determination threshold X_th (S1006).

Then, when the variable N is less than the determination threshold X_th (No in S1006), the controller 50 increments the variable N by 1 (S1007) and executes the processing from step S1002 again. When the variable N reaches the determination threshold X_th (Yes in S1006), the controller 50 determines that the detection of the leading end of the continuous sheet P is successful and ends the leading end detection process.

That is, when the controller 50 determines the passing time within the third time range t3 included in each second time of X_th times (Yes in S1004) while the second time t2 elapses X_th times (No in S1006), the controller 50 executes the processing in step S904 at the X_th-th passing time. The determination threshold X_th is a value to determine whether the number of times the controller 50 detects the leading end of the continuous sheet P exceeds a predetermined number of times. The determination threshold X_th may be a certain fixed number, or may be a value of N input through the control panel 57. The determination threshold X_th is an integer that may be 1, or 2 or more.

On the other hand, when the second time t2 has elapsed before the first change rate K1 exceeds the first threshold (No in S1002 and Yes in S1003) or when the first change rate K1 exceeds the first threshold outside the third time range t3, the controller 50 compares the variable R with a rotation threshold R_th (S1008). Similarly, when the first time t1 has elapsed (Yes in S1005) before the second change rate K2 exceeds the second threshold (No in S1004), the controller 50 compares the variable R with the rotation threshold R_th (S1008).

Then, when the variable R is less than the rotation threshold R_th (No in S1008), the controller 50 increments the variable R by 1 (S1009) and executes the processing from step S1002 again. When the variable R reaches the rotation threshold R_th (Yes in S1008), the controller 50 determines that the detection of the leading end of the continuous sheet P in the leading end detection process fails and executes the alternative detection process (S1010).

That is, when the controller 50 fails to detect the first change rate K1 and the second change rate K2 (No in S1002 and No in S1004) until the roll 9 rotates R_th times in the winding direction (No in S1008), the controller 50 executes the alternative detection process (S1010). The rotation threshold R_th is a value to determine whether the number of times the controller 50 fails to detect the leading end of the continuous sheet P exceeds a predetermined number of times from the start of the leading end detection process (S1001) to the alternative detection process (S1010). The rotation threshold R_th may be a predetermined fixed number, or may be a value of R input through the control panel 57. The rotation threshold R_th is an integer that may be 1, or 2 or more.

As illustrated in FIG. 11, the controller 50 initializes variables R and N stored in RAM 52 to 1 (S1101). The definitions of the variables R and N, the determination threshold X_th, and the rotation threshold R_th are the same as the above-described definitions in the leading end detection process.

Next, the controller 50 waits for subsequent processing until the second change rate K2 of the detection signal exceeds the second threshold (S1102) or until the second time t2 elapses (S1103). The controller 50 determines that the leading end of the continuous sheet P has passed through the leading end sensor 16, that is, the passing time when the second change rate K2 exceeds the second threshold within the predetermined third time range t3 (Yes in S1102) until the second time t2 elapses (No in S1103).

When the controller 50 determines the passing time (Yes in S1102), the controller 50 compares the variable N with the determination threshold X_th (S1104). Then, when the variable N is less than the determination threshold X_th (No in S1104), the controller 50 increments the variable N by 1 (S1105) and executes the processing from step S1102 again. When the variable N reaches the determination threshold X_th (Yes in S1104), the controller 50 determines that the detection of the leading end of the continuous sheet P is successful and ends the alternative detection process. That is, when the second change rate K2 exceeds the second threshold within the third time range t3 included in each second time t2 of X_th times while the second time t2 elapses X_th times (No in S1104), the controller 50 determines the timing at which the second change rate K2 exceeds the second threshold X_th times as the passing time.

On the other hand, when the second time t2 has elapsed before the second change rate K2 exceeds the second threshold (No in S1102 and Yes in S1103) or when the second change rate K2 exceeds the second threshold outside the third time range t3, the controller 50 compares the variable R with the rotation threshold R_th (S1106). Then, when the variable R is less than the rotation threshold R_th (No in S1106), the controller 50 increments the variable R by 1 (S1107) and executes the processing from step S1102 again. When the variable R reaches the rotation threshold R_th (Yes in S1106), the controller 50 determines that the detection of the leading end of the continuous sheet P in the alternative detection process fails and ends the alternative detection process.

According to the above-described embodiment, the following operational effects, for example, are achieved.

According to the above-described embodiment, the leading end of the continuous sheet P is detected in a state in which the leading end is in close contact with the outer circumferential surface of the roll 9. Therefore, the leading end of the continuous sheet P can be stably detected regardless of the thickness, stiffness, and curl of the continuous sheet P. As the roll 9 is just mounted on the support 11, the leading end is automatically detected and inserted between the guide plates 19a and 19b. Thus, the continuous sheet P can be stably inserted between the guide plates 19a and 19b compared with the case in which an operator manually inserts the continuous sheet P.

Further, according to the above-described embodiment, the controller 50 determines the timing at which the second change rate K2 exceeds the second threshold as the passing time until the first time t1 elapses after the first change rate K1 exceeds the first threshold. Accordingly, the controller 50 does not erroneously detect the unevenness of the roll 9 as the leading end of the continuous sheet P.

Further, according to the above-described embodiment, the controller 50 repeatedly detects the leading end of the continuous sheet P X_th times, thereby improving the accuracy of detection. Further, the operator can set the determination threshold X_th large when the continuous sheet P is thin, and small when the continuous sheet P is thick, for example. As a result, the accuracy and throughput of the detection are compatible with each other.

When the leading end of the continuous sheet P is inclined with respect to the feeding direction, the first change rate K1 when the leading end of the continuous sheet P passes through the rollers 17a and 17b is likely to decrease. As described in the above embodiment, when the controller 50 does not appropriately detect the leading end of the continuous sheet P in the leading end detection process, the controller 50 executes the alternative detection process. Accordingly, the controller 50 can appropriately detect the leading end of the continuous sheet P regardless of the degree of inclination of the continuous sheet P.

A skew control process according to a variation of the present disclosure is described with reference to FIGS. 13 and 14. FIG. 13 is a schematic view illustrating an arrangement of leading end sensors 16a and 16b according to the variation. FIG. 14 is a flowchart of the skew control process. Note that a detailed description of common points with the above-described embodiment is omitted, and differences are mainly described.

The facing portion 13a according to the variation is different from the above-described embodiment in that the facing portion 13a includes the multiple leading end sensors 16a and 16b. The leading end sensors 16a and 16b are disposed facing the outer circumferential surface of the roll 9 at positions separated from each other in the width direction of the continuous sheet P. According to the variation, the controller 50 determines the passing times using the respective leading end sensors 16a and 16b in the leading end detection process and the alternative detection process. The controller 50 executes the skew control process illustrated in FIG. 14 instead of the processing after step S903 in FIG. 9.

As illustrated in FIG. 13, when the leading end of the continuous sheet P is inclined with respect to the feeding direction, a time difference ΔT is generated between the passing times determined using the leading end sensors 16a and 16b. As illustrated in FIG. 14, when the detection of the leading end of the continuous sheet P is successful (Yes in S903), the controller 50 calculates the time difference ΔT (S1401). Next, the controller 50 compares the calculated time difference ΔT with a first threshold time T_th1 and a second threshold time T_th2 (S1402 and S1403). Note that the first threshold time T_th1 is smaller than the second threshold time T_th2.

When the time difference ΔT is less than the first threshold time T_th1 (Yes in S1402), the controller 50 executes the processing in steps S904 and S905. When the time difference ΔT is equal to or greater than the first threshold time T_th1 and less than the second threshold time T_th2 (No in S1402 and Yes in S1403), the controller 50 executes the processing in steps S904 and S905 and causes the cutter 18 to cut the leading end of the continuous sheet P fed along the guide portion 13b (S1404). Further, when the time difference ΔT is equal to or greater than the second threshold time T_th2 (No in S1402 and No in S1403), the controller 50 displays an error on the control panel 57 without executing the processing in steps S904 and S905 (S1405).

As described in the above variation, since the leading end sensors 16a and 16b are disposed separately from each other in the width direction of the continuous sheet P, the controller 50 can determine the degree of inclination of the leading end of the continuous sheet P based on the time difference ΔT between the passing times. According to the above variation, when the time difference ΔT is large to some extent (the skew is not so large), the leading end is cut by the cutter 18, and when the time difference ΔT is very large (the skew is large), the controller 50 stops feeding the continuous sheet P and displays the error. Thus, the controller 50 can selectively execute desirable one of multiple operations of the sheet feeding device 10 according to the degree of inclination (skew).

As described above, according to the present disclosure, the sheet feeding device feeds the continuous sheet wound around the spool, and can stably detect the leading end of the continuous sheet regardless of the type of the continuous sheet.

Note that the present disclosure is not limited to specific embodiments described above, and numerous additional modifications and variations are possible in light of the teachings within the technical scope of the appended claims. It is therefore to be understood that, the disclosure of this patent specification may be practiced otherwise by those skilled in the art than as specifically described herein, and such, modifications, alternatives are within the technical scope of the appended claims. Such embodiments and variations thereof are included in the scope and gist of the embodiments of the present disclosure and are included in the embodiments described in claims and the equivalent scope thereof.

Any one of the above-described operations may be performed in various other ways, for example, in an order different from the one described above. Each of the functions of the described embodiments may be implemented by one or more processing circuits or circuitry. Processing circuitry includes a programmed processor, as a processor includes circuitry. A processing circuit also includes devices such as an application specific integrated circuit (ASIC), a digital signal processor (DSP), a field programmable gate array (FPGA), and conventional circuit components arranged to perform the recited functions.

Claims

1. A sheet feeding device comprising: a support configured to detachably support a roll formed of a continuous sheet wound around a spool;a rotation driver configured to rotate the spool supported by the support in a feeding direction and a winding direction of the continuous sheet;a guide including: a facing portion configured to face an outer circumferential surface of the roll; anda guide portion extending downstream from the facing portion in the feeding direction;a support shaft configured to swingably support the guide around a downstream end of the guide in the feeding direction, in a direction in which the facing portion contacts and separates from the roll;a biasing member configured to press the guide in a direction in which the facing portion approaches the roll;a sensor configured to: retractably project from the facing portion toward the roll to contact the outer circumferential surface of the roll; andoutput a detection signal having a signal level in response to an amount of projection of the sensor;a roller supported by the facing portion, the roller configured to contact the outer circumferential surface of the roll at a different position from the sensor in a circumferential direction of the roll; andcircuitry configured to: control the rotation driver based on a signal change rate that is an amount of change in the signal level of the detection signal per unit time;cause the rotation driver to rotate the spool in the winding direction to determine a passing time at which a leading end of the continuous sheet passes through the sensor based on a first change rate that is the signal change rate when the senser retracts and a second change rate that is the signal change rate when the sensor projects;cause the rotation driver to rotate the spool by a predetermined angle in the winding direction, from the passing time, to position the leading end at a feeding start position that is upstream from the sensor and the roller in the winding direction and facing the guide portion; andcause the rotation driver to rotate the spool in the feeding direction to feed the continuous sheet from the feeding start position along the guide portion.

2. The sheet feeding device according to claim 1, wherein the roller is disposed upstream from the sensor in the winding direction, andwherein the circuitry is configured to determine, as the passing time, a timing at which the second change rate exceeds a second threshold until a first time elapses after the first change rate exceeds a first threshold, the first time corresponding to a distance between the roller and the sensor.

3. The sheet feeding device according to claim 2, wherein, when a second time corresponding to one rotation of the roll elapses Xth times, and the circuitry determines the passing time to be within a third time range included in the second time in each time of the Xth times, the circuitry causes the rotation driver to rotate the spool by the predetermined angle in the winding direction from Xth-th passing time, where Xth is an integer greater than or equal to 2.

4. The sheet feeding device according to claim 1, wherein, when the circuitry fails to detect the first change rate until the roll rotates Rth times in the winding direction, the circuitry determines the passing time based on the second change rate, where Rth is an integer greater than or equal to 1.

5. The sheet feeding device according to claim 4, wherein, when a second time corresponding to one rotation of the roll elapses Xth times, and the second change rate exceeds a second threshold within a third time range included in the second time in each time of the Xth times, the circuitry determines, as the passing time, a timing at which the second change rate exceeds the second threshold Xth times, where Xth is an integer greater than or equal to 2.

6. The sheet feeding device according to claim 3, further comprising an input unit configured to accept an operation of inputting a value of Xth.

7. The sheet feeding device according to claim 1, wherein the sensor includes multiple sensors disposed separately from each other in a width direction of the continuous sheet.

8. The sheet feeding device according to claim 7, wherein the circuitry is configured to execute any one of multiple operations based on a time difference between the passing times determined using the multiple sensors.

9. An image forming apparatus comprising: the sheet feeding device according to claim 1, configured to feed the continuous sheet; andan image forming unit configured to form an image on the continuous sheet.