Embodiments described herein relate generally to a sheet storage device, an image processing apparatus, and a control method.
An image processing apparatus includes a sheet storage device that stores a plurality of sheets before processing. The sheet storage device specifies a remaining number of the stored sheets. However, there is room for improvement in an accuracy of specifying the remaining number of sheets.
In general, according to one embodiment, a sheet storage device is provided. The sheet storage device includes a body, a tray, a rotating member, an angle sensor, and a controller. The tray is vertically repositionable relative to the body and supports a sheet placed on the tray. The rotating member rotates in conjunction with a vertical movement of the tray. The angle sensor detects a rotation angle of the rotating member. The controller determines a remaining number of sheets placed on the tray based on a detection result of the angle sensor.
Hereinafter, a sheet storage device, an image processing apparatus, and a control method according to an embodiment will be described with reference to the drawings. An image processing apparatus 1 according to the present embodiment is an image forming apparatus such as a multifunction peripheral (MFP) printer or a copier. Hereinafter, an example in which the image processing apparatus 1 is an image forming apparatus as illustrated in
As illustrated in
The image reading unit 100 (e.g., a scanner, a camera, etc.) converts characters and images printed on a sheet into electronic data.
The control panel unit 200 (e.g., a user interface) includes a display 201 (e.g., an output device) and a control panel 202 (e.g., an input device). The display 201 and the control panel 202 are used when a user operates the image processing apparatus 1. The display 201 is an image display device such as a liquid crystal display (LCD) or an organic electro-luminescence (EL) display. The display 201 displays various kinds of information on the image processing apparatus 1. The control panel 202 receives inputs of various operation instructions.
The image forming unit 300 (e.g., a printer) forms an image on a sheet S. For example, the sheet S is a sheet of paper. The image forming unit 300 may be a device that fixes a toner image, or may be an inkjet device.
The sheet storage unit 400 (e.g., a storage portion, a storage area, a storage assembly, a sheet storage, etc.) stores the sheet S to be supplied to the image forming unit 300.
The control unit 500 (e.g., a controller) is a computer that controls the image reading unit 100, the control panel unit 200, the image forming unit 300, and the sheet storage unit 400. For example, the control unit 500 is a dedicated computer that controls the image processing apparatus 1. The control unit 500 may include a memory (e.g., a non-volatile memory) that stores instructions and a processor that executes the stored instructions to perform the functions described herein.
The sheet storage unit 400 of a first embodiment will be described in detail.
The sheet feed cassette 10 stores a plurality of sheets S (e.g., arranged in a stack) to be supplied to the image forming unit 300. The sheet feed cassette 10 is stored in a housing of the image processing apparatus 1. The sheet feed cassette 10 can be pulled out from the housing of the image processing apparatus 1. Hereinafter, the plurality of sheets S stored in the sheet feed cassette 10 may be referred to as a sheet-bundle.
The sheet feed cassette 10 includes a cassette main body 11 (e.g., a drawer, a housing, a frame, a chassis, etc.), a tray 12 (e.g., a support portion), a drive unit 20 (e.g., a driver), an angle sensor 30, a tray sensor 40, and a sheet sensor 50.
The cassette main body 11 is slidably supported by the housing of the image processing apparatus 1. The cassette main body 11 is formed in a box shape that opens upward. The sheets S are disposed inside the cassette main body 11.
The tray 12 is disposed inside the cassette main body 11. The sheets S disposed inside the cassette main body 11 are placed on the tray 12. The tray 12 is formed so as to be vertically movable (e.g., vertically repositionable) with respect to the cassette main body 11 (e.g., the tray 12 is slidably coupled to the cassette main body 11). For example, the tray 12 is formed so as to be movable in parallel to a vertical direction. In this case, the tray 12 may be supported by a guide portion such as a rail or slide that allows only vertical movement with respect to the cassette main body 11. However, the tray 12 may be formed so as to be vertically movable (e.g., tiltable) so as to incline an upper surface. The tray 12 moves to a lowering end when the sheet feed cassette 10 is pulled out from the housing of the image processing apparatus 1 and the sheets S are added.
The drive unit 20 vertically moves the tray 12 with respect to the cassette main body 11. The drive unit 20 includes a wire 21 (e.g., a connecting member, a tensile member, a cable, a belt, a chain, etc.) coupled to the tray 12, a sheave 22 (e.g., an idler, a pulley, etc.) that suspends the wire 21 above the tray 12, a drum 23 (e.g., a rotating member) that winds the wire 21, and a drive source 24 that rotates the drum 23. A first end portion of the wire 21 is coupled to the tray 12. A second end portion of the wire 21 is coupled to the drum 23. The sheave 22 is a fixed pulley (e.g., a pulley with a fixed position that is free-spinning). The sheave 22 is disposed at a predetermined position with respect to the cassette main body 11. The sheave 22 suspends the wire 21 vertically above the first end portion of the wire 21. The drive source 24 generates power for vertically moving the tray 12. The drive source 24 is a motor (e.g., an electric motor). The drum 23 is coupled to an output shaft of the drive source 24. Accordingly, the drive source 24 constitutes a winch together with the drum 23. Further, the drum 23 may be connected to the output shaft of the drive source 24 via a power transmission mechanism (e.g., a transmission) such as a gear device (e.g., a gearbox) or a belt drive mechanism.
The tray 12 vertically moves so as to change a position in the vertical direction according to a winding amount of the wire 21 wound by the drum 23. In other words, as the drum 23 rotates, the wire 21 is wound around the drum 23 to vary a working length of the wire 21. As the working length decreases, the tray 12 moves upward, and as the working length increases, the tray 12 moves downward. The sheave 22 and the drum 23 rotate in conjunction with the vertical movement of the tray 12. In the present embodiment, the drum 23 rotates 360° or more in conjunction with the vertical movement of the tray 12. That is, the drum 23 rotates 360° or more while the tray 12 moves (e.g., throughout a range of motion) from one of the lowering end (e.g., a lowermost position, a lower end, etc.) and a raising end (e.g., an uppermost position, an upper end, etc.) to the other one.
As illustrated in
The sheet sensor 50 detects the upper surface of the topmost sheet S placed on the tray 12 at a predetermined position in the vertical direction. The sheet sensor 50 is a contact sensor, an optical sensor, or the like. The sheet sensor 50 detects presence or absence of the upper surface of the sheet S at a position of the upper surface of the sheet-bundle having a predetermined upper limit number of sheets in a state where the tray 12 is positioned at the lowering end.
The drive control unit 71 controls the drive source 24.
The angle calculation unit 72 calculates, based on a detection value of the angle sensor 30, a rotation angle of the drum 23 with a state where the tray 12 is positioned at the lowering end as a reference (0°) within a range of 0° to 360°. The rotation angle of the drum 23 is set to increase as the tray 12 raises.
The counter 73 counts the number of rotations of the drum 23 with the state where the tray 12 is positioned at the lowering end as a reference. The counter 73 counts the number of times the rotation angle of the drum 23 calculated by the angle calculation unit 72 exceeds 360° (e.g., the number of full rotations of the drum 23).
The remaining number specifying unit 74 specifies a remaining number (e.g., quantity) of sheets S placed on the tray 12 based on the rotation angle of the drum 23 when the sheet sensor 50 detects the upper surface of the sheet S. The remaining number specifying unit 74 calculates, based on a calculated value of the angle calculation unit 72 and a value of the counter 73, a rotation angle of the drum 23 with the state where the tray 12 is positioned at the lowering end as a reference. The remaining number specifying unit 74 specifies the remaining number of sheets S with reference to a data table stored in the memory unit 80. The remaining number specifying unit 74 controls to display the specified remaining number of sheets S on the display unit 60.
The comparison unit 75 compares the number of sheets S to be supplied from the tray 12 to the image forming unit 300 with the remaining number of sheets S specified by the remaining number specifying unit 74. The comparison unit 75 specifies, based on a command from the control unit 500, the number of sheets S to be supplied from the sheet feed cassette 10 to the image forming unit 300 (e.g., to complete a print job or copy job).
The notification unit 76 notifies a shortage of the number of sheets S based on a comparison result of the comparison unit 75 (e.g., when the number of sheets S is insufficient to complete the print job or copy job). The notification unit 76 controls the display unit 60 and notifies the shortage of the number of sheets S. Note that a notification regarding the shortage of the number of sheets S may be a voice notification. For example, before the sheet S is supplied from the sheet feed cassette 10 to the image forming unit 300, the notification unit 76 notifies the shortage of the number of sheets S.
The memory unit 80 stores the data table in which information on the rotation angle of the drum 23 and information on the remaining number of sheets S are associated with each other. The information on the rotation angle of the drum 23 is the rotation angle of the drum 23 that rotates in a process of raising the tray 12 from the lowering end to the raising end with the state where the tray 12 is positioned at the lowering end as the reference (0°). Hereinafter, the rotation angle of the drum 23 when the tray 12 is positioned at the raising end is referred to as a maximum rotation angle. The information on the remaining number of sheets S is the number of sheets S placed on the tray 12.
As illustrated in
Next, a processing flow of the sheet storage unit 400 of the present embodiment will be described.
The remaining number specifying unit 74 determines whether the sheet sensor 50 detects the sheet S placed on the tray 12 (ACT 10). When the sheet sensor 50 detects the sheet S (YES in ACT 10), the remaining number specifying unit 74 determines whether the tray sensor 40 detects the tray 12 (ACT 20). That is, the remaining number specifying unit 74 determines whether the tray 12 is positioned at the lowering end. When it is determined that the tray 12 is positioned at the lowering end (YES in ACT 20), the remaining number specifying unit 74 specifies that the predetermined upper limit number of sheets S are placed on the tray 12. In this case, the remaining number specifying unit 74 may specify the remaining number of sheets S with reference to the data table stored in the memory unit 80. The remaining number specifying unit 74 causes the display unit 60 to display that the remaining number of sheets S is 100% (ACT 30), and a series of processing ends.
When it is determined that the tray 12 is not positioned at the lowering end (NO in ACT 20), the remaining number specifying unit 74 specifies a ratio of the remaining number of sheets S (ACT 40). Specifically, the remaining number specifying unit 74 specifies a ratio of the remaining number of sheets S based on a ratio of the rotation angle of the drum 23 to the maximum rotation angle of the drum 23. In the present embodiment, the remaining number specifying unit 74 specifies a remaining number of sheets S with reference to the data table stored in the memory unit 80. Then, the remaining number specifying unit 74 causes the display unit 60 to display the specified remaining number of sheets S (ACT 50), and a series of processing ends.
On the other hand, when the sheet sensor 50 does not detect the sheet S (NO in ACT 10), the drive control unit 71 raises the tray 12 by a predetermined distance (ACT 60). Then, the remaining number specifying unit 74 determines whether the sheet sensor 50 detects the sheet S placed on the tray 12 (ACT 70). When the sheet sensor 50 detects the sheet S (YES in ACT 70), the remaining number specifying unit 74 calculates a rotation angle of the drum 23 (ACT 80). The remaining number specifying unit 74 specifies a ratio of the remaining number of sheets S based on a ratio of the rotation angle of the drum 23 to the maximum rotation angle of the drum 23 (ACT 90). In the present embodiment, the remaining number specifying unit 74 specifies a remaining number of sheets S with reference to the data table stored in the memory unit 80.
Then, the remaining number specifying unit 74 causes the display unit 60 to display the specified remaining number of sheets S (ACT 100), and a series of processing ends.
When the sheet sensor 50 does not detect the sheet S (NO in ACT 70), the remaining number specifying unit 74 calculates a rotation angle of the drum 23 (ACT 110). Subsequently, the remaining number specifying unit 74 determines whether the calculated rotation angle of the drum 23 matches the maximum rotation angle of the drum 23 (ACT 120). When the rotation angle of the drum 23 does not match the maximum rotation angle of the drum 23 (NO in ACT 120), the tray 12 is positioned below the raising end. Therefore, the drive control unit 71 again raises the tray 12 by a predetermined distance (ACT 60). When the rotation angle of the drum 23 matches the maximum rotation angle of the drum 23 (YES in ACT 120), the sheet S is not placed on the tray 12. Therefore, the remaining number specifying unit 74 causes the display unit 60 to display that there is no sheet S (ACT 130), and a series of processing ends.
As described above, the image processing apparatus 1 of the present embodiment includes: the drum 23 that rotates in conjunction with the vertical movement of the tray 12; the angle sensor 30 that detects the rotation angle of the drum 23; and the remaining number specifying unit 74 that specifies the remaining number of sheets S placed on the tray 12 based on the detection result of the angle sensor 30. According to this configuration, a vertical movement distance of the tray 12 can be accurately specified as compared with the configuration in which the remaining number of sheets placed on the tray is specified based on a vertical movement time of the tray. Therefore, the image processing apparatus 1 can improve an accuracy of specifying the remaining number of the stored sheets S based on the vertical movement distance of the tray 12.
The remaining number specifying unit 74 specifies a remaining number of sheets based on a rotation angle of the drum 23 when the tray 12 is displaced between a state where the tray 12 positioned at the lowering end is detected by the tray sensor 40 and a state where the upper surface of the sheet S is detected by the sheet sensor 50. According to this configuration, a distance between the upper surface of the sheet-bundle placed on the tray 12 and a position detected by the sheet sensor 50 can be detected. Accordingly, a difference between the position of the upper surface of the sheet-bundle having the predetermined upper limit number of sheets and the position of the upper surface of the sheet-bundle placed on the tray 12 can be calculated.
Therefore, the remaining number of the stored sheets S can be specified.
The image processing apparatus 1 includes the display unit 60 that displays the remaining number of sheets S specified by the remaining number specifying unit 74. According to this configuration, the remaining number of sheets S can be recognized by the user.
The image processing apparatus 1 includes the comparison unit 75 and the notification unit 76. The comparison unit 75 compares the number of sheets S to be supplied from the tray 12 with the remaining number of sheets S specified by the remaining number specifying unit 74. The notification unit 76 notifies the shortage of the number of sheets S based on the comparison result of the comparison unit 75. According to this configuration, the user can recognize the sheet shortage before the sheet S is discharged from the tray 12. Accordingly, it is possible to prevent the processing on the sheet S supplied from the tray 12 from being interrupted due to the sheet shortage.
The angle sensor 30 includes the magnet 31 that rotates integrally with the drum 23, and the plurality of magneto-resistance effect elements that output a detection signal corresponding to a change in a magnetic field caused by the rotation of the magnet 31. The plurality of magneto-resistance effect elements output detection signals having phase differences from each other.
According to this configuration, the angle sensor 30 can output a detection signal corresponding to an absolute angle within the range of 0° to 360° as the rotation angle of the drum 23. That is, it is possible to avoid the specified detection signal output by the angle sensor 30 corresponding to a plurality of rotation angles of the drum 23 within a range of 0° to 360°. Therefore, the detection value of the angle sensor 30 and the remaining number of the sheets S can be easily associated with each other.
A sheet storage unit 400A according to a second embodiment will be described in detail. The second embodiment is different from the first embodiment in that the angle sensor 30 detects a rotation angle of a rotation body 90 provided separately from the drive unit 20.
The angle sensor 30 detects the rotation angle of the rotation body 90. The magnet 31 of the angle sensor 30 is fixed to the rotation body 90. The magnet 31 rotates integrally with the rotation body 90. The magnet 31 is disposed such that a magnetic field is oriented in a direction orthogonal to an axial direction of the rotation body 90. A direction of the magnetic field of the magnet 31 changes according to a rotation of the rotation body 90.
In the present embodiment, the rotation body 90 rotates less than 360° in conjunction with the vertical movement of the tray 12. According to this configuration, the detection value of the angle sensor 30 can be associated with the rotation angle of the drum 23 on a one-to-one basis. Accordingly, the remaining number specifying unit 74 can calculate the rotation angle of the drum 23 without using a value of the counter 73. Therefore, the detection value of the angle sensor 30 and the remaining number of sheets S can be easily associated with each other.
Although the drum 23 rotates 360° or more in conjunction with the vertical movement of the tray 12 in the first embodiment, the present disclosure is not limited to this configuration. A drum may rotate less than 360° in conjunction with the vertical movement of the tray 12. In this case, the same functions and effects as those of the second embodiment are obtained.
Although the magnet 31 of the angle sensor 30 is fixed to the drum 23 of the drive unit 20 in the first embodiment, the present disclosure is not limited to this configuration. A magnet of an angle sensor may be fixed to a rotation body that rotates in conjunction with the vertical movement of the tray 12, and may be fixed to, for example, the sheave 22 of the drive unit 20.
Although the rotation body 90 has a gear structure in which the rotation body 90 meshes with the drum 23 in the second embodiment, the present disclosure is not limited to this configuration. A rotation body may rotate in conjunction with the operation of the drive unit 20, for example, the rotation body may be connected to the drum 23 via a power transmission mechanism such as a belt drive mechanism.
Although the drive unit 20 includes the wire 21 coupled to the tray 12 in the above-described embodiments, the present disclosure is not limited to this configuration. A drive unit may include a belt, a chain, or another tensile member instead of a wire. The drive unit may be a rack-and-pinion mechanism. In this case, by fixing the magnet of the angle sensor to the rotation body such as a pinion, the above-described functions and effects are obtained. Further, the drive unit may be a belt drive mechanism including a pulley and a belt. In this case, by fixing the magnet of the angle sensor to the rotation body such as the pulley, the above-described functions and effects are obtained.
Although the remaining number specifying unit 74 specifies the remaining number of sheets S with reference to the data table stored in the memory unit 80 in the above-described embodiments, the present disclosure is not limited to this configuration. That is, a remaining number specifying unit may calculate a remaining number of sheets S based on the calculated rotation angle of the drum 23, the predetermined upper limit number of sheets S set in advance, and the maximum rotation angle of the drum 23.
According to at least one of the embodiments described above, the remaining number of sheets is specified based on the rotation angle of the rotation body that rotates in conjunction with the vertical movement of the tray. Therefore, it is possible to improve an accuracy of specifying the remaining number of the stored sheets based on the vertical movement distance of the tray.
While certain embodiments have been described these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions, and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the invention.