Patent Application
20160216649
1. Field of the Invention
The present invention relates to a transfer device and an image forming apparatus.
2. Description of the Related Art
Conventionally, there is known a transfer device of an image forming apparatus that forms a transfer nip by a nip forming member that abuts an image bearer, sandwiches the sheet that is a transfer material in the nip, and transfers a toner image on the image bearer onto the sheet. As one example, there is known a secondary transfer device that transfers a superimposed toner image formed on an intermediate transfer belt, onto a sheet. Specifically, first, toner images of different colors are formed on corresponding photoconductive drums, and the toner images are sequentially transferred, by primary transfer, onto the intermediate transfer belt, to form the superimposed toner image. The intermediate transfer belt is a belt image bearer that is rotatably stretched around a plurality of stretching members. Then, the superimposed toner image formed on the intermediate transfer belt is transferred, by secondary transfer, onto the sheet.
In the secondary transfer device, a nip forming member is provided. The nip forming member includes a secondary transfer roller that abuts the front side of the intermediate transfer belt, and a secondary transfer counter roller that is faces the secondary transfer roller and that abuts the back side 1 of the intermediate transfer belt. The secondary transfer counter roller is one of the plurality of stretching members. The secondary transfer roller and the secondary transfer counter roller sandwich the intermediate transfer belt to form a secondary transfer nip. The superimposed toner image formed on the intermediate transfer belt is transferred onto a sheet, which is conveyed to the secondary transfer nip.
In an image forming apparatus provided with the above secondary transfer device, when the movement speed of the intermediate transfer belt varies within one rotation period of the intermediate transfer belt due to variations in the thickness of the intermediate transfer belt, etc., the superimposition position may shift. The superimposition position is where the toner images of different colors are to be superimposed from the plurality of photoconductive drums. Thus, when the superimposition position is shifted, a failure such as color shift may occur.
An image forming apparatus described in Patent Document 1 is provided with a driving roller speed detector for detecting the rotational speed of a driving roller, which is one of the plurality of stretching members for drivingly rotating the intermediate transfer belt, and a belt speed detector for detecting the movement speed of the intermediate transfer belt. Based on the detection results of the driving roller speed detector and the belt speed detector, the rotational speed of the driving roller is adjusted by controlling a driving motor for driving the driving roller, such that the movement speed of the intermediate transfer belt becomes a constant speed.
However, in a conventional secondary transfer device, the rotating shaft of the secondary transfer roller is drivingly rotated at a constant speed by the motor. Therefore, when the roller diameter changes as the surface of the secondary transfer deforms, etc., the surface speed of the secondary transfer roller varies. Furthermore, the secondary transfer roller generates a belt conveying force by contacting the intermediate transfer belt, and therefore when the surface speed of the secondary transfer roller varies, the conveying force of the intermediate transfer belt, which is caused by the secondary transfer roller, also varies.
As described above, when the conveying force of the intermediate transfer belt by the secondary transfer roller varies, a phenomenon occurs, in which the belt part between the driving roller and the secondary transfer roller is pulled and loosened in the intermediate transfer belt rotation direction. When this phenomenon occurs significantly, even by controlling the rotational speed of the driving roller such that the movement speed of the intermediate transfer belt becomes constant, it is difficult to control the movement speed of the intermediate transfer belt with high precision.
That is, when the surface speed of the secondary transfer roller increases, and the conveying amount of the intermediate transfer belt by the secondary transfer roller increases, the intermediate transfer belt is pulled with respect to the driving roller and the belt tension increases, the conveying load on the driving roller is decreased, and the conveying torque of the driving roller is decreased. In this state, even by slightly increasing the turning force of the driving roller, the conveying amount of the intermediate transfer belt becomes excessively large. Accordingly, it becomes difficult to finely adjust the movement speed of the intermediate transfer belt, and it becomes difficult to control the movement speed of the intermediate transfer belt with high precision by controlling the rotational speed of the driving roller.
Meanwhile, when the surface speed of the secondary transfer roller decreases, and the conveying amount of the intermediate transfer belt decreases, the intermediate transfer belt is loosened with respect to the driving roller and the belt tension decreases, and the conveying load on the driver roller increases, and the conveying torque of the driving roller increases. In this state, when the conveying torque of the driving torque extremely increases, slipping is caused between the driving roller surface and the intermediate transfer belt, and the conveying amount of the intermediate transfer belt by the driving roller decreases. Therefore, a conveying failure of the intermediate transfer belt by the driving roller occurs, and therefore it becomes difficult to control the movement speed of the intermediate transfer belt with high precision by controlling the rotational speed of the driving roller.
As described above, even when the rotational speed of the driving roller is controlled such that the movement speed of the intermediate transfer belt becomes constant, due to the impact of the variations in the surface speed of the secondary transfer roller, the movement speed of the intermediate transfer belt cannot be controlled with high precision.
In the image forming apparatus described in Patent Document 1, when the current value of the driving motor detected by a current value detecting unit is lower than a target current value of a predetermined range, in the state where the secondary transfer roller and the intermediate transfer belt are in contact, it is determined that drag turning of the intermediate transfer belt has occurred. In order to resolve the drag turning, control is implemented to decrease the rotational speed of the secondary transfer roller such that the current value is included in the predetermined range of the target current value, and the set speed of the secondary transfer roller is adjusted.
However, the target current value of a predetermined range is set according to design parameters such as the motor specification and the control margin, and the target current value is set to have a wide range in consideration of the individual differences (tolerance), the environment, and time-dependent variations. Therefore, by adjusting the set speed of the secondary transfer roller based on a wide predetermined range, such that the current value of the driving motor detected by the current value detecting unit is lower than the target current value of a predetermined range, the adjustment is insufficient, and the image quality demanded by the market cannot be obtained.
Furthermore, there is known an image forming apparatus of a direct transfer method, in which a toner image on a photoconductive belt that is a belt image bearer, is directly transferred onto a transfer material such as a sheet, at a transfer part formed by causing the photoconductive belt and the transfer roller to contact each other. Also in such an image forming apparatus of a direct transfer method, according to the same reasons as above, it is difficult to control the movement speed of the photoconductive belt with high precision due to the impact of the variations in the surface speed of the transfer roller.
Patent Document 1: Japanese Laid-Open Patent Publication No. 2011-180565
The present invention provides a transfer device and an image forming apparatus, in which one or more of the above-described disadvantages are eliminated.
According to an aspect of the present invention, there is provided a transfer device including an endless belt image bearer which is rotatably stretched around a plurality of stretching members; a driving roller configured to drivingly rotate the belt image bearer, the driving roller being one of the plurality of stretching members; a first driving motor configured to drivingly rotate the driving roller; a first speed detecting unit configured to detect a rotational speed of the belt image bearer; a rotatable transfer member configured to abut an outer peripheral surface of the belt image bearer and form a transfer nip, wherein an image borne on the outer peripheral surface of the belt image bearer is transferred onto a transfer material that is sandwiched in the transfer nip; a second driving motor configured to drivingly rotate the transfer member; a second speed detecting unit configured to detect a rotational speed of the transfer member; a contact separation unit configured to cause the belt image bearer and the transfer member to contact and separate from each other; a relative speed setting unit configured to obtain and set a relative speed of the belt image bearer and the transfer member, such that a variation amount is less than a predetermined variation amount, the variation amount being an amount of variation of a value relating to a driving torque of the first driving motor and a value relating to a driving torque of the second driving motor in a second state in which the belt image bearer and the transfer member are caused to contact each other by the contact separation unit, with respect to a value relating to the driving torque of the first driving motor and a value relating to the driving torque of the second driving motor in a first state in which the belt image bearer and the transfer member are caused to separate from each other by the contact separation unit; and a control unit configured to control at least one of the first driving motor and the second driving motor such that the belt image bearer and the transfer member are rotated at rotational speeds corresponding to the relative speed set by the relative speed setting unit.
According to an aspect of the present invention, there is provided an image forming apparatus including a toner image forming unit configured to form a toner image; a belt image bearer configured to bear the toner image formed by the toner image forming unit; and a transfer unit configured to transfer the toner image from the belt image bearer to a transfer material, wherein the transfer device described above is used as the transfer unit.
According to an aspect of the present invention, there is provided a non-transitory computer-readable recording medium storing a program that causes a computer that constitutes a transfer device to execute a process, the transfer device being controlled to transfer an image, which is borne on a peripheral surface of a belt image bearer rotatably stretched around a plurality of stretching members including a driving roller, onto a transfer material sandwiched in a transfer nip formed by causing the belt image bearer and a transfer member to abut each other, the process including obtaining and setting, by a relative speed setting unit, a relative speed of the belt image bearer and the transfer member, such that a variation amount is less than a predetermined variation amount, the variation amount being an amount of variation of a value relating to a driving torque of a first driving motor, which drivingly rotates the driving roller, and a value relating to a driving torque of a second driving motor, which drivingly rotates the transfer member, in a second state in which the belt image bearer and the transfer member are caused to contact each other by a contact separation unit, with respect to a value relating to the driving torque of the first driving motor and a value relating to the driving torque of the second driving motor in a first state in which the belt image bearer and the transfer member are caused to separate from each other by the contact separation unit, and controlling, by a control unit, at least one of the first driving motor and the second driving motor such that the belt image bearer and the transfer member are rotated at rotational speeds corresponding to the relative speed set by the relative speed setting unit.
Other objects, features and advantages of the present invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings, in which:
A description is given of a first embodiment applied to a color printer of an electrophotographic method (hereinafter, simply referred to as a “printer”) that is an image forming apparatus for which the present invention will be implemented. Note that the printer according to the present embodiment is a so-called tandem-type image forming apparatus, adopting a dry two-component developing method using a dry two-component developer; however, the present invention is not so limited.
As illustrated in
The photoconductive drums 1Y, 1M, 1C, 1Bk are arranged side-by-side along a belt movement direction of an intermediate transfer belt 5, so as to be in contact with the intermediate transfer belt 5, which is an endless belt supported by a plurality of rotatable rollers including a driving roller 10 (see
When forming a full-color image with the printer according to the present embodiment, the photoconductive drum 1Y is uniformly charged by the charger 2Y while being drivingly rotated, and then the photoconductive drum 1Y is irradiated with a light beam LY from an optical writing device, to form a Y electrostatic latent image on the photoconductive drum 1Y. The Y electrostatic latent image is developed with the Y toner in the developer, by the developing device 9Y. At the time of development, a predetermined developing bias is applied between the developing roller and the photoconductive drum 1Y, and the Y toner on the developing roller is electrostatically attracted on the Y electrostatic latent image part of the photoconductive drum 1Y.
The Y toner image developed and formed as above is conveyed, according to the rotation of the photoconductive drum 1Y, to the primary transfer position where the photoconductive drum 1Y and the intermediate transfer belt 5 contact each other. At this primary transfer position, on the back side of the intermediate transfer belt 5, a predetermined bias voltage is applied by a primary transfer roller 6Y. Then, by a primary transfer electric field generated by this bias application, the Y toner image on the photoconductive drum 1Y is drawn toward the intermediate transfer belt 5, and is transferred onto the intermediate transfer belt 5 by primary transfer. Similarly, an M toner image, a C toner image, and a Bk toner image are also sequentially transferred by primary transfer to be superimposed on the Y toner image on the intermediate transfer belt 5.
Then, the toner image in which four colors are superimposed on each other on the intermediate transfer belt 5, is conveyed to a secondary transfer position facing a secondary transfer roller 7, according to the rotation of the intermediate transfer belt 5. Furthermore, to this secondary transfer position, a sheet that is a transfer material is conveyed, at a predetermined timing by a pair of registration rollers 30. Then, at this secondary transfer position, a predetermined bias voltage is applied to the back side of the sheet by the secondary transfer roller 7, and due to the secondary transfer electric field generated by the bias application and the contact pressure at the secondary transfer position, the superimposed toner images on the intermediate transfer belt 5 are transferred at once on the sheet by secondary transfer. Subsequently, the sheet, on which the toner image has been transferred by secondary transfer, is subjected to a fixing process by a pair of fixing rollers 8, and is ejected outside the apparatus.
As a conveying speed detector of the intermediate transfer belt 5, there is a detector of a belt encoder method. On the front side or the back side of the intermediate transfer belt 5, encoder patterns 16 are inscribed. By reading these encoder patterns 16 with a belt encoder sensor 15, the belt surface speed is detected.
In
For example, if the belt encoder sensor 15 is laid out on a rotating shaft that is not flat, the curvature of the shaft affects the detection results, and the detected intervals between the encoder patterns 16 change due to the variation in the thickness of the intermediate transfer belt 5 caused by manufacturing defects and variations in the environment. Thus, the belt surface speed cannot be correctly measured, and therefore it is necessary to avoid locating the belt encoder sensor 15 on a rotating shaft that is not flat.
The encoder patterns 16 may be manufactured by any method, such as attaching sheet type encoder patterns, directly performing pattern processing on the belt, or processing the patterns at the same time as the manufacturing process of the intermediate transfer belt 5.
Here, the belt encoder sensor 15 is assumed to be a reflective optical sensor including equally spaced slits; however, the belt encoder sensor 15 may be any sensor as long as the belt encoder sensor 15 can accurately detect the belt surface position from the encoder patterns 16. For example, a CCD camera, etc., may be used to detect the surface position by image processing.
Furthermore, the encoder patterns 16 may be eliminated, in the case of a Doppler method or a sensor method of detecting the surface position by image processing based on the asperity of the belt surface.
Another example of a conveying speed detector of the intermediate transfer belt 5 is a rotary encoder method. Specifically, a rotation detector is provided on the rotating shaft of the driven roller 11, which is one of the plurality of stretching rollers. The driven roller 11 is a roller that rotates by being driven according to the endless movement of the intermediate transfer belt 5, and can detect the conveying speed of the intermediate transfer belt 5.
In the entire area of the intermediate transfer belt 5 in the circumferential direction, an area past the position wound around the driven roller 11 and before entering the position wound around the driving roller 10, is the area that comes in contact with the photoconductors for M, C, Y, K to form primary transfer nips for M, C, Y, K. Transfer rollers abut the positions for forming the primary transfer nips for M, C, Y, K on the intermediate transfer belt 5, from the back side of the belt. As a transfer bias is applied to these transfer rollers from a power source, transfer electric fields are formed between the belt and the photoconductors at the primary transfer nips of the respective colors.
A color image is formed at the primary transfer part, and therefore the belt conveying speed is preferably detected and controlled at this part. Thus, it is preferable to dispose a rotary encoder on the driven roller 11, or to dispose the belt encoder sensor 15 between the driven roller 11 and the driving roller 10.
Furthermore, a stretching roller denoted by a reference numeral 12 in the figure, is a tension roller. The tension roller 12 is pressed against the belt from the outside of the belt loop, and generates a fixed belt tension.
According to the belt tension generated by the tension roller 12, the intermediate transfer belt 5 abuts the surfaces of the respective stretching rollers, and the intermediate transfer belt 5 is conveyed in the circumferential direction. Particularly, the abutment force between the surface of the driving roller 10 and the intermediate transfer belt 5 has a correlation with the belt conveying frictional force of the driving roller 10, and is thus important. Therefore, the pressing force of the tension roller 12 is set such that the conveying frictional force necessary for conveying the intermediate transfer belt 5 can be secured.
Furthermore, a stretching roller denoted by a reference numeral 13 in the figure, is a secondary transfer counter roller. Note that on the outside of the belt loop, the secondary transfer roller 7 is disposed at the position facing the secondary transfer counter roller 13, and the secondary transfer roller 7 abuts the front side of the intermediate transfer belt 5. By applying electrical charges on the secondary transfer roller 7 and the front side of the intermediate transfer belt 5, the sheet is attracted onto the front side of the intermediate transfer belt 5.
Furthermore, on the outside of the belt loop, a belt cleaning device 14, which is disposed on the downstream side of the secondary transfer roller 7 in the belt conveying direction, abuts the belt 5. The belt cleaning device 14 collects foreign objects such as toner, which are adhering on the front side of the belt, from the front side of the belt by the potential difference between the toner and the belt cleaning device 14 itself.
In order to fix the conveying speed of the intermediate transfer belt 5, the motor control unit 20 implements feedback control on the intermediate transfer driving motor 17. The motor control unit 20 outputs intermediate transfer driving motor drive control signals 23, based on sensor output 21, which is the conveying speed information of the intermediate transfer belt 5, and sensor output 22, which is the rotation information of the driving roller 10.
Furthermore, at the same time, in order to suppress variations in the conveying speed of the intermediate transfer belt 5, which is caused by the abutment of the secondary transfer roller 7 and a sheet passing through the secondary transfer part, the motor control unit 20 implements feedback control on a secondary transfer driving motor 42 (see
Next, a description is given of a driving mechanism of the secondary transfer roller 7.
Apart from the intermediate transfer driving motor 17 for drivingly rotating the driving roller 10, there is provided the secondary transfer driving motor 42 for drivingly rotating the secondary transfer roller 7. By the secondary transfer driving motor control signals 24 sent from the motor control unit 20 (see
The rotational speed of the secondary transfer driving motor 42 is decelerated by a decelerating mechanism including a small diameter gear 42a at the rotating shaft of the secondary transfer driving motor 42, and a large diameter gear 7a at the rotating shaft of the secondary transfer roller 7. As the secondary transfer roller 7, which is connected to the decelerating mechanism, rotates in the counterclockwise direction as viewed in the figure, the sheet that is conveyed to the secondary transfer part is conveyed.
Opposite to the secondary transfer roller 7, there is provided the secondary transfer counter roller 13 that supports the intermediate transfer belt 5. The secondary transfer roller 7 abuts the secondary transfer counter roller 13 across the intermediate transfer belt 5. The abutment of the secondary transfer roller 7 is caused by a spring. Furthermore, by a cam mechanism, the secondary transfer roller 7 can separate from the intermediate transfer belt 5, against the biasing force of the spring.
As the secondary transfer roller 7 is moved in the direction of the arrow in the figure by a contact/separation unit including the spring and the cam mechanism, state of the secondary transfer roller 7 with respect to the intermediate transfer belt 5 (secondary transfer counter roller 13) at the secondary transfer part, is switched between an abutment state and a separated state. Furthermore, by separating the secondary transfer roller 7 from the intermediate transfer belt 5, it is possible to retrieve a belt mechanism and to perform maintenance when a paper conveying jam occurs.
In order to improve the transfer properties of the secondary transfer part, an elastic layer is provided on the surface of the secondary transfer roller 7. Accordingly, the transfer roller 7 abuts the intermediate transfer belt 5 such that the nip area is increased, and to follow the surface roughness of the sheet. In an example of the secondary transfer roller 7, a low inertia thin metallic pipe is at the center, a low hardness rubber material roller part (elastic rubber layer) made of silicon rubber, etc., is provided around the pipe, and an urethane coating layer is applied on the surface layer.
In a secondary transfer roller 7 applied to image forming apparatuses in recent years, a conductive rubber roller part includes a lower layer made of vulcanized rubber or silicon based rubber having a rubber hardness of less than or equal to 40 [°] (rubber hardness A scale), and the surface layer has a thin layer that is an urethane coating layer that invalidates the viscosity. Accordingly, due to the abutment deformation of the conductive rubber roller part, the nip area is increased, and appropriate pressure necessary for transfer can be secured.
Generally, in order to realize a low hardness of less than or equal to 40 [°] by a method other than a foamed rubber structure, the viscosity increases by adding a plasticizer in the case of vulcanized rubber. Furthermore, the viscosity increases also in the case of silicon rubber. As a result, a movement failure occurs between the two moving bodies, due to the adhesion at the transfer belt contact part or the adhesion with the sheet contact part. In order to avoid such a failure, it is effective to have the urethane coating layer applied on the surface layer as described above.
In the drive control method in a conventional secondary transfer driving motor, the rotation of the motor itself is driven at a constant speed by using a stepping motor having excellent constant speed properties, or the rotation of the motor shaft is detected by FG signals and the motor shaft rotational speed is driven at a constant speed by using a brushless DC motor.
The intermediate transfer driving motor 17 drivingly controls the intermediate transfer belt 5 to be conveyed by a predetermined speed, by implementing the above-described intermediate transfer belt drive control. Meanwhile, the secondary transfer driving motor 42 drives the motor shaft or the secondary transfer roller shaft at a constant speed. At this time, when the deformation amount of the secondary transfer roller 7 changes from the initial design value, the secondary transfer roller surface speed becomes different from the intermediate transfer belt conveying speed, which affects the conveyance of the secondary transfer belt.
In recent years, in order to improve the transfer properties when transferring an image from the intermediate transfer belt 5 to a sheet at the secondary transfer part, as the secondary transfer roller 7, a roller member that is easily deformable having a rubber hardness of approximately 40 [°] and that has a low surface hardness has been used. Accordingly, the variation amount of the roller shape is large, due to the tolerance of the secondary transfer roller diameter, variations in the contact pressure, the environment, and time-dependent variations. This causes a serious deviation (variation) in the surface speed of the secondary transfer roller 7. Accordingly, the difference between the secondary transfer roller surface speed and the intermediate transfer belt conveying speed is likely to vary. Furthermore, a urethane coating is applied on the surface layer of the secondary transfer roller 7; however, the frictional force between the secondary transfer roller 7 and the transfer belt 5 increases due to the increase of the nip area, and the above speed difference has a large impact on the intermediate transfer belt 5.
In recent years, there is increased demand for handling various kinds of sheets, and the range of thicknesses of conveyed sheets is increasing. Due to the thickness of the sheet, the deformation amount of the secondary transfer roller 7 also changes, and the variation in the speed difference further increases. Furthermore, by conveying sheets of different types, particularly surface-coated paper and Japanese paper having rough paper fiber on the surface, the frictional force between the secondary transfer roller 7 and the transfer belt varies significantly, and the impact of the speed difference on the intermediate transfer belt 5 further increases.
The surface speed of the secondary transfer roller 7 with respect to the surface speed of the intermediate transfer belt 5 does not only affect the intermediate transfer belt drive control performance, but also significantly affects the transfer image. When the surface speed of the secondary transfer roller 7 is higher than the surface speed of the intermediate transfer belt 5, the image that is transferred from the intermediate transfer belt 5 to the sheet is extended and the image length becomes long. Conversely, when the surface speed of the secondary transfer roller 7 is lower than the surface speed of the intermediate transfer belt 5, the image that is transferred from the intermediate transfer belt 5 to the sheet is reduced and the image length becomes short.
For example, when an image having a length of 400 [mm] is transferred onto an A3 size sheet, if the surface speed of the secondary transfer roller 7 is higher than the surface speed of the intermediate transfer belt 5 by 0.1 [%], the image transferred from the intermediate transfer belt 5 to the sheet becomes longer by 0.4 [mm]. Such a change in the image length becomes a significant problem in the case of printed matter that requires precision in the positions of transfer images on the front and back sides of a sheet, and in the case of printed matter in which an image frame is already set.
In
Furthermore, in the motor control unit 20, the control CPU 25 collects various kinds of information described below, calculates the control output to the respective motors, and outputs the calculated output as PWM (pulse-width modulation signals). The following are examples of various kinds of information. There are the rotational speed information from the belt encoder sensor 15, a secondary transfer roller encoder 26, and a secondary transfer driving motor encoder 27; and a driving current value from the intermediate transfer driving motor 17 and the secondary transfer driving motor 42.
Predrivers 350, 450 recognize the rotation angle of the motors by Hall element signals, convert the PWM signals into motor three-phase output signals, and drive the motors via FET 360, 460. Accordingly, the rotational speeds of the intermediate transfer driving motor 17 and the secondary transfer driving motor 42 are controlled to become target speeds, based on target speed signals which are instruction values of the motors.
The driving current of the motor can be calculated for PWM signals; however, errors may occur due to the impact of variations and the responsiveness of the motor driving circuit including the predriver. Therefore, in order to recognize the driving current of the motor with higher precision, the driving current may be recognized by measuring the current of an FET.
Furthermore, according to need, the control CPU 25 stores the collected data and calculated data in the memory 43 (corresponding to a storage unit in the rotation body abutment device) and reports information such as an abnormality report of the intermediate transfer device to the main control unit 44.
The main control unit 44 acquires abutment operation information of the secondary transfer roller 7 according to another motor. Furthermore, the main control unit 44 is connected to an operation unit 45, and an operator can implement control by giving instructions from the operation unit 45 to the motor control unit 20 via the main control unit 44.
The intermediate transfer belt 5 is drivingly conveyed by implementing feedback control on the rotational speed of the intermediate transfer driving motor 17 such that the rotational speed becomes constant at a target value, based on speed information from the belt encoder sensor 15, and therefore the surface speed of the intermediate transfer belt 5 is always constant. Meanwhile, the secondary transfer roller 7 is subjected to feedback control based on the speed information of the secondary transfer driving motor encoder 27 and the secondary transfer roller encoder 26, and therefore the speed of the rotating shaft of the secondary transfer roller 7 is always constant.
However, the surface speed of the secondary transfer roller 7 does not match that of the intermediate transfer belt 5 due to the roller diameter tolerance. Furthermore, at the time of abutment, the surface linear speed changes significantly according to the deformation amount, and therefore a linear velocity difference arises between the surface speed of the secondary transfer roller 7 and the surface speed of the intermediate transfer belt 5.
For example, as in the case of
Here, as in the case of
An interference torque is a torque component imposed on the secondary transfer driving motor 42 for bearing the conveying torque of not only the secondary transfer roller 7 but also the intermediate transfer belt 5. Alternatively, the interference torque is a torque component imposed on the intermediate transfer driving motor 17 for bearing the rotation torque of not only the intermediate transfer belt 5 but also the secondary transfer roller 7. In
In recent years, in order to respond to demand for higher image quality, image forming apparatuses have been required to have higher control performance. Thus, it has been needed to adjust the speed of the secondary transfer roller 7 so as not to affect the conveying torque of the intermediate transfer belt 5. For example, when an interference torque is generated, and the interference torque changes in the rotation period of the secondary transfer roller, variations occur in the speed of the intermediate transfer belt 5.
Thus, in accordance with the abutment state of the secondary transfer roller 7 and the intermediate transfer belt 5 as illustrated in
Furthermore, the generation of the interference torque is largely affected by the surface linear speed difference between the secondary transfer roller 7 and the intermediate transfer belt 5, and the friction coefficient of the secondary transfer part (between the secondary transfer roller 7 and the intermediate transfer belt 5, between the sheet and the intermediate transfer belt 5, and between the sheet and the secondary transfer roller 7).
Even when the surface linear speed difference is large, if the friction coefficient is zero, the interference torque will be zero. Meanwhile, even when the surface linear speed difference is small, if the friction coefficient is high, the interference torque will be large. Therefore, the interference torque varies largely depending on each image forming apparatus and the type of paper of the sheet, and it is difficult to recognize the interference torque beforehand.
Due to the above problems, the image forming apparatus according to the present embodiment recognizes the interference torque characteristics when the secondary transfer roller 7 and the intermediate transfer belt 5 are in an abutment state, derives an optimum speed setting according to the abutment state of the secondary transfer roller 7, and uses the derived speed setting.
The vertical axis in
The driving torque of the intermediate transfer belt 5 is obtained by converting the torque estimation value of the intermediate transfer driving motor 17 into a conveying force of the surface of the intermediate transfer belt 5, in consideration of the deceleration ratio, the driving roller diameter, and the thickness of the intermediate transfer belt 5. Furthermore, the driving torque of the secondary transfer roller 7 is obtained by converting the torque estimation value of the secondary transfer driving motor 42 into the conveying force on the surface of the secondary transfer roller 7, in consideration of the deceleration ratio the driving roller diameter, etc.
Note that the torque estimation value is a load torque value calculated by the main control unit 44, based on current values of the respective driving motors or drive instruction values such as PWM instruction values to the respective driving motors, and the actual rotational speeds of the intermediate transfer belt 5 and the secondary transfer roller 7. In a state where the respective driving motors are controlled with high precision at a constant speed or a default speed, the load torque value can be calculated from only the current values and the PWM instruction values.
A description is given of the interference torque in
For example, when the secondary transfer roller 7 abuts the intermediate transfer belt 5 and the secondary transfer roller 7 is largely deformed, and the surface speed increases, the secondary transfer driving torque increases, and the conveying torque of the intermediate transfer belt 5 decreases. The inverse correlation of the torque transitions of the secondary transfer roller 7 and the intermediate transfer belt 5 corresponds to the interference torque. Furthermore, in
According to these interference torque characteristics (here, the conveyance force characteristics), the optimum value of the secondary transfer roller speed setting value of the zero cross point, is near 1.5 [%] in the property example of
Condition 1: room temperature environment (25 [° C.]), in-device temperature 30 [° C.], secondary transfer roller contact pressure 100 [%], conveying speed 200 [mm/s]
Condition 2: room temperature environment (25 [° C.]), in-device temperature 30 [° C.], secondary transfer roller contact pressure 80 [%], conveying speed 400 [mm/s]
Condition 3: room temperature environment (35 [° C.]), in-device temperature 45 [° C.], secondary transfer roller contact pressure 100 [%], conveying speed 200 [mm/s]
The optimum value differs according to these conditions, and therefore there is a need to measure the interference torque characteristics as needed, and to optimize the speed setting value of the secondary transfer roller 7.
In the present embodiment, the speed setting of the secondary transfer roller 7 is derived from the above interference torque characteristics, by a control unit provided in the image forming apparatus.
However, the motor torque estimation value in the actual device does not only include the interference torque components, but also many other load torque components. Examples of a load torque component are a contact load of the cleaning blade, a contact load of the photoconductive drum 1, an acceleration and deceleration torque for correcting the variations in the speed of the secondary transfer roller 7 and the intermediate transfer belt 5, etc.
In order to remove such noise components and determine the interference torque component, a filter process is needed. Measurement data (measurement time) for performing the filter process is necessary. Furthermore, the characteristics are often non-linear, and if the number of measurement points is small, the zero cross point cannot be determined with high precision. In order to measure the interference torque characteristics, in which the number of measurement points has been increased, a tremendous amount of time will be taken. For the purpose of responding to individual differences of devices, operation conditions, the environment, and time-dependent variations, in order to frequently measure the interference torque characteristics on the machine and not in the production process, the measurement time becomes a significant problem.
With respect to the above problems in the measurement precision and time reduction for measuring the interference torque characteristics, an effective means is proposed. The load torque components which are noise, include many steady components and period variation components that change in the rotation period of the photoconductive drum 1 and the driving roller 10. Furthermore, there are variation components that gradually increase or decrease, for which the periodicity cannot be confirmed by a measurement time of a few minutes.
Therefore, for the measurement of interference torque characteristics, an effective method is to change the period variation of the interference torque components, into a period variation that does not occur in the load torque components. For example, the period of the photoconductive drum and the period of the respective rollers are approximately 1 [Hz] through 40 [Hz]. The speed setting change of the secondary transfer roller 7 that is a level change performed at the time of property measurement, is changed into a sinusoidal waveform, and the sinusoidal wave period is set as approximately 0.2 [Hz]. The characteristics of the torque estimation value components that change in this period, are evaluated as the characteristics of interference torque components. Note that when the intermediate transfer belt 5 and the secondary transfer roller 7 are in the abutment state, the relative speed of the intermediate transfer belt 5 and the secondary transfer roller 7 (set speed of secondary transfer roller 7) is to be changed into a period waveform such as a sinusoidal wave or a triangular wave.
For example, when the secondary transfer roller 7 is in an abutment state, the set speed of the secondary transfer roller 7 is changed to a sinusoidal waveform of approximately 6 second periods, as illustrated in
According to changes in the set speed of the secondary transfer roller 7, the conveying forces of the intermediate transfer belt 5 and the secondary transfer roller 7 change into the same sinusoidal waveform. This property data can be extracted by using a low pass filter. Furthermore, there are many speed setting levels, and the zero cross point can be accurately determined. From the zero cross point time of
As illustrated in
Next, when the secondary transfer roller 7 and the intermediate transfer belt 5 are in a separated state, the torque transition data of the respective driving motors of the secondary transfer roller 7 and the intermediate transfer belt 5 is acquired (step 2). Then, according to need, a low pass filter process is performed on the torque transition data, and a torque estimation value estimated by this process is set as the standard torque at the time of monolithic driving.
Subsequently, an abutment operation of causing the secondary transfer roller 7 to abut the intermediate transfer belt 5 is performed (step 3). Then, an interference torque characteristic evaluation is performed (step 4). Specifically, the secondary transfer roller 7 is driven while changing the set speed of the secondary transfer roller 7 into a sinusoidal waveform. Based on the respective driving torque estimation values of the secondary transfer roller 7 and the intermediate transfer belt 5 at this time, the variation amount from the previous standard torque value is calculated. Next, by using a low pass filter, the components having the same period as the sinusoidal wave are extracted, and are set as the interference torque characteristics.
Based on the interference torque transition data of the secondary transfer roller 7 and the intermediate transfer belt 5, the correlation coefficient of the two data items of
When the contact friction between the secondary transfer roller 7 and the intermediate transfer belt 5 is significantly low, and the secondary transfer roller 7 and the intermediate transfer belt 5 completely slip on each other, an inverse correlation will not be seen. In this state, the sheet conveying operation tends to become unstable, and therefore error information is sent to the image forming apparatus main unit.
Furthermore, when the secondary transfer roller 7 abuts the intermediate transfer belt 5, there are cases where the bearing part and the roller part deform excessively, and the load torque increases at both the secondary transfer roller 7 and the intermediate transfer belt 5. In this case, the correlation coefficient becomes positive, and this is also reported as a failure to the image forming apparatus by error information.
The optimum set speed of the secondary transfer roller 7 is derived from the zero cross point, and the default speed is changed to the optimum value (step 6). This optimum value represents a state where the surface speeds of the secondary transfer roller 7 and the intermediate transfer belt 5 match each other, and the interference torque is zero.
Meanwhile, in the secondary transfer process, when the transfer rate can be increased by setting a slight amount of interference torque, a default offset value may be added to the optimum value. A transfer rate is an index indicating how much of the toner amount on the intermediate transfer belt 5 has been transferred onto the sheet. It is known that when there is a slight difference in the surface speed, the toner can be transferred more easily by the friction between the sheet and the intermediate transfer belt 5.
Note that the optimum set speed of the secondary transfer roller 7 represents a state where the surface speeds of the secondary transfer roller 7 and the intermediate transfer belt 5 match each other and the interference torque becomes zero. By this optimum set speed, it is possible to suppress the speed variation of the intermediate transfer belt 5 caused by the interference torque. Meanwhile, even when there is a slight variation of the torque estimation value with respect to the monolithic driving torque, it is possible to reduce the speed variation of the intermediate transfer belt 5 caused by the interference torque.
For example, a relative speed of the secondary transfer roller 7 and the intermediate transfer belt 5 is derived, by which the variation amount of the torque estimation value with respect to the monolithic driving torque becomes less than 10 [Nm], and the rotational speed of the secondary transfer roller 7 by which the derived relative speed can be attained, is set as the secondary transfer set speed.
Furthermore, the set speed of the intermediate transfer belt 5 can be derived from the interference torque characteristic by a control unit provided in the image forming apparatus, and the rotational speed of the intermediate transfer belt 5 by which the relative speed can be attained, may be set as the intermediate transfer belt set speed.
Note that in the present embodiment, a description is given of an image forming apparatus in which the intermediate transfer belt 5 is used as the belt image bearer; however, the present invention is not so limited. That is, the present invention is similarly applicable to an image forming apparatus of a direct transfer method, in which a photoconductive belt stretched around a plurality of stretching rollers including a driving roller is used, and a toner image is transferred from the photoconductive belt to a sheet, at a transfer part formed by causing the photoconductive belt and a transfer roller to contact each other. Furthermore, in the present embodiment, a description is given of an image forming apparatus in which the secondary transfer roller 7 is used as the transfer member; however, the present invention is not so limited. That is, the present invention is similarly applicable to an image forming apparatus in which a secondary transfer belt 7c, which is rotatably stretched around a plurality of stretching rollers including a driving roller, is used as the transfer member, as illustrated in
Next, a description is given of a second embodiment of the present invention applied to a printer that is an image forming apparatus. Note that the basic configuration and operations of the image forming apparatus according to the present embodiment are substantially the same as those of the image forming apparatus according to the first embodiment, and therefore descriptions thereof are omitted.
In the interference torque characteristic evaluation, the secondary transfer roller 7 was driven while changing the speed setting of the secondary transfer roller 7 to a sinusoidal waveform, the period of the sinusoidal wave was set at 0.1 [Hz], 0.2 [Hz], 0.4 [Hz], 1.0 [Hz], and the variation transition of the secondary transfer roller speed and the intermediate transfer belt conveying force was actually measured. With respect to the intermediate transfer belt conveying force variation, two types of data are indicated, representing different levels of hardness and thicknesses of the rubber surface layer of the secondary transfer roller 7. Note that the intermediate transfer belt conveying force (soft) in the figures represents data when the rubber surface layer of the secondary transfer roller 7 has a low level of hardness and a large thickness. Furthermore, the intermediate transfer belt conveying force (rigid) in the figures represents data when the rubber surface layer of the secondary transfer roller 7 has a high level of hardness and a small thickness. As a matter of convenience in confirming the difference, the intermediate transfer belt conveying force (rigid) indicates the results obtained by removing noise from the actual measurement data and fitting the data by an approximation function.
The variation transition of the secondary transfer roller speed and the intermediate transfer belt conveying force (rigid) indicates an antiphase relationship, in which the intermediate transfer belt conveying force decreases as the secondary transfer roller speed increases, similar to that illustrated in
The factor of the delay in the response of the conveying force change of the intermediate transfer belt 5, may be a shear deformation of the rubber of the secondary transfer roller 7 at the secondary transfer nip. The secondary transfer roller 7 includes a cylindrical hollow cored bar, an elastic layer made of an elastic material fixed on the outer peripheral surface of the cored bar, and a surface layer covering the outer peripheral surface. The metal forming the hollow cored bar may be stainless steel, aluminum, etc.; however, the material is not so limited.
As the elastic layer, epichlorohydrin rubber having conductivity, EPDM in which carbon is dispersed, Si rubber, NBR having an ion conductive function, urethane rubber, etc., may be used. The elastic material is preferably has a hardness that is a JIS-A hardness of approximately 40 [°] through 70 [°], and the elastic layer of the secondary transfer roller 7 of the rigid type has a thickness of 0.5 [mm] and a hardness of 70 [°]. Meanwhile, the elastic layer of the secondary transfer roller 7 of the soft type has a thickness of 5 [mm] and a hardness of 40 [°]. In the elastic layer of the secondary transfer roller 7 of the soft type, not only does a significant pressure deformation occur when abutting the intermediate transfer belt 5, but a significant shear deformation occurs in the rotational direction due to the speed difference in the intermediate transfer belt surface speed and the secondary transfer roller surface speed. Thus, when interference torque characteristic evaluation is performed by the process of step 4, in which the surface speed difference is changed to a sinusoidal waveform, the shear deformation of the elastic layer of the secondary transfer roller 7 also changes between a large deformation and a small deformation. The shear deformation of the elastic layer of the secondary transfer roller 7 is considered to cause the delay in the response of the conveying force change of the intermediate transfer belt 5.
As illustrated in
Next, when the secondary transfer roller 7 and the intermediate transfer belt 5 are in a separated state, the torque transition data of the respective driving motors of the secondary transfer roller 7 and the intermediate transfer belt 5 is acquired (step 2). Then, according to need, a low pass filter process is performed on the torque transition data, and a torque estimation value estimated by this process is set as the standard torque at the time of monolithic driving. Subsequently, an abutment operation of causing the secondary transfer roller 7 to abut the intermediate transfer belt 5 is performed (step 3). Then, an interference torque characteristic evaluation is performed (step 4). Specifically, the secondary transfer roller 7 is driven while changing the set speed of the secondary transfer roller 7 into a sinusoidal waveform. Based on the respective driving torque estimation values of the secondary transfer roller 7 and the intermediate transfer belt 5 at this time, the variation amount from the previous standard torque value is calculated. Next, by using a los path filter, the components having the same period as the sinusoidal wave are extracted, and are set as the interference torque characteristics. Based on the interference torque transition data of the secondary transfer roller 7 and the intermediate transfer belt 5, the correlation value of the two data items is calculated (step 5).
Next, by an approximation calculation process according to the orthogonal detection of the secondary transfer roller speed and the intermediate transfer belt driving torque, the amplitude, the phase, and the average value of each of the secondary transfer roller speed and the intermediate transfer belt driving torque are acquired (step 6). Next, the phase difference is derived from the calculation formula of the secondary transfer roller speed and the intermediate transfer belt driving torque described below (step 7). Then, the optimum set speed of the secondary transfer roller is derived from the standard torque and the target torque of the intermediate transfer belt driving torque, the phase difference, and the approximation formula of the secondary transfer roller speed and the intermediate transfer belt driving torque (step 8).
A detailed description is given of the process of step 6 and onward of the flowchart in FIG. 10. First, the variation data y of the sinusoidal waveform period ω of each of the secondary transfer roller speed and the intermediate transfer belt driving torque (rotation torque conversion value of intermediate transfer belt conveying force) is acquired by performing an approximation calculation process according to orthogonal detection, based on the amplitude C, the phase θ, and the average value b. The intermediate transfer belt driving torque variation y1 is expressed by the following formula 1.
y
1
=b
1
+C
1 Sin(ω t+θ1) [Formula 1]
Furthermore, the speed variation y2 of the secondary transfer roller 7 is expressed by the following formula 2. Note that as the secondary transfer roller speed, either an approximation calculation process performed on actually measured data or a setting value may be used.
y
2
=b
2
+C
2 Sin(ω t+θ2) [Formula 2]
The aimed intermediate transfer belt driving torque value (target torque) Rt to be adjusted is obtained by adding the offset torque Roff to the standard torque Rb obtained by the process of step 2 in
R
t
=R
b
+R
off [Formula 3]
In the data of the intermediate transfer belt driving torque variation in the process of step 6 in
In the intermediate transfer belt driving torque variation in one period of a sinusoidal waveform, there are two time points at which the torque becomes a value Rt, and either time point may be used. The obtained time tr is assigned to the time t of the above formula 2, and the optimum speed of the secondary transfer roller 7 is derived.
Next, a description is given of a third embodiment of the present invention applied to a printer that is an image forming apparatus. Note that the basic configuration and operations of the image forming apparatus according to the present embodiment are substantially the same as those of the image forming apparatus according to the first embodiment, and therefore descriptions thereof are omitted.
A description is given of the interference torque in
Note that when the difference between the driving speed of the secondary transfer roller 7 and the driving speed of the intermediate transfer belt 5 becomes greater than a certain range, slipping occurs at the surfaces of the secondary transfer roller 7 and the intermediate transfer belt 5. In a completely slipped state, the contact friction between the secondary transfer roller 7 and the intermediate transfer belt 5 becomes significantly low. Therefore, an inverse correlation cannot be seen, and the inverse correlation relationship between the secondary transfer roller speed and the intermediate transfer belt driving torque changes. In such a state, the paper conveying operation tends to become unstable. In the present embodiment, the set speed of the secondary transfer roller 7 is derived on-machine, from the above interference torque character.
The measurement of the interference torque characteristic illustrated in
First, a separation operation of separating the secondary transfer roller 7 from the intermediate transfer belt 5 is performed (step 1). Then, the intermediate transfer belt 5 is drivingly controlled by a standard speed instruction value at the time of image forming, and furthermore, the secondary transfer roller 7 is drivingly controlled at a default speed. Next, when the secondary transfer roller 7 and the intermediate transfer belt 5 are in a separated state, the secondary transfer roller speed and the driving conveying force transition data of the intermediate transfer belt 5 are acquired (step 2). According to need, a low pass filter process is performed on the conveying force transition data. The value of this conveying force is set as the standard conveying force at the time of monolithic driving. Subsequently, an abutment operation of causing the secondary transfer roller 7 to abut the intermediate transfer belt 5 is performed (step 3). Then, the secondary transfer roller 7 is driven such that the set speed of the secondary transfer roller 7 becomes periodic (step 4), and the secondary transfer roller speed when driving is performed in step 4 and the drive conveying force transition data of the intermediate transfer belt 5 are acquired (step 5). Then, a low pass filter process is performed on the conveying force transition data according to need. The optimum set speed of the secondary transfer roller 7 is derived from the zero cross point, and the default speed is changed to the optimum value (step 6). The zero cross point is the intersection point where the standard conveying force at the time of driving motor monolithic driving of the intermediate transfer belt 5 of step 2 and the driving conveying force transition data of the intermediate transfer belt 5 of step 5, match each other. The optimum value of the secondary transfer roller speed represents a state where the surface speed of the secondary transfer roller 7 and the surface speed of the intermediate transfer belt 5 match each other, and the interference torque of the intermediate transfer belt 5 is zero. However, in the secondary transfer process, when the transfer rate can be increased by setting a slight amount of interference torque, a default offset value may be added to the optimum value. Next, it is determined whether the adjustment of step 4 through step 6 has been performed an N number of times (step 7). When the adjustment has not been performed an N number of times (No in step 7), the adjustment of step 4 through step 6 is performed again. When the adjustment has been performed an N number of times (Yes in step 7), the flowchart is completed at step 7.
An approximation formula of the secondary transfer roller speed and the intermediate transfer belt driving conveying force is calculated (step 6). The optimum set speed of the secondary transfer roller 7 is derived from the zero cross point, and the default speed is changed to the optimum value (step 7). The zero cross point is the intersection point where the standard conveying force at the time of driving motor monolithic driving of the intermediate transfer belt 5 of step 2 and the approximation formula of the driving conveying force of the intermediate transfer belt 5 of step 6 match each other. The optimum value of the secondary transfer roller speed represents a state where the surface speed of the secondary transfer roller 7 and the surface speed of the intermediate transfer belt 5 match each other, and the interference torque of the intermediate transfer belt 5 is zero. However, in the secondary transfer process, when the transfer rate can be increased by setting a slight amount of interference torque, a default offset value may be added to the optimum value. Next, it is determined whether the adjustment of step 4 through step 7 has been performed an N number of times (step 8). When the adjustment has not been performed an N number of times (No in step 8), the adjustment of step 4 through step 7 is performed again. When the adjustment has been performed an N number of times (Yes in step 8), the flowchart is completed at step 8.
Next, a description is given of a fourth embodiment of the present invention applied to a printer that is an image forming apparatus. Note that the basic configuration and operations of the image forming apparatus according to the present embodiment are substantially the same as those of the image forming apparatus according to the first embodiment, and therefore descriptions thereof are omitted.
With reference to
In the measurement of the interference torque characteristic illustrated in
With respect to the above problems in the measurement precision and time reduction for measuring the interference torque characteristics, an effective means is proposed. The load torque components which are noise, include many steady components and period variation components that change in the rotation period of the photoconductive drum 1 and the driving roller 10. Furthermore, there are variation components that gradually increase or decrease, for which the periodicity cannot be confirmed by a measurement time of a few minutes. Therefore, for the measurement of interference torque characteristics, an effective method is to change the period variation of the interference torque components, into a period variation that does not occur in the load torque components. For example, the period of the photoconductive drum and the period of the respective rollers are approximately 1 [Hz] through 40 [Hz]. The speed setting change of the secondary transfer roller 7 that is a level change performed at the time of property measurement, is changed into a sinusoidal waveform, and the sinusoidal wave period is set as approximately 0.2 [Hz]. The characteristics of the torque estimation value components that change in this period, are evaluated as the characteristics of interference torque components.
When the secondary transfer roller 7 is in an abutment state, the set speed of the secondary transfer roller 7 is changed to a sinusoidal waveform of approximately 6 second periods, as illustrated in
The measurement of the interference torque characteristic illustrated in
Therefore, in the present embodiment, the method of deriving the optimum value of the secondary transfer roller speed is performed a plurality of times to increase the adjustment precision. The purpose of the method of deriving the optimum value of the secondary transfer roller speed is divided into coarse adjustment and fine adjustment. Coarse adjustment is performed within a secondary transfer roller speed range in which slipping does not occur, according to secondary transfer roller sinusoidal waveform driving. Fine adjustment is performed by a method of deriving the optimum value of the secondary transfer roller speed within a secondary transfer roller speed range in which slipping does not occur, to obtain the secondary transfer roller speed with high precision. By changing the adjustment purpose each time the deriving method is performed, high-precision adjustment can be achieved.
First, a separation operation of separating the secondary transfer roller 7 from the intermediate transfer belt 5 is performed, and the intermediate transfer belt 5 is drivingly controlled by a standard speed instruction value at the time of image forming, and furthermore, the secondary transfer roller 7 is drivingly controlled at a default speed. In the case of the initial stage of device operation when there is no default speed profile, a constant value is used as the profile to execute the following deriving process (step 1). Next, when the secondary transfer roller 7 and the intermediate transfer belt 5 are in a separated state, the conveying force transition data of the driving motors of the secondary transfer roller 7 and the intermediate transfer belt 5 is acquired. According to need, a low pass filter process is performed on the conveying force transition data. The value of this conveying force is set as the standard conveying force at the time of monolithic driving (step 2). Subsequently, an abutment operation of causing the secondary transfer roller 7 to abut the intermediate transfer belt 5 is performed (step 3). Then, an interference torque characteristic evaluation is performed (step 4). Note that the interference torque characteristic is obtained by driving the secondary transfer roller 7 while changing the set speed of the secondary transfer roller 7 into a sinusoidal waveform, and calculating the variation amount from the standard conveying force ahead of the conveying force waveform of the secondary transfer roller 7 and the intermediate transfer belt 5 at this time. Then, by using a low pass filter, the components having the same period as the sinusoidal wave are extracted, and are set as the interference torque characteristics.
Next, the correlation coefficient of the two data items of the interference torque transition data (
First, a separation operation of separating the secondary transfer roller 7 from the intermediate transfer belt 5 is performed, and the intermediate transfer belt 5 is drivingly controlled by a standard speed instruction value at the time of image forming, and furthermore, the secondary transfer roller 7 is drivingly controlled at a default speed (step 1). Next, when the secondary transfer roller 7 and the intermediate transfer belt 5 are in a separated state, the secondary transfer roller speed and the driving conveying force transition data of the intermediate transfer belt 5 are acquired. According to need, a low pass filter process is performed on the conveying force transition data. The value of this conveying force is set as the standard conveying force at the time of monolithic driving (step 2). Subsequently, an abutment operation of causing the secondary transfer roller 7 to abut the intermediate transfer belt 5 is performed (step 3). Then, the secondary transfer roller 7 is driven such that the set speed of the secondary transfer roller 7 becomes periodic (step 4), and the secondary transfer roller speed when driving is performed in step 4 and the drive conveying force transition data of the intermediate transfer belt 5 are acquired (step 5). Then, a low pass filter process is performed on the conveying set speed of the secondary transfer roller 7 is derived from the zero cross point, and the default speed is changed to the optimum value (step 6). The zero cross point is the intersection point where the standard conveying force at the time of driving motor monolithic driving of the intermediate transfer belt 5 of step 2 and the driving conveying force transition data of the intermediate transfer belt 5 of step 5 match each other. The optimum value of the secondary transfer roller speed represents a state where the surface speed of the secondary transfer roller 7 and the surface speed of the intermediate transfer belt 5 match each other, and the interference torque of the intermediate transfer belt 5 is zero. However, in the secondary transfer process, when the transfer rate can be increased by setting a slight amount of interference torque, a default offset value may be added to the optimum value. Next, it is determined whether the adjustment of step 4 through step 6 has been performed an N number of times (step 7). When the adjustment has not been performed an N number of times (No in step 7), the adjustment of step 4 through step 6 is performed again. When the adjustment has been performed an N number of times (Yes in step 7), the flowchart is completed at step 7.
An approximation formula of the secondary transfer roller speed and the intermediate transfer belt driving conveying force is calculated (step 6). The optimum set speed of the secondary transfer roller 7 is derived from the zero cross point, and the default speed is changed to the optimum value (step 7). The zero cross point is the intersection point where the standard conveying force at the time of driving motor monolithic driving of the intermediate transfer belt 5 of step 2 and the approximation formula of the driving conveying force of the intermediate transfer belt 5 of step 6 match each other. The optimum value of the secondary transfer roller speed represents a state where the surface speed of the secondary transfer roller 7 and the surface speed of the intermediate transfer belt 5 match each other, and the interference torque of the intermediate transfer belt 5 is zero. However, in the secondary transfer process, when the transfer rate can be increased by setting a slight amount of interference torque, a default offset value may be added to the optimum value. Next, it is determined whether the adjustment of step 4 through step 7 has been performed an N number of times (step 8). When the adjustment has not been performed an N number of times (No in step 8), the adjustment of step 4 through step 7 is performed again. When the adjustment has been performed an N number of times (Yes in step 8), the flowchart is completed at step 8.
The above describes examples, and the present invention has unique effects in each of the following aspects.
A transfer device includes an endless belt image bearer such as the intermediate transfer belt 5 which is rotatably stretched around a plurality of stretching members; a driving roller such as the driving roller 10 configured to drivingly rotate the belt image bearer, the driving roller being one of the plurality of stretching members; a first driving motor such as the intermediate transfer driving motor 17 configured to drivingly rotate the driving roller; a first speed detecting unit such as the belt encoder sensor 15 configured to detect a rotational speed of the belt image bearer; a rotatable transfer member such as the secondary transfer roller 7 configured to abut an outer peripheral surface of the belt image bearer and form a transfer nip, wherein an image borne on the outer peripheral surface of the belt image bearer is transferred onto a transfer material such as a sheet that is sandwiched in the transfer nip; a second driving motor such as the secondary transfer driving motor 42 configured to drivingly rotate the transfer member; a second speed detecting unit such as the secondary transfer roller encoder 26 configured to detect a rotational speed of the transfer member; a contact separation unit configured to cause the belt image bearer and the transfer member to contact and separate from each other; a relative speed setting unit configured to obtain and set a relative speed, such that a variation amount is less than a predetermined variation amount, the variation amount being an amount of variation of a value relating to a driving torque of the first driving motor and a value relating to a driving torque of the second driving motor in a second state in which the belt image bearer and the transfer member are caused to contact each other by the contact separation unit, with respect to a value relating to the driving torque of the first driving motor and a value relating to the driving torque of the second driving motor in a first state in which the belt image bearer and the transfer member are caused to separate from each other by the contact separation unit; and a control unit such as the motor control unit 20 configured to control at least one of the first driving motor and the second driving motor such that the belt image bearer and the transfer member are rotated at rotational speeds corresponding to the relative speed set by the relative speed setting unit.
In (Aspect A), first, in a first state in which the belt image bearer and the transfer member are separated, a value relating to the driving torque of the first driving motor and a value relating to the driving torque of the second driving motor are obtained. Next, in a second state in which the belt image bearer and the transfer member are in contact, a value relating to the driving torque of the first driving motor and a value relating to the driving torque of the second driving motor are obtained. Then, the relative speed setting unit obtains and sets a relative speed, such that a variation amount is less than a predetermined variation amount. The variation amount is an amount of variation of the values relating to the driving torques of the first driving motor and the second driving motor in the second state, with respect to the values relating to the driving torques of the first driving motor and the second driving motor in the first state. Then, the belt image bearer and the transfer member are rotated at a rotational speed corresponding to the relative speed set by the relative speed setting unit. Accordingly, in the second state, the belt image bearer and the transfer member can be rotated at a rotational speed that can attain the relative speed such that the values relating to the driving torques of the first driving motor and the second driving motor become close to those of the first state as much as possible. Thus, it is possible to reduce the interference torque of the first driving motor and the second driving motor in the second state, and the movement speed of the belt image bearer can be controlled with high precision by the first driving motor. Therefore, it is possible to improve the stability in drivingly rotating the belt image bearer and in conveying a transfer material at the transfer nip.
The transfer device according to aspect A, further including a first driving torque estimating unit such as the main control unit 44 configured to estimate a first driving torque applied on the first driving motor; and a second driving torque estimating unit such as the main control unit 44 configured to estimate a second driving torque applied on the second driving motor, wherein the value relating to the driving torque of the first driving motor and the value relating to the driving torque of the second driving motor in the first state are respectively the first driving torque and the second driving torque applied when the belt image bearer and the transfer member are rotated at a constant speed in the first state, which are estimated by the first driving torque estimating unit and the second driving torque estimating unit, and the value relating to the driving torque of the first driving motor and the value relating to the driving torque of the second driving motor in the second state are respectively the first driving torque and the second driving torque applied when the belt image bearer and the transfer member are rotated at a constant speed in the second state, which are estimated by the first driving torque estimating unit and the second driving torque estimating unit.
In (Aspect B), first, in the first state where the belt image bearer and the transfer member are separated, an estimation value of a first driving torque and an estimation value of a second driving torque are obtained, in a state where the belt image bearer and the transfer member are rotated at a constant speed. The obtained estimation value of the first driving torque and the estimation value of the second driving torque are set as target torque estimation values of the present state to which the individual differences (tolerance) of the belt image bearer and the transfer member, the environment, and time-dependent variations are reflected. Next, in a state where the belt image bearer and the transfer member are in contact, the estimation value of the first driving torque and the estimation value of the second driving torque are obtained, when the belt image bearer and the transfer member are rotated while changing the relative speed of the belt image bearer and the transfer member. Then, the relative speed is obtained, such that a variation amount is less than the predetermined variation amount. The variation amount is an amount of variation of the estimation value of the first driving torque and the estimation value of the second driving torque in the second state, with respect to the estimation value of the first driving torque and the estimation value of the second driving torque in the first state. Then, the belt image bearer and the transfer member are rotated at a rotational speed that can attain the relative speed in the second state. Accordingly, in the second state, the belt image bearer and the transfer member can be rotated at a rotational speed that can attain the relative speed such that the estimation value of the first driving torque and the estimation value of the second driving torque become close to those of the first state as much as possible. Thus, it is possible to reduce the interference torque of the first driving motor and the second driving motor in the second state, and the movement speed of the belt image bearer can be controlled with high precision by the first driving motor. Therefore, it is possible to improve the stability in drivingly rotating the belt image bearer and in conveying a transfer material at the transfer nip.
The transfer device according to aspect A, wherein the value relating to the driving torque is at least one of a motor current value, a motor control voltage, a motor control voltage instruction value, and a motor PWM signal value. Accordingly, as described in the above embodiment, the driving can be adjusted by using these values as indexes, similar to the load torque (torque measurement value, torque estimation value).
The transfer device according to aspects A through C, wherein the relative speed setting unit sets the relative speed a plurality of times. Accordingly, as described in the above embodiment, the adjustment precision can be increased.
The transfer device according to aspect B or D, wherein the first driving torque estimating unit can estimate the first driving torque based on a drive instruction value of the first driving motor and a detection result of the first speed detecting unit, and the second driving torque estimating unit can estimate the second driving torque based on a drive instruction value of the second driving motor and a detection result of the second speed detecting unit.
The transfer device according to aspects A through E, wherein the relative speed of the belt image bearer and the transfer member is changed into a period waveform such as a sinusoidal wave or a triangular wave in the second state, and the belt image bearer and the transfer member are rotated. Accordingly, as described in the above embodiment, although the first driving torque and the second driving torque include load torque variation, the interference torque can be determined with high precision from the correlation with the period waveform such as a sinusoidal wave or a triangular wave.
The transfer device according to aspects A through F, further including a rotatable first drive transmitting member configured to transmit a drive to the driving roller from the first driving motor; and a rotatable second drive transmitting member configured to transmit a drive to the transfer member from the second driving motor, wherein in the second state, the relative speed of the belt image bearer and the transfer member is changed into the period waveform such as a sinusoidal wave or a triangular wave having a longer period than a rotation period of a relative speed of the belt image bearer, the transfer member, the first drive transmitting member, and the second drive transmitting member. Accordingly, as described in the above embodiment, the interference torque components can be extracted separately from the torque variation of other rotation periods.
The transfer device according to aspect F or G, further including a variation of an estimation value of the first driving torque and an estimation value of the second driving torque in the second state, with respect to an estimation value of the first driving torque and an estimation value of the second driving torque in the first state is measured, a result of the measured variation is approximated into the period waveform, and the relative speed is obtained based on a result of the approximation such that the variation amount of the estimation value of the first driving torque and the estimation value of the second driving torque is less than the predetermined variation amount. Accordingly, as described in the above embodiment, the minimum variation amount can be easily obtained by the zero cross point; however, the precision increases by determining the zero cross point from the entire data by approximating the variation to the period waveform.
The transfer device according to aspect B and aspects D through H, wherein a correlation coefficient of the belt image bearer and the transfer member is derived from a transition of a variation amount of an estimation value of the first driving torque and an estimation value of the second driving torque in the second state, with respect to an estimation value of the first driving torque and an estimation value of the second driving torque in the first state, and when the correlation coefficient indicates an inverse correlation, the relative speed is obtained such that the variation amount is less than the predetermined variation amount. Accordingly, as described in the above embodiment, in a state where there is no interference torque at all, a peculiar speed setting can be avoided.
The transfer device according to aspects A through I, wherein the control unit controls at least one of the first driving motor and the second driving motor such that the belt image bearer and the transfer member are rotated at rotational speeds that attain a relative speed which is obtained by adding a default relative speed to the relative speed at which the variation amount is less than the predetermined variation amount. Accordingly, as described in the above embodiment, an optimum value having high a transfer rate can be set.
The transfer device according to aspects A through J, wherein the predetermined variation amount is within plus or minus five percent of an estimation value of the first driving torque and an estimation value of the second driving torque in the first state. Accordingly, as described in the above embodiment, variations in the speed of the belt image bearer caused by the interference torque can be reduced.
The transfer device according to aspect B and aspects D through K, wherein a phase lag amount is calculated, which is the phase lag amount of a variation of a driving torque estimation value estimated by the first driving torque estimating unit or the second driving torque estimating unit, with respect to a phase obtained changing the relative speed of the belt image bearer and the transfer member into a sinusoidal waveform, and when a variation of the relative speed and a variation of the driving torque estimation value occur simultaneously, a relative speed is derived, at which a variation amount of the driving torque estimation value is small with respect to an estimation value of the first driving torque or an estimation value of the second driving torque in the first state. Accordingly, as described in the above embodiment, even when the torque variation repose of the soft type transfer member is delayed due to a shear deformation, an optimum set speed of the transfer member can be accurately derived by sinusoidal wave modulation in a short time.
An image forming apparatus such as a printer including a toner image forming unit configured to form a toner image; a belt image bearer such as the intermediate transfer belt 5 configured to bear the toner image formed by the toner image forming unit; and a transfer unit such as an intermediate transfer device configured to transfer the toner image from the belt image bearer to a transfer material, wherein the transfer device according to aspects A through L is used as the transfer unit. Accordingly, as described in the above embodiment, the stability in driving a belt image bearer and in conveying a transfer material can be improved, and favorable image forming can be performed.
A program that is read and executed by a transfer device to execute a process, the transfer device being controlled to transfer an image, which is borne on a peripheral surface of a belt image bearer such as the intermediate transfer belt 5 rotatably stretched around a plurality of stretching members including a driving roller such as the driving roller 10, onto a transfer material such as a sheet sandwiched in a transfer nip formed by causing the belt image bearer and a transfer member such as the secondary transfer roller 7 to abut each other, wherein the process includes a process of obtaining and setting, by a relative speed setting unit, a relative speed of the belt image bearer and the transfer member, such that a variation amount is less than a predetermined variation amount, the variation amount being an amount of variation of a value relating to a driving torque of a first driving motor such as the intermediate transfer driving motor 17, which drivingly rotates the driving roller, and a value relating to a driving torque of a second driving motor such as the secondary transfer driving motor 42, which drivingly rotates the transfer member, in a second state in which the belt image bearer and the transfer member are caused to contact each other by a contact separation unit, with respect to a value relating to the driving torque of the first driving motor and a value relating to the driving torque of the second driving motor in a first state in which the belt image bearer and the transfer member are caused to separate from each other by the contact separation unit, and a process of controlling, by a control unit such as the motor control unit 20, at least one of the first driving motor and the second driving motor such that the belt image bearer and the transfer member are rotated at rotational speeds corresponding to the relative speed set by the relative speed setting unit. Accordingly, as described in the above embodiment, the stability in driving a belt image bearer and in conveying a transfer material can be improved.
According to one embodiment of the present invention, a transfer device and an image forming apparatus are provided, which are capable of improving the stability in driving a belt image bearer and in conveying a transfer material.
The transfer device and the image forming apparatus are not limited to the specific embodiments described herein, and variations and modifications may be made without departing from the spirit and scope of the present invention.
The present application is based on and claims the benefit of priority of Japanese Priority Patent Application No. 2015-011633, filed on Jan. 23, 2015, and Japanese Priority Patent Application No. 2015-134777, filed on Jul. 3, 2015, the entire contents of which are hereby incorporated herein by reference.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2015-011633 | Jan 2015 | JP | national |
| 2015-134777 | Jul 2015 | JP | national |
