# Patent

## Title
Inkjet recording apparatus

## Abstract

An inkjet recording apparatus includes a plurality of line heads disposed along a conveyance direction of a recording sheet and including a plurality of nozzles to discharge ink droplets, the plurality of nozzles disposed in a direction perpendicular to the conveyance direction of the recording sheet; a plurality of edge sensors corresponding to respective line heads, to detect a lateral edge of the recording sheet; a plurality of actuators corresponding to the respective line heads, to move to the respective line heads laterally in a sheet width direction; a head position adjustor to determine movement amounts of the respective line heads in accordance with outputs of the plurality of edge sensors; and a failure determiner to obtain outputs of the plurality of edge sensors simultaneously and identify a failure of the plurality of edge sensors based on a combination of the outputs from the plurality of edge sensors.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 14/931,094, filed Nov. 3, 2015, which claims priority pursuant to 35 U.S.C. §119(a) from Japanese patent application numbers 2014-234533 and 2015-130075, filed on Nov. 19, 2014 and Jun. 29, 2015, respectively, the entire contents of each of which are incorporated by reference herein.


BACKGROUND
Technical Field
The present invention relates to an inkjet recording apparatus.
Background Art
An inkjet recording apparatus that forms a color image includes line heads for each color, aligned in a conveyance direction of a sheet of paper (hereinafter, simply a sheet). Each line head includes a plurality of nozzles to discharge ink droplets, disposed in a direction of a width of the sheet perpendicular to the sheet conveyance direction, and discharges ink droplets of each color in a superimposed manner while conveying the sheet to form a color image on the sheet.
When the inkjet recording apparatus forms an image while conveying the long sheet wound in a roll, the sheet wobbles and gets wrinkles, so that precise superimposition of colors is degraded.
A method is disclosed, in which wobbles of an intermediate transfer belt and a sheet conveyance belt, and an index to detect a peripheral edge of the belt, are detected by a single sensor.
There is a large difference between an upper limit of output when detecting the wobble and another upper limit when detecting the index, so that the output as to the wobble and the output regarding the index can be clearly distinguished, thereby preventing erroneously taking one output for the other.
SUMMARY
In one embodiment of the disclosure, provided is an optimal inkjet recording apparatus including a plurality of line heads disposed along a conveyance direction of a recording sheet and including a plurality of nozzles to discharge ink droplets, the plurality of nozzles disposed in a direction perpendicular to the conveyance direction of the recording sheet; a plurality of edge sensors corresponding to respective line heads of the plurality of line heads, to detect a lateral edge of the recording sheet; a plurality of actuators corresponding to the respective line heads, to move to the respective line heads laterally in a sheet width direction; a head position adjustor to determine movement amounts of the respective line heads in accordance with outputs of the plurality of edge sensors; and a failure determiner to obtain outputs of the plurality of edge sensors simultaneously and identify a failure of the plurality of edge sensors based on a combination of the outputs from the plurality of edge sensors.
These and other objects, features, and advantages of the present invention will become apparent upon consideration of the following description of the preferred embodiments of the present invention when taken in conjunction with the accompanying drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an image forming apparatus according to an embodiment of the present invention;
FIG. 2 is a plan view illustrating a principle of reduction of precision in color superimposition due to wobble of a recording sheet;
FIG. 3 is a plan view illustrating a structure to prevent reduction of the precision in the color superimposition;
FIG. 4 is a block diagram of a controller;
FIG. 5 is a side view illustrating a structure of an edge sensor;
FIGS. 6A and 6B illustrate changes of outputs from each edge sensor, in which FIG. 6A shows output changes when the edge sensor 24K is abnormal/has failed and FIG. 6B shows output changes when the conveyed position of the recording sheet is changed;
FIG. 7 is a table explaining combinations of outputs of the edge sensors and determination results;
FIGS. 8A and 8B (correctively referred to as FIG. 8) are a flowchart illustrating how the controller determines that a sensor is abnormal/has failed;
FIG. 9 is a table explaining combinations of outputs of the edge sensors and determination results to identify the sensor abnormality/failure after it is determined that all sensors are abnormal; and
FIG. 10 is a flowchart illustrating how the controller identifies the sensor abnormality/failure after it is determined that all sensors are abnormal.



DETAILED DESCRIPTION
To prevent degradation of precision in color superimposition, for example, an edge of a conveyed sheet for each color is measured by a sensor, and line heads for each color are moved laterally (in the sheet width direction) to adjust for a wobble of the edge of the sheet, so that the discharge position of the ink droplets of each color can be adjusted.
When the sensor fails, however, a correct positional adjustment amount for the line head cannot be obtained, and the precision in the color superimposition is degraded. Whether or not the sensor fails is determined when the sensor output shows an abnormal value. The abnormal value in this case implies a value that does not generally occur. However, even when the sensor has not failed, an abnormal value happens due to changes in the feed position of the sheet due to the wobble or skew.
In this case, an erroneous detection of sensor failure suspends printing operation of the inkjet recording apparatus, thereby decreasing productivity due to down time during which printing operation is suspended.
Considering such a current situation, according to at least one embodiment of the present disclosure, an inkjet recording apparatus prevents erroneous detection as to a sensor failure and reduction of productivity due to occurrence of the down time.
Hereinafter, a preferred embodiment according to the present invention will be described referring to accompanying drawings.
FIG. 1 illustrates an inkjet recording system 15. The inkjet recording system 15 includes a sheet feeder 2 to feed a recording sheet 1 as a recording medium and an inkjet recording apparatus 14 according to the present embodiment, and a sheet collector 13.
The inkjet recording apparatus 14 is an on-demand line scan-type inkjet recording apparatus.
The sheet feeder 2 includes a recording sheet 1 wound in a roll shape and rotatably supported therein. The recording sheet 1 is fed out at a high speed from the sheet feeder 2, a predetermined color image is formed thereon, and the recording sheet 1 is sequentially rolled up by the sheet collector 13 and is collected.
The sheet feed device inside the inkjet recording apparatus 14 will be described.
The inkjet recording apparatus 14 includes a regulator 3 to regulate a position of the recording sheet 1 laterally, an infeed device 4 including a drive roller and a driven roller, and a dancer roller 5 that floats up and down with the tension on the recording sheet 1, to thereby output a positional signal.
The inkjet recording apparatus 14 further includes an Edge Position Control (EPC) 6 to control a wobble of the recording sheet 1, a wobble amount detector 7 to detect the wobble amount for use in a feedback loop, an outfeed device 11 including a drive roller and a driven roller that rotate at a constant speed to convey the recording sheet 1 at a predetermined speed, and a puller 12 including a drive roller and a driven roller that discharge the recording sheet 1 outside the apparatus.
The sheet feed device as described above performs positional detection of the dancer roller 5, controls rotation of the infeed device 4, and keeps the tension of the recording sheet 1 while being conveyed constant, that is, the present sheet feed device is a tension controlling type feeder.
Further, the inkjet recording apparatus 14 includes an inkjet recording head module 8, a platen 9 disposed opposite the inkjet recording head module 8, and a dryer 10.
The inkjet recording head module 8 includes line heads for respective colors each including a plurality of print nozzles to discharge ink droplets, disposed along an entire print area laterally of the recording sheet 1 perpendicular to the conveyance direction thereof.
Color printing is performed by each line head of respective colors of black (K), cyan (C), magenta (M), and yellow (Y), and the nozzle surface of each line head is supported above the platen 9 with a predetermined gap in between.
The inkjet recording head module 8 discharges ink droplets in synchrony with the sheet conveyance speed, so that a color image is formed on the recording sheet 1.
In the present embodiment, the dryer 10 employs a non-contact drying device disposed slightly apart from the recording sheet 1, but a contact-type drying device may also be used.
Referring now to FIG. 2, reduction of the precision in color superimposition due to a wobble of the recording sheet 1 will be described.
The inkjet recording head module 8 includes a line head 16K to discharge a black ink, a line head 16C to discharge a cyan ink, a line head 16M to discharge a magenta ink, and a line head 16Y to discharge a yellow ink.
Along a conveyance direction indicated by an arrow F of the recording sheet 1, the line head 16K, the line head 16C, the line head 16M, and the line head 16Y are disposed in this order from upstream to downstream.
As indicated by a broken line 18, each position of the line head 16K, the line head 16C, the line head 16M, and the line head 16Y in the sheet width direction is aligned.
When the recording sheet 1 wobbles relative to a reference line 20 in the conveyance direction, a printed position of each color of K, C, M, and Y deviates as illustrated by lines 22, and as a result, leading to a reduction of the precision in the color superimposition.
Referring now to FIGS. 3 and 4, a structure to prevent reduction of the precision in the color superimposition will be described.
The structure to prevent a reduction of the precision in the color superimposition includes, as illustrated in FIGS. 3 and 4, an edge sensor 24, a driver 28, and a controller 26. The edge sensor 24 detects an end of the recording sheet 1 laterally, the driver 28 serves as a head moving means to move the line head 16 in the sheet width direction, and the controller 26 serves as a head position adjustor to determine a movement amount of the line head 16 depending on an output from the edge sensor 24.
As illustrated in FIG. 4, an actuator 29 as a head driving means, the driver 28 to drive the actuator 29, and the edge sensor 24 are disposed for each color. Specifically, an edge sensor 24 is provided to each line head.
An output of the edge sensor 24K mounted to the line head 16K defines a reference position. With the output from the edge sensor 24K as a reference position, the controller obtains a difference from outputs from the edge sensors 24C, 24M, and 24Y mounted to other line heads 16C, 16M, and 16Y, as a movement amount of the line head.
Herein, the edge sensor 24K is denoted as K sensor, the edge sensor 24C is denoted as C sensor, the edge sensor 24M is denoted as M sensor, and the edge sensor 24Y is denoted as Y sensor.
The controller 26 adjusts positions of the line heads 16C, 16M, and 16Y laterally in the sheet width direction via each driver 28C, 28M, or 28Y, based on the movement amount of each line head 16C, 16M, or 16Y.
As configured as such, even when the recording sheet 1 wobbles, a relative position of the recording sheet 1 and the line head 16 does not change, thereby preventing the precision of color superimposition from deteriorating.
As illustrated in FIG. 5, each edge sensor 24 (24K, 24C, 24M, 24Y) is a reflection-type optical sensor including a light emitting element 24a and a light receiving element 24b. 
The detection range of the edge sensor 24 is 10 mm according to the present embodiment, and the edge sensor 24 outputs 5V when detecting 10 mm, and outputs 0V when detecting 0 mm according to analog conversion. Thus, when the recording sheet 1 is not present in the detection area of the edge sensor 24, the edge sensor 24 outputs 5V, and when the recording sheet 1 covers all the detection area of the edge sensor 24, the edge sensor 24 outputs 0V.
Using FIGS. 6A and 6B, a difference of the output from each edge sensor 24 when the edge sensor 24K is abnormal/has failed and when the conveyed position of the recording sheet 1 laterally is changed, will be described.
In the graphs of FIGS. 6A and 6B, a vertical axis shows output voltage of the edge sensor 24 and a horizontal axis shows an elapsed time. The output voltage of 4.9V to 5.0V from the edge sensor 24 is set as an abnormal range A1 and the output voltage of 0.0V to 0.1V an abnormal range A2. Specifically, an upper limit abnormal range and a lower limit abnormal range, that is, two abnormal ranges are set with a normal range in between, in the sensor output range.
The abnormal range can be set arbitrarily. The controller 26 serving as a failure determination means determines whether or not the sensor output is within the abnormal range based on the conveyance time period of the recording sheet 1 from the edge sensor 24K farthest upstream in the conveyance direction of the recording sheet 1 to the edge sensor 24Y farthest downstream.
The above conveyance time period as an abnormal value determination time period changes depending on the conveyance speed of the recording sheet 1, and is five seconds when the conveyance speed is fifty meters per minute (50 m/s). It is to be noted that the abnormal value determination time period can be set arbitrarily.
As illustrated in FIG. 6A, during the conveyance of the recording sheet 1, when an output 510 of the edge sensor 24K enters the abnormal range A2 of 0.0V to 0.1V, if the edge sensor 24K alone continues to be in the abnormal range of 0.0V to 0.1V after five seconds, the controller 26 determines that the edge sensor 24K is abnormal/has failed. As illustrated in FIG. 6B, when an output 510 of the edge sensor 24K enters the abnormal range A2 of 0.0V to 0.1V, if the output 510 of the edge sensor 24K, an output 511 of the edge sensor 24C, an output 512 of the edge sensor 24M, and an output 513 of the edge sensor 24Y are all within the abnormal range of 0.0V to 0.1V after five seconds, the controller 26 determines that the conveyance position changes due to wobbling of the recording sheet 1.
However, the change of the conveyance position of the recording sheet 1 is obtained by outputs of the abnormal value from the edge sensors 24 sequentially from the edge sensor 24K.
Accordingly, after the conveyance distance of the recording sheet 1 is monitored and the edge sensor 24K outputs an abnormal value, the time period of the conveyance distance from the position of the edge sensor 24K to the position of the edge sensor 24Y is defined as the abnormal value determination time period.
As described above, the controller 26 simultaneously recognizes outputs from each edge sensor 24, and determines the failure of the edge sensor 24 based on the relation between outputs from each edge sensor 24. Specifically, the controller 26 determines the failure based on a determination result whether or not each output from each edge sensor 24 is within the abnormal range.
FIG. 7 is a table explaining combinations of outputs of the edge sensors 24 for each color.
If all the outputs from the K sensor, C sensor, M sensor, and Y sensor are within the normal range of from 0.1V to 4.9V, which corresponds to Combination #1, the determination result is normal.
If the outputs of all sensors are within the abnormal range A1 of from 4.9V to 5.0V, which corresponds to Combination #2, the determination result is that the conveyance position of the recording sheet 1 has changed, or that there is no sheet.
If the outputs of all sensors are within the abnormal range A2 of from 0.0V to 0.1V, which corresponds to Combination #3, the determination result is that the conveyance position of the recording sheet 1 has changed.
When the output of one sensor alone is within the abnormal range, any of the combinations 4 to 11 is determined. When a combination other than the above occurs, it is determined that such a case is classified in Combination #12 and all sensors are abnormal.
The combination patterns as illustrated in FIG. 7 are stored in a memory 27 of the controller 26 as a control table, and the controller 26 determines which combination pattern the outputs from each of the edge sensors 24 correspond to, and selects a corresponding determination result.
When it is determined that the sensor is abnormal/has failed, the controller 26 suspends operation of the inkjet recording apparatus 14 and displays a message prompting a user to replace the failed sensor.
FIGS. 8A and 8B are a flowchart illustrating how the controller 26 determines that a sensor is abnormal/has failed. Such a flowchart is previously generated and is stored in the memory 27.
First, whether or not all the sensor outputs are within the normal range is determined (in step S101). When the output from any sensor is within the abnormal range, the controller 26 waits during a time period to feed the sheet by a distance from the position of K sensor to the position of Y sensor (S102) to prevent a detection error due to a damaged sheet.
Thereafter, whether or not all the sensor outputs are within the normal range is again determined (S103), and it is determined whether or not all the sensor outputs are within the abnormal range (S104) when any sensor output is within the abnormal range.
If all sensor outputs are within the abnormal range and the abnormal range corresponds to A1, the determination result is that the conveyance position of the recording sheet 1 has changed, or that there is no sheet (S105, S106).
If the abnormal range corresponds to A2, the determination result is that there is no sheet (S107, S108). If the abnormal ranges include A1 and A2 in combination, it is determined that all the sensors are abnormal (S109).
If any of the sensor output is within abnormal range, it is determined whether or not the sensor is abnormal/has failed from sequentially K-sensor. If K-sensor output alone is within the abnormal range which corresponds to A1, it is determined that the K-sensor is abnormal A1. If the abnormal range corresponds to A2, it is determined that the K-sensor is abnormal A2 (S111 to S113).
Similarly to the case of the K-sensor, the C-sensor, M-sensor, and Y-sensor are determined (S114 to S125).
If not all but some sensor outputs are within abnormal range, it is determined that all sensors are abnormal (S126).
FIG. 9 is a table explaining combinations of outputs of the edge sensors 24 for each color to identify the sensor abnormality/failure after it is determined that all sensors are abnormal based on Combination #12 in the determination table of FIG. 7 or the step S126 in FIG. 8.
When the output of one sensor alone is within the abnormal range, either of the combinations 13 to 28 is determined.
When a combination other than the above occurs, it is determined that such a case is classified as Combination #12 meaning that all sensors are abnormal similarly to the determination table of FIG. 7.
FIG. 10 is a flowchart illustrating how the controller 26 identifies the sensor abnormality/failure after it is determined that all sensors are abnormal based on FIGS. 7 and 8. Such a flowchart is previously generated and is stored in the memory 27.
When it is determined that all sensors are abnormal based on FIGS. 7 and 8, whether or not the sensor output is within a different range other than other sensor outputs is determined (in step S210 to S217).
When the plural sensor outputs are within a different range, it is determined that all sensors are abnormal as well (S218).
In the present embodiment, the controller 26 serves also as a failure determination means; but the failure determination means may be disposed separately.
In addition, as an edge sensor, an area laser sensor or the like may be employed.
Preferred embodiments of the present invention have been described heretofore; however, the present invention is not limited to the described embodiments and various modifications are possible within the scope of claims unless explicitly limited in the description.
Effects described in the present embodiments are examples of preferred results obtained by the embodiments of the present invention and are not limited to what has been described herein.
Additional modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.

## Claims

1. An inkjet recording apparatus, comprising:
a plurality of line heads positioned along a conveyance direction of a sheet, each line head of the plurality of line heads including a plurality of nozzles, each nozzle of the plurality of nozzles configured to discharge ink droplets, the plurality of nozzles positioned in a width direction perpendicular to the conveyance direction of the sheet;
a plurality of sensors, each sensor of the plurality of sensors corresponding to a separate line head of the plurality of line heads, each sensor of the plurality of sensors configured to detect a position of the sheet in the width direction; and
a controller configured to,
receive an output from each sensor of the plurality of sensors, such a that a plurality of outputs is received, and
identify a first failure associated with at least one sensor of the plurality of sensors, based on the received plurality of outputs.

2. The inkjet recording apparatus of claim 1, further comprising:
a plurality of actuators, each actuator of the plurality of actuators configured to move each line head of the plurality of line heads in the width direction, respectively.

3. The inkjet recording apparatus of claim 1, wherein the controller is configured to determine a movement magnitude associated with each line head of the plurality of line heads, based on the received plurality of outputs.

4. The inkjet recording apparatus of claim 1, wherein,
each received output includes an output range;
the output range includes a first abnormal range; and
the controller is further configured to,
identify a second failure based on whether the received plurality of outputs include output ranges that are within the first abnormal range, respectively.

5. The inkjet recording apparatus of claim 4, wherein the controller is further configured to,
determine whether each sensor of the plurality of sensors is not associated with at least one failure of the first failure and the second failure; and
determine whether a change in a conveyance position of the sheet is within the first abnormal range, based on the received plurality of outputs.

6. The inkjet recording apparatus of claim 4, wherein the controller is further configured to,
identify a third failure based on a first received output from a first sensor of the plurality of sensors, the first received output indicating that the first sensor is within the first abnormal range, the third failure indicating that the first sensor has failed.

7. The inkjet recording apparatus of claim 4, wherein the controller is further configured to,
determine whether the received plurality of outputs are within the first abnormal range based on a conveyance time period associated with the sheet, the conveyance time period including a time period associated with a movement of the sheet in the conveyance direction from a first sensor of the plurality of sensors to a second sensor of the plurality of sensors, the first sensor being a farthest upstream sensor of the plurality of sensors, and the second sensor being a farthest downstream sensor of the plurality of sensors.

8. The inkjet recording apparatus of claim 4, further comprising:
a memory configured to store a control table, the control table including a plurality of combination patterns and a determination result associated with each combination pattern of the plurality of combination patterns, the plurality of combination patterns being based on a difference of the determination result as to whether the received plurality of outputs are within the first abnormal range;
wherein the controller is further configured to identify a third failure based on the control table.

9. The inkjet recording apparatus of claim 8, wherein,
the memory is configured to and store a flowchart in the memory; and
the controller is further configured to determine, based on the flowchart, whether the received plurality of outputs are within the first abnormal range.

10. The inkjet recording apparatus of claim 4, wherein the controller is further configured to determine that a first sensor of the plurality of sensors has failed, based on a determination that a received output from the first sensor is in a first range and a received output from one or more remaining sensors of the plurality of sensors is in a second range, the first range being different from the second range.

11. The inkjet recording apparatus of claim 4, wherein,
the output range of the received output of each sensor of a first sensor of the plurality of sensors and a second sensor of the plurality of sensors includes a normal range, the first abnormal range and a second abnormal range;
the first abnormal range is set as an upper limit, the upper limit being above the normal range; and
the second abnormal range is set as a lower limit, the lower limit being below the normal range.

12. A method, comprising:
receiving a plurality of outputs from a plurality of sensors, each output being received from a separate sensor of the plurality of sensors, each sensor of the plurality of sensors corresponding to a separate line head of a plurality of line heads positioned along a conveyance direction of a sheet, each line head including a plurality of nozzles positioned in a width direction perpendicular to the conveyance direction of the sheet, each nozzle configured to discharge ink droplets, each sensor configured to detect a position of the sheet in the width direction; and
identifying a first failure associated with at least one sensor of the plurality of sensors, based on the received plurality of outputs.

13. The method of claim 12, further comprising:
determining a movement magnitude associated with each line head of the plurality of line heads, based on the received plurality of outputs.

14. The method of claim 12, wherein,
each received output includes an output range, the output range including a first abnormal range; and
the method further includes,
identifying a second failure based on whether the received plurality of outputs include output ranges that are within the first abnormal range, respectively.

15. The method of claim 14, further comprising:
determining whether each sensor of the plurality of sensors is not associated with at least one failure of the first failure and the second failure; and
determining whether a change in a conveyance position of the sheet is within the first abnormal range, based on the received plurality of outputs.

16. The method of claim 14, further comprising:
identifying a third failure based on a first received output from a first sensor of the plurality of sensors, the first received output indicating that the first sensor is within the first abnormal range, the third failure indicating that the first sensor has failed.

17. The method of claim 14, further comprising:
determining whether the received plurality of outputs are within the first abnormal range based on a conveyance time period associated with the sheet, the conveyance time period including a time period associated with a movement of the sheet in the conveyance direction from a first sensor of the plurality of sensors to a second sensor of the plurality of sensors, the first sensor being a farthest upstream sensor of the plurality of sensors, and the second sensor being a farthest downstream sensor of the plurality of sensors.

18. The method of claim 14, further comprising:
determining that a first sensor of the plurality of sensors has failed, based on a determination that a received output from the first sensor is in a first range and a received output from one or more remaining sensors of the plurality of sensors is in a second range, the first range being different from the second range.

19. The method of claim 14, wherein,
the output range of the received output of each sensor of a first sensor of the plurality of sensors and a second sensor of the plurality of sensors includes a normal range, the first abnormal range and a second abnormal range;
the first abnormal range is set as an upper limit, the upper limit being above the normal range; and
the second abnormal range is set as a lower limit, the lower limit being below the normal range.