Abstract:
An image forming apparatus is configured to develop a latent image corresponding to a line-like image of a predetermined pitch on photosensitive bodies provided for respective colors for a color image formation and rotatable about a predetermined axis and transfer the developed image to a transfer belt. The apparatus detects the presence or absence of any line from the transferred line-like image for respective colors and calculates a phase displacement, from a phase of a reference photosensitive drum, of the phases of the other photosensitive drums on the basis of waveforms calculated from the detected line pitches for respective colors. The apparatus adjusts the rotation positions of these other photosensitive drums to allow the phases of these other photosensitive bodies to be substantially matched to the phase of that given photosensitive body.

Description:
The present application is a continuation of U.S. application Ser. No. 10/391,621, filed Mar. 20, 2003, now U.S. Pat. No. 6,788,914, the entire contents of which are incorporated herein by reference. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to an image forming apparatus and, in particular, to an image forming apparatus for preventing color mismatching, by rotating photosensitive bodies for respective colors in a matched state, and a method for preventing a color mismatch in the image forming apparatus. 
   2. Description of the Related Art 
   Known is an image forming apparatus for forming a color image by arranging image forming sections for colors such as yellow (Y), magenta (M), cyan (C) and black (K) near a transfer belt along a running direction of the transfer belt and allowing images based on image data for respective colors to be color matched. The respective image forming section of this apparatus comprises a photosensitive drum, a control section configured to allow a light exposure to be applied to the photosensitive body, a developing agent supply section, and so on. In the image forming apparatus thus formed, it is considered necessary to set the portions of respective drums over a transfer belt and, by drawing lines on the transfer belt with an integral multiple of a circumference length of the drum and detecting the lines, a light exposure timing is controlled to prevent any adverse effect exerted by a rotation vibration on a transfer surface during a rotation of the drum about a drum shaft. By doing so, an image of respective color components is transferred to the transfer belt, avoiding color mismatching. 
   In the case where, however, a rotation vibration is involved in the photosensitive drum itself, an image interval to be formed on the transfer belt varies during a rotation cycle of the photosensitive drum and there occurs a matched image on the transfer belt at some area but there sometimes arises a color mismatch on the transferred image at other areas. As a result, image quality formed in the image forming apparatus is somewhat lowered. 
   Therefore, there is a need for an image forming apparatus which prevent an image from being transferred from the photosensitive drum for respective colors onto a transfer surface throughout the rotation cycle of the drum in a color-mismatched state. 
   BRIEF SUMMARY OF THE INVENTION 
   According to an aspect of the present invention, there is provided an image forming apparatus comprising photosensitive bodies each rotatable about a predetermined axis and configured to from a color image for respective colors; light exposure sections provided for the respective colors and configured to form a latent image corresponding to a line-like image of a predetermined pitch in an axial direction of the respective photosensitive body; developing sections provided for the respective colors and configured to supply a developing agent corresponding to the respective photosensitive body to allow the latent image which corresponds to the line-like image of the predetermined pitch to be developed; and a transfer belt configured to allow the developed line-like image of a predetermined pitch to be transferred. Further, the apparatus includes sensors each arranged at a predetermined position and configured to detect the presence or absence of any line of the line-like image for the respective colors transferred to the transfer belt, and an adjusting section configured to, based on the phases of waveforms for respective colors calculated from the pitch of the lines which has been detected, relative to the phase of a given photo-sensitive body adjust the rotation positions of the other photosensitive bodies to allow the phases of the other photosensitive bodies to be substantially matched to the phase of the given photosensitive body. 
   Objects and advantages of the invention will become apparent from the description which follows, or may be learned by practice of the invention. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
     The accompanying drawings illustrate embodiments of the invention, and together with the general description given above and the detailed description given below, serve to explain the principles of the invention. 
       FIG. 1  is a view showing a general arrangement of a color copier according to one embodiment of the present invention; 
       FIG. 2  is a view showing an arrangement of a transfer belt and respective image forming section; 
       FIG. 3  is a view showing a drive unit and drum unit; 
       FIG. 4  is a view showing another practical form of drive unit and drum unit; 
       FIG. 5  is a view showing another practical form of drive unit and drum unit; 
       FIG. 6  is a view showing a phase matching unit; 
       FIG. 7  is a view showing a reference position of a photosensitive drum; 
       FIG. 8  is a view showing one practical form of an arrangement of sensors; 
       FIG. 9  is a view showing a general control structure of the color copier; 
       FIG. 10  is a flow chant showing the process of a control section; 
       FIG. 11  is a view showing waveforms calculated from line intervals before a phase adjustment; 
       FIG. 12  is a view showing waveforms calculated from line intervals after the phase adjustment; 
       FIG. 13A  is a view showing another form of a phase matching section; 
       FIG. 13B  is a view showing one form of a dial; and 
       FIG. 14  is a view showing an arrangement of a sensor configured to read out color information or density information. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   With reference to the drawing an explanation will be made below about the respective embodiments of the present invention. 
   (First Embodiment) 
     FIG. 1  is a view diagrammatically showing a structure of a four-series type color copier  1  having a plurality of electrophotographic image forming sections arranged relative to the same transfer belt. The color copier  1  has a scanner section  2 , a printer section  3  and a sheet supply section  4 . The color copier  1  has a document glass  2   a  where a document, such as a to-be-copied material, is placed. The copier scans an image of the document on the document glass  2   a , applies a predetermined process to the scanned image data and, by doing so, forms a color image. As a type of image data used for forming an image in a color copier  1 , use is made of, for example, image data of yellow (Y), magenta (M), cyan (C) and black (K) color components which are generated from red (R), green (G), and blue (B) colors of image data corresponding to a scanned document image. 
   The printer section  3  has image forming sections  5 Y,  5 M,  5 C and  5 K configured to form an image corresponding to the Y, M, C and K color components. The image forming sections  5 Y,  5 M,  5 C and  5 K are arranged at predetermined intervals in an opposed relation relative to an endless type transfer belt  6  for conveying a sheet, etc., and at predetermined intervals L relative to the belt along a plane direction of the transfer belt  6 . It is to be noted that  FIG. 2  shows an arrangement of the transfer belt  6  and image forming sections  5 Y,  5 M,  5 C and  5 K. In this embodiment, the image forming sections  5 Y,  5 M,  5 C and  5 K are arranged in that order as viewed from an upstream side of a sheet conveying direction. 
   In the image forming sections  5 Y,  5 M,  5 C and  5 K, corresponding photosensitive drum  7 Y,  7 M,  7 C and  7 K are provided so as to allow latent image corresponding to image data of Y, M, C and K to be formed. Further, in the image forming sections  5 Y,  5 M,  5 C and  5 K, developing units  8 Y,  8 M,  8 C and  8 K are incorporated each with a toner of a respective color (Y, M, C, K) held there to allow the latent images formed on the photosensitive drums  7  to be made a visible image. 
   Around the photosensitive drums  7 Y,  7 M,  7 C and  7 K of the image forming sections  5 Y,  5 M,  5 C and  5 K, transfer units  9 Y,  9 M,  9 C and  9 K are respectively arranged to allow corresponding toner images, which are formed on the corresponding drums  7 , to be transferred, under electrostatic attraction, to a conveying sheet on a transfer belt  6  in a sandwiched state. Further around the photosensitive drums  7 Y,  7 M,  7 C and  7 K cleaners  10 Y,  10 M,  10 C and  10 K, charge eliminators  11 Y,  11 M,  11 C and  11 K and chargers  12 Y,  12 M,  12 C and  12 K are arranged respectively, the cleaner being used to eliminate a residual toner on the drum left after a toner image has been transferred to the sheet by the transfer unit, the charge eliminator being used to eliminate a charge remaining on the drum after the toner has been cleaned by the cleaner, and the charger being used to apply a predetermined charge to the drum. 
   The transfer belt  6  is tensioned between a drive roller  13   a  and a driven roller  13   b . By rotating the drive roller  13   a  the transfer belt  6  is run in a predetermined direction. At a predetermined position near the driven roller  13   b , an attraction charger  14  is provided to electrostatically charge the sheet to allow the sheet to be attracted to the transfer belt  6 . At a somewhat downstream side in a sheet conveying direction at a position where a sheet from the sheet supply section  4  is set in contact with the transfer belt  6 , an attraction roller  19  is arranged to allow the sheet to be set in close contact with the transfer belt  6  which is electrically charged by the attraction charger  14 . 
   At a predetermined position above each image forming section ( 5 Y,  5 M,  5 C,  5 K) of the printer section  3 , a light exposure unit  15  is provided to allow an image forming signal, which is image-processed for each color image data by a later-described control section  51 , to be illuminated with a corresponding color laser beam at an image forming timing. In accordance with the image forming signal corresponding to each color, the light exposure unit  15  allows its own emitting laser beam to, while deflecting the beam by a polygon mirror  16   a , etc., in an axial direction of the respective photosensitive drum ( 7 Y,  7 M,  7 C and  7 K), be directed by a plurality of cylindrical lenses  16   b  and plane mirrors  16   c ,  16   d , etc., onto the photosensitive drums  7 Y,  7 M,  7 C,  7 K in a sequential fashion. By doing so, electrostatic latent images corresponding to the respective colors are formed on the photosensitive drums  7 Y,  7 M,  7 C and  7 K. 
   In a direction in which the sheet is conveyed on the transfer belt  6 , a fixing unit  17  is provided for allowing a toner image of four colors borne on the sheet to be fixed to the sheet. The fixing unit  17  comprises a heating roller having an inside heater and a pressing roller (not shown). The fixing unit  17  allows a sheet to pass between the heating roller and the pressing roller, while applying a predetermined pressure between the heating roller and the pressing roller, and electrostatically deposited toner on the sheet is fixed to the sheet under both heating and pressure. Thus, the color copier  1  forms a color image on the sheet. 
   Further, the color copier  1  has a color mode for forming a color image and a monochrome mode for forming a monochrome image. In the color mode, a color image is so formed that the photosensitive drums  7 Y,  7 M,  7 C and  7 K for Y, M, C and K colors are set in close contact with the transfer belt  6 . In the monochrome mode, the photosensitive drum  7 K for black color K is set in close contact with the transfer belt  6  to form an image, in which case the photosensitive drums  7 Y,  7 M and  7 C for Y, M, C colors are set away from the transfer belt  6 . 
     FIG. 3  is a view showing a practical form when any of the photosensitive drums  7 Y,  7 M,  7 C and  7 K are incorporated into the color copier  1 . 
   A drum unit  21  is provided which has a photo-sensitive drum  7  and a drive unit  20  configured to transmit a drive force to the photosensitive drum  7  from a drive source such as a motor, not shown. By connecting a coupling member  22   a  of the drive unit  20  to a coupling member  22   b  of a drum unit  21 , a drive force is transmitted from the drive unit  20  to the drum unit  21 . The coupling member  22   a  of the drive unit  20  is coupled to a shaft  23  which is in mesh with a gear  24 . The gear  24  is rotationally driven upon receipt of a drive force from the drive source such as a motor, not shown. The shaft  23  is supported by a plurality of bearings  25 . A compression spring  28  is provided between a moving plate  26 , which configured to be moved by a solenoid mechanism section  27 , provided at a back surface of the coupling member  22   a  and the bearing  25  nearest on the coupling member  22   a  side to the moving plate. The drum  7  is rotated about a shaft  29 . The shaft  29  is journalled by a plurality of bearings  30 . 
   The solenoid mechanism section  27  operates a solenoid mechanism by a given instruction from a later-described control section  51  to move the moving plate  26  away from the photosensitive drum  7 . In synchronism with the moving of the moving plate  26 , the coupling member  22   a  is moved in a direction away from the drum unit  21 . By doing so, the drive force from the gear  24  ceases to be transmitted to the drum unit  21 . Further, when the operation of the solenoid mechanism is stopped by a given instruction of the control section  51 , the coupling member  22   a  is moved under a reaction force of the compression spring  28  to be connected to the coupling member  22   b . By doing so, the drive force from the gear  24  is transmitted to the photosensitive drum  7 . 
   The mechanism for transmitting a drive force from the drive unit  20  to the drum unit  21  may be so configured as to transmit a drive force by means of an electromagnetic clutch  35 , as shown in FIG.  4 . Further, a drive force transmitting structure may be provided by a one-way clutch  36 , configured to be rotated only in one direction and configured to be formed of shaft  23  and shaft  29  as shown in FIG.  5 . 
     FIG. 6  shows a mechanism of a phase matching section  31  for adjusting the phase of the photo-sensitive drum  7 . The phase matching section  31  is coupled to the shaft  29  of the photosensitive drum  7 . The phase matching section  31  is so arranged that a gear  31   a  rotated in synchronism with the rotation of the shaft  29  of the photosensitive drum  7  is set in mesh with a gear  31   c  which is driven by a drive source of motor  31   b . The motor  31   b  has its drive controlled by the control section  51 . The phase matching section  31  is of a one-way clutch type such that a drive force from the motor  31   b  is transmitted only when the gear  31   c  is rotated in a direction opposite to that in which the gear  31   a  is rotated. Further, a drum rotation angle read-out sensor  32  is set at a predetermined position near the shaft  29  to read out the rotation angle of the photosensitive drum  7 . 
   It is to be noted that, although the drum rotation angle read-out sensors  32 Y,  32 M,  32 C and  32 K are provided in a way to correspond to the photosensitive drums  7 Y,  7 M,  7 C and  7 K for respective colors, the phase matching section  31  is provided in a way to correspond to the photosensitive drums  7 Y,  7 M and  7 C other than that photosensitive drum serving as a standard for phase adjustment. This is because the rotation positions of these other photosensitive drums are adjusted to the reference photosensitive drum. As this standard drum, use is made, in this embodiment, of the photosensitive drum  7 K for K color. 
   Further, the rotation position of the photo-sensitive drum  7  has its given rotation standard position initially set as shown in FIG.  7 . The drum rotation angle reading-out sensor  32  reads out the rotation angle of the photosensitive drum  7  from the standard position. The rotation angle from the standard position is indicated by θ. 
     FIG. 8  shows one practical arrangement of sensors at a portion of a downstream side of the transfer belt  6  which read out respective color lines for image formation on the transfer belt. A bar-like member  41  is provided somewhat above the transfer belt in a direction orthogonal to the longitudinal direction of the transfer belt  6 . Sensors  42   a ,  42   b  are arranged for detecting each color line transferred to a corresponding position at both end portions of the transfer belt  6 . 
   As shown in  FIG. 9 , a schematic control structure of the color copier  1  comprises the control section  51 , scanner section  2 , memory section  52 , operation panel  53 , sheet supply section  4 , interface (I/F) section  54  and printer section  3 . Further, the control section  51 , scanner section  2 , memory section  52 , operation panel  53 , sheet supply section  4 , printer section  3 , and I/F section  54  are connected together via a bus line  56 . 
   The control section  51  comprises a CPU, ROM, RAM, etc., not shown. Based on a control program stored in the ROM, the control section  51  implements various kinds of operations on the color copier  1 . An adjusting section  57 , which adjusts a color mismatching, is provided in the control section  51 . 
   The scanner section  2  reads out image data from a document on the document glass  2   a  as set out above. The memory section  52  stores image data, etc., of the document read out by the scanner section  2 . The sheet supply section  4  comprises cassettes for holding sheets to be supplied to the printer section  3 , a mechanism for supplying a sheet to the printer section  3 , etc., as shown in FIG.  1 . 
   The operation panel  53  receives a user&#39;s instruction from an input section  53   a  under control of the control section  51 . Further, the operation panel  53  displays information to be notified to the user at a display section  53   b  under control of the control section  51 . A switch is set by the user to an ON/OFF state. With the switch is in the ON state, a power source is rendered ON on the color copier  1 . The I/F section  54  is used to be connected to an external device, not shown. 
   The printer section  3  comprises the image forming sections  5 Y,  5 M,  5 C and  5 K for respective colors Y, M, C and K as set out above. In the image forming sections  5 Y,  5 M,  5 C, drum rotation angle reading-out sensors  32 Y,  32 M and  32 C and phase matching sections  31 Y,  31 M and  31 C are provided, respectively. The image forming section  5 K includes a drum section angle reading-out sensor  32 K but does not have a phase matching section because it includes the reference photosensitive drum  7 K. Further, a signal from the respective drum rotation reading-out sensor  32  is sent to the adjusting section  57  and a signal from the adjusting section  57  is sent to the phase matching section  31 . 
   With reference to  FIG. 10 , an explanation will be made below about the process of the adjusting section  57  for adjusting the rotation position of the photo-sensitive drum  7  of each color. 
   In step ST  101 , the adjusting section  57  detects whether on not the power source is turned ON by rendering the switch  550 N. If the adjusting section detects the ON state of the power source, in step ST  202 , the adjusting section  57  controls the printer section  3  to form, for respective colors, lines at predetermined intervals at both end portions of the transfer belt  6  in a longitudinal direction of the photosensitive drum  7 . Although the lines are formed on the transfer belt  6 , lines for respective colors may be formed on a sheet coming from the sheet supply section  4 . If such lines are formed on a sheet, then the sheet involved becomes wasteful but it is advantageous to accurately detect the intervals between the lines by the sensors  42   a ,  42   b.    
   In step ST  103 , the adjusting section  57  calculates, based on the information from the sensors  42   a ,  42   b , the interval of lines for respective colors formed on the transfer belt  6 .  FIG. 11  conceptually shows waveforms which are calculated from the line intervals for respective colors with the line interval and transfer belt&#39;s running direction plotted on the ordinate and abscissa, respectively. The phase displacement of the waveforms are caused by the rotation vibration of the photosensitive drum  7 . Since it is caused by the rotation vibration of the drum  7 , a waveform of substantially the same locus is described for each one cycle rotation of the drum  7 . 
   In step ST  104 , the adjusting section  57  calculates a phase displacement from the calculated waveform as described above. That is, with a waveform of the K color as a reference, calculation is made about each phase difference from those waveforms for Y, M and C colors. The phase of the waveform is such that, when the photosensitive drum  7 K for the K color, for example, is set to a position of angle θ, the interval of the waveform of the photosensitive drum  7 C is set to the widest position. At this time, with θ′ given as the widest waveform interval for the photosensitive drum  7 C spaced a distance L apart on the transfer belt  6 , a phase difference is so calculated as to satisfy θ′=θ+2πL/πD (D: the diameter of the respective photosensitive drum) with respect to the drum  7 K. 
   In step ST  105 , the adjusting section  57  calculates the photosensitive drum&#39;s rotation angle based on the phase displacement between the photo-sensitive drum  7 K as a standard and the photosensitive drum  7 Y,  7 M and  7 C. 
   In step ST  106 , the adjusting section  57  sets a monochrome mode for performing an image formation on the color copier  1 . In this mode setting, the photo-sensitive drum  7 K is set in close contact with the transfer belt  6  but the photosensitive drums  7 Y,  7 M and  7 C are set away from the transfer belt  6 . In this step ST  106 , even if the monochrome mode is not set, it is possible to replace it by an operation for spacing all the photosensitive drums  7 Y,  7 M,  7 C and  7 K away from the transfer belt  6 . 
   In step ST  107 , the adjusting section  57  operates the solenoid mechanism section  27  of the drive units  20 Y,  20 M and  20 C and prevents a drive force from being transmitted from the gear  24 . 
   In step ST  108 , the adjusting section  57  controls the phase matching sections  31 Y,  31 M and  31 C. That is, the rotation number of the motor for the phase matching sections  31 Y,  31 M and  31 C is rotation-controlled by the rotation angle calculated in step ST  104 . The rotation number of the photosensitive drums  7 Y,  7 M and  7 C at this time is read out by the rotation angle reading-out sensor  32 Y,  32 M and  32 C and, when the rotation is made through the calculated rotation angle, the adjusting section  57  stops the photosensitive drums  7 Y,  7 M and  7 C from being rotated. 
   In step ST  109 , the adjusting section  57  operates the solenoid mechanism section  27  of the drive units  20 Y,  20 M and  20 C and a drive force is transmitted from the corresponding gear  24 . This completes the process for adjusting the position of the drum  7 . 
     FIG. 12  shows practical waveforms calculated when the processes in steps ST  102  and ST  103  are done after adjustment has been made by the adjusting section  57 . As shown in  FIG. 12 , adjustment is made to secure less phase displacement of the waveform. Since the rotation positions of the photosensitive drums  7 Y,  7 M and  7 C are so adjusted as to match the phase of the drum  7 K, it is possible to prevent color mismatching produced upon image formation. Further, the adjusting operation is performed each time to secure phase matching on the color copier  1  after the power source has been turned ON. Therefore, it is possible to cope with color mismatching which may be produced due to the rotation vibration resulting from ageing. 
   Further, at a time of the phase adjustment, the photosensitive drums  7 Y,  7 M and  7 C are spaced apart from the transfer belt  6  since the monochrome mode is set, and it is possible to prevent any damage to the transfer belt  6  at a time of making the phase adjustment. 
   Further, the phase adjustment is set at a time the power source is turned ON. However, the adjusting section  57  may be so configured as to include a count section for counting the number of copied sheets and a memory area for storing the number of sheets, such as 100 or 200. In this case, the adjusting section  57  performs adjustment when the number counted by the count section reaches a set number of sheets. Further, a phase adjusting mode may be set to the input section  53   a  of the operation panel  53  to adjust the phase of the photosensitive drum  7  and the above-mentioned process may perform when this mode is set. Further, it is possible to provide all these structures and perform phase adjustment the user wishes. 
   (Second Embodiment) 
   An explanation will be made below about the second embodiment of the invention. The same reference numerals are employed to designate parts or elements corresponding to those shown in the first embodiment. A detailed description is omitted. 
   As shown in  FIG. 13A , as phase matching section  31 ′ use is made of a rotation angle adjusting dial  31 ′ b  provided on an end  31 ′ a  of a substantially cylindrical body coupled to a photosensitive drum  7 . The dial  31 ′ is so configured as to be able to rotate through an angle of 360 as shown in FIG.  13 B. The angle of the photosensitive drum  7  is adjusted in synchronism with the angle of the dial  31 ′ by the user. Even in this embodiment, a photosensitive drum  7 K serves as a reference photosensitive drum. 
   A key for an adjusting mode for adjusting the position of the photosensitive drum  7  is provided on an input section  53   a  of an operation panel  53 . When this key is depressed by the user as an input operation, the processes in steps ST  102  to ST  105  as set out above are performed. That is, the phase mismatching of the photosensitive drums  7 Y,  7 M and  7 C relative to the photosensitive drum  7 K are calculated based on the interval of those lines detected by sensors  42   a ,  42   b , and rotation angles for adjusting the rotation positions of the photosensitive drums  7 Y,  7 M and  7 C relative to the reference photosensitive drum  7 K are calculated, etc. And the rotation angle as a result of the process is displayed on a display section  53   b  of the operation panel  53   b . The user, after seeing this display, rotates the dial  31 ′ b  of the drums  7 Y,  7 M and  7 C through displayed angle and, while the angle is adjusted by the user, the photosensitive drums  7 Y,  7 M and  7 C are so set in a spaced-apart state as in steps ST  107  and ST  109  to prevent a drive force from being transmitted from a gear  24 . Setting the photosensitive drums  7 Y,  7 M and  7 C in close contact with, and away from, a transfer belt is accomplished by, for example, operating the input section  53   a  of the operation panel  53 . 
   Even in such a structure, it is possible to prevent color mismatching which may be produced at the formation of an image on the color copier  1 . Since the adjustment of the dial  31 ′ b  is performed by the user, a phase adjusting control structure can be simplified and a resultant color copier can be made lower in cost. 
   In both the embodiments above, it is possible to obtain a rotation angle through which the photo-sensitive drums  7 Y,  7 M and  7 C are rotated based on lines for respective colors which are formed at the end portions of the transfer belt  6 . As shown in  FIG. 14 , however, a sensor  60  may be provided to read out color information or concentration information formed on the transfer belt  6  and, based on this information, any phase mismatch can be read out. 
   Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the invention as defined by the appended claims and equivalents thereof.