Patent Publication Number: US-11660884-B2

Title: Image forming apparatus

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application relates to and claims priority rights from Japanese Patent Application No. 2021-008157, filed on Jan. 21, 2021, the entire disclosures of which are hereby incorporated by reference herein. 
     BACKGROUND 
     1. Field of the Present Disclosure 
     The present disclosure relates to an image forming apparatus. 
     2. Description of the Related Art 
     An image forming apparatus measures a transportation movement amount using a rotary encoder that detects rotation of a motor or a roller for transporting a recording paper sheet, and/or a linear encoder that measures a movement amount of a transportation belt, adjusts the transportation movement amount such that the transportation movement amount of a recording paper sheet gets the same as a reference value, and ejects ink to a proper position and thereby forms an image. 
     However, in order to accurately adjust the aforementioned transportation movement amount, it is required to install plural encoders or a high resolution encoder, and consequently, it results in a high cost of the apparatus. Further, when a rotary encoder is used to detect rotation of the motor or the roller, a transportation speed of the paper sheet may not be accurately detected, even if the rotary encoder is a high resolution rotary encoder, because a speed of the transportation belt fluctuates due to some causes in a driving system from the motor or the roller to the transportation belt (e.g. a bearing of the motor or the roller, a deflection of the belt, and/or the like). Furthermore, on a measurement value of the transportation speed, an error due to the speed fluctuation of the transportation belt induced by the driving system from the motor or the roller to the transportation belt is not detected and accumulated, and therefore, an error on an ink ejection timing may get large over time and result in a low image quality. 
     SUMMARY 
     An image forming apparatus according to an aspect of the present disclosure includes a transportation belt, a print engine, and an ejection timing control unit. The transportation belt is configured to transport a print sheet. The print engine is configured to eject ink onto the print sheet. The ejection timing control unit is configured to adjust an ink ejection timing of the print engine. The transportation belt includes a flushing opening part. The print engine repeatedly performs ink flushing to the flushing opening part at predetermined timings. Further the ejection timing control unit derives an adjustment amount for the ink ejection timing of the print engine on the basis of: a number of the ink ejection timings in a period from a previous flushing time to a current flushing time, a distance from the flushing opening part for the flushing at the previous flushing time to the flushing opening part for the flushing at the current flushing time, and a print resolution. 
     These and other objects, features and advantages of the present disclosure will become more apparent upon reading of the following detailed description along with the accompanied drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    shows a side view that indicates an internal mechanical configuration of an image forming apparatus in an embodiment according to the present disclosure; 
         FIG.  2    shows a plane view of the image forming apparatus shown in  FIG.  1   ; 
         FIG.  3    shows a diagram that indicates an example of a transportation belt  2  shown in  FIG.  1   ; 
         FIG.  4    shows a block diagram that indicates an electronic configuration of the image forming apparatus  10  in the embodiment according to the present disclosure; 
         FIG.  5    shows a block diagram that indicates a configuration of an ejection timing control unit  81   a  shown in  FIG.  4   ; 
         FIG.  6    shows a diagram that explains a flushing timing corresponding to a type of a print sheet; and 
         FIG.  7    shows a diagram that indicates another example of the transportation belt  2  shown in  FIG.  1   . 
     
    
    
     DETAILED DESCRIPTION 
     Hereinafter, embodiments according to an aspect of the present disclosure will be explained with reference to drawings. 
     Embodiment 1 
       FIG.  1    shows a side view that indicates an internal mechanical configuration of an image forming apparatus in an embodiment according to the present disclosure.  FIG.  2    shows a plane view of the image forming apparatus shown in  FIG.  1   . 
     The image forming apparatus  10  in this embodiment is an apparatus such as printer, copier, facsimile machine or multi function peripheral, and in this embodiment, includes an inkjet color printing mechanism of a line head type. 
     The image forming apparatus  10  shown in  FIG.  1    includes a print engine  10   a  and a sheet transportation unit  10   b . The print engine  10   a  physically prints an image to be printed on a print sheet (print paper sheet or the like). An ink cartridge is enabled to be mounted and demounted to and from the print engine  10   a , and the print engine  10   a  performs printing using ink supplied from the ink cartridge. The sheet transportation unit  10   b  transports the print sheet to the print engine  10   a.    
     In this embodiment, the print engine  10   a  includes line-head-type inkjet recording units  1   a  to  1   d  corresponding to four ink colors: Cyan, Magenta, Yellow, and Black, and ejects ink onto the print sheet using the inkjet recording units  1   a  to  1   d.    
     As shown in  FIG.  2   , in this embodiment, each of the inkjet recording units  1   a  to  1   d  includes a single or plural (here, three) head units  11 . The head units  11  are arranged along a primary scanning direction, and are capable of being mounted to and demounted from a main body of the image forming apparatus. 
     Further, in this embodiment, the sheet transportation unit  10   b  includes (a) a circular-type transportation belt  2  that is arranged so as to be opposite to the print engine  10   a  and transports a print sheet, (b) a driving roller  3 , a driven roller  4 , and a tension roller  4   a  around which the transportation belt  2  is hitched, (c) a nipping roller  5  that nips the print sheet with the transportation belt  2 , (d) a post-stage transportation belt  6 , and (e) a dryer  7 . 
     The driving roller  3 , the driven roller  4 , and the tension roller  4   a  cause the transportation belt  2  to rotate. The nipping roller  5  nips an incoming print sheet transported from a sheet feeding cassette  20  mentioned below, and the nipped print sheet is transported by the transportation belt  2  to printing positions of the inkjet recording units  1   a  to  1   d  in turn, and on the print sheet, images of respective colors are printed by the inkjet recording units  1   a  to  1   d . In this situation, the passing print sheet is detected by a sheet sensor  2   a , and a current position of the print sheet on a transportation path is determined on the basis of a detection timing by the sheet sensor  2   a , and thereby an image is printed at a proper position on the print sheet. Subsequently, the print sheet after printing is outputted by the post-stage transportation belt  6  to an output tray  10   c  or the like. In this process, the dryer  7  dries the print sheet on which the ink has been ejected. 
       FIG.  3    shows a diagram that indicates an example of a transportation belt  2  shown in  FIG.  1   . 
     The transportation belt  2  includes flushing opening parts  31 - 1  to  31 -M (here, M=6). For example, as shown in  FIG.  3   , a single or plural flushing opening parts  31 - 1  to  31 -M is/are formed in the transportation belt  2 , and each flushing opening part  31 - i  (i=1, . . . , M) is formed along a primary scanning direction. Further, sheet suction holes  32  are substantially uniformly arranged at a predetermined density in an area (whole area) other than the flushing opening parts  31 - 1  to  31 -M. 
     For example, as shown in  FIG.  1   , ink receiver units  8   a  to  8   d  are installed under the head units  11  of the inkjet recording units  1   a  to  1   d . Ink flushing (line flushing) of each inkjet recording unit  1   a ,  1   b ,  1   c , or  1   d  is performed when any flushing opening part  31 - i  is located at a position right under the head unit  11  of the inkjet recording unit  1   a ,  1   b ,  1   c , or  1   d ; and ink is ejected in line from the head unit  11  for the flushing, and passes through the flushing opening part  31 - i ; and the ink is received by the corresponding ink receiver unit  8   a ,  8   b ,  8   c , or  8   d  and thereafter corrected to a waste ink tank. 
     Further, sheet suction units  9  are arranged along the transportation path of the print sheet in parts other than the ink received units  8   a  to  8   d . A negative pressure is applied to the sheet suction units  9 , and thereby the print sheet is adsorbed to the transportation belt  2 . It should be noted that a lower negative pressure is applied to the ink receiver units  8   a  to  8   d , than that applied to the sheet suction units  9 . 
     Further the sheet transportation unit  10   b  includes a sheet feeding cassette  20  as a sheet supply source. The sheet feeding cassette  20  stores print sheets  101 , and pushes up the print sheets  101  using a lift plate  21  so as to cause the print sheets  101  to contact with a pickup roller  22 . The print sheets  101  put on the sheet feeding cassette  20  are picked up to a sheet feeding roller  23  by the pickup roller  22  sheet by sheet from the upper side. The sheet feeding roller  23  is a roller that transports the print sheets  101  sheet by sheet fed by the pickup roller  22  from the sheet feeding cassette  20  onto a transportation path. 
     A transportation roller  27  is a roller to transport the print sheet  101  on the transportation path. A registration roller  28  temporarily stops the print sheet  101  when the incoming print sheet  101  in transportation is detected by a registration sensor  28   a , and transports this print sheet  101  to the print engine  10   a  (specifically, to a nipping position of the nipping roller  5  and the transportation belt  2 ) at a secondary sheet feeding timing. The secondary sheet feeding timing is specified by a control unit  81  mentioned below such that an image is formed at a position specified on the print sheet  101 . 
       FIG.  4    shows a block diagram that indicates an electronic configuration of the image forming apparatus  10  in the embodiment according to the present disclosure. As shown in  FIG.  4   , the image forming apparatus  10  includes not only a printing device  71  that includes the mechanical configuration shown in  FIGS.  1  and  2    but an operation panel  72 , a storage device  73 , a communication device  74 , and a processor  75 . 
     The operation panel  72  is arranged on a housing surface of the image forming apparatus  10 , and includes a display device  72   a  such as a liquid crystal display and an input device  72   b  such as a hard key and/or touch panel, and displays sorts of messages for a user using the display device  72   a  and receives a user operation using the input device  72   b.    
     The storage device  73  is a non-volatile storage device (flash memory, hard disk drive or the like) in which data, a program and the like for controlling the image forming apparatus  10  have been stored. 
     The image scanning device  74  includes a platen glass and an auto document feeder, and optically scans a document image from a document put on the platen glass or a document fed by the auto document feeder, and generates image data of the document image. 
     The processor  75  includes a computer that operates in accordance with a program, an ASIC (Application Specific Integrated Circuit) that performs a predetermined action, and/or the like, and acts as sorts of processing units using the computer, the ASIC and/or the like. This computer includes a CPU (Central Processing Unit), a ROM (Read Only Memory), a RAM (Random Access Memory) and the like, and loads a program stored in the storage device  73 , the ROM or the like to the RAM and executes the program using the CPU and thereby acts as processing units (with the ASIC if required). 
     Here the processor  75  acts as a control unit  81  and an image processing unit  82 . 
     The control unit  81  controls the printing device  71  (the print engine  10   a , the sheet transportation unit  10   b  and the like), and thereby performs a print job requested by a user. In this embodiment, the control unit  81  causes the image processing unit  82  to perform a predetermined image process, and controls the print engine  10   a  (the head units  11 ) and causes the head units  11  to eject ink and thereby forms a printing image on a print sheet. The image processing unit  82  performs a predetermined image process such as RIP (Raster Image Processing), color conversion, halftoning and/or the like for image data of an image to be printed. 
     The control unit  81  causes the printing device  71  to print an image specified by a user. Specifically, the control unit  81  causes the print engine  10   a  to print a user document image based on printing image data specified by a user. 
     The control unit  81  causes the print engine  10   a  to eject ink when printing the user document image, and also causes the print engine  10   a  to eject ink at predetermined flushing timings. Consequently, at the predetermined flushing timings, the print engine  10   a  repeatedly performs ink flushing to the flushing opening parts  31 - 1  to  31 -M. The ink flushing is performed for discarding ink thickened in the head nozzle. 
     Further the control unit  81  includes an ejection timing control unit  81   a  that adjusts an ink ejection timing of the print engine  10   a  (here, an ink ejection period in image forming). 
     When performing the flushing at the m-th time, the ejection timing control unit  81   a  derives an adjustment amount for the ink ejection timing of the print engine  10   a  on the basis of: (a) a number of the ink ejection timings P(m) in a period (i.e. time length L(m)=Tf(m)−Tf(m−1)) from the ink flushing at a previous flushing timing Tf(m−1) to the ink flushing at a current flushing timing Tf(m), (b) a distance S(m) from the flushing opening part  31 - i  for the ink flushing at the previous flushing timing Tf(m−1) to the flushing opening part  31 - j  for the ink flushing at the current flushing timing Tf(m), and (c) a print resolution R. 
     Here the ejection timing control unit  81   a  derives the adjustment amount for the ink ejection timing of the print engine  10   a  on the basis of a difference (P(m)−Q(m)) between the number of the ink ejection timings P(m) and a reference ejection number Q(m) based on the distance S(m) and the print resolution R (e.g. 600 dpi) (Q(m)=S(m)*R). 
     In this embodiment, the image forming apparatus  10  further includes a rotary encoder (not shown). The rotary encoder detects rotation of a roller (e.g. the driven roller  4  or the like) that contacts with the transportation belt  2  and rotates with movement of the transportation belt  2 , and generates an encoder output signal corresponding to the rotation of the roller. This encoder output signal is a rectangular wave having a period corresponding to a rotation speed of the roller. 
     The ejection timing control unit  81   a  (a) derives a first correction amount C1 and a second correction amount C2 such that the first correction amount C1 is based on the encoder output signal and the second correction amount C2 is based on the number of the ink ejection timings P(m), the distance S(m), and a print resolution R; and (b) derives the adjustment amount for the ink ejection timing of the print engine  10   a  using the first correction amount C1 and the second correction amount C2. 
     Specifically, the ejection timing control unit  81   a  derives an ink ejection period U(n), as the ink ejection timings, in accordance with the following formula.
 
 U ( n )= T 0+ C 1+ C 2
 
     Here T0 is an ink ejection period at an ideal transportation speed (i.e. a theoretical value of the ink ejection period at a specified transportation speed). 
     Further the first correction amount C1 and the second correction amount C2 are derived in accordance with the following formulas.
 
 C 1= T ( n )− K*T  
 
 C 2=( P ( m )− Q ( m ))* T 0/ Q ( m )
 
     Here T(n) is a measurement value of an n-th pulse period of the encoder output signal, T is a theoretical value of the pulse period of the encoder output signal, and k is an adjustment coefficient that indicates a tolerance of the roller. It should be noted that T(n) is a value after eccentricity correction. For example, T(n) is set as an average value of the pulse periods of the encoder output signals generated at plural positions in a circumferential direction of the rotary encoder. Thus, the first correction amount C1 is an adjustment amount corresponding to speed fluctuation of the roller. 
       FIG.  5    shows a block diagram that indicates a configuration of the ejection timing control unit  81   a  shown in  FIG.  4   . 
     In the ejection timing control unit  81   a , an ejection timing counting unit  91  counts the ink ejection timing, a correction amount calculation unit  92  ( a ) determines the flushing timings on the basis of a flushing timing signal and determines the number of the ink ejection timings P(m) in a period between flushing timings on the basis of a counting value by the ejection timing counting unit  91 , and (b) derives the aforementioned second correction amount C2 on the basis of the ink ejection period theoretical value T0 as a constant, the distance S(m), the print resolution R, and the determined number of the ink ejection timings P(m). Thus the second correction amount C2 is an adjustment amount corresponding to a deviation of the number of the ink ejection timings. 
     Meanwhile a pulse period measurement unit  93  measures the pulse period T(n) of the encoder output signal, an ejection period correction unit  94  ( a ) derives the aforementioned first correction amount C1 on the basis of the pulse period theoretical value T as a constant, the coefficient k, and the measured pulse period T(n), and (b) corrects the ink ejection period theoretical value T0 with this first correction amount C1 and the derived second correction amount C2, and derives the ejection period U(n). Subsequently, a control signal generation unit  95  generates the ejection timing control signal that specifies ejection timings, on the basis of the derived ejection period U(n). 
     The inkjet recording units  1   a  to  1   d  determine the ink ejection timings in accordance with this ejection timing control signal, and eject ink at the ink ejection timings when ink should be ejected for a pixel in an image to be printed. 
     The flushing timing signal is a signal that specifies flushing timings to the inkjet recording units  1   a  to  1   d , and the control unit  81  generates the flushing timing signal on the basis of a position of the transportation belt  2  determined from a sensor signal generated by a belt sensor  29 . The belt sensor  29  is arranged at a predetermined position as shown in  FIG.  1   , for example, and optically detects an opening part of the transportation belt  2  such as the flushing opening part  31 - i  that passes through this position and thereby detects a rotational position of the transportation belt  2 . 
       FIG.  6    shows a diagram that explains a flushing timing corresponding to a type of a print sheet. The aforementioned flushing timing is set at a single or plural phases in a belt period length, for example, as shown in  FIG.  6   , such that each of the phases becomes in an interval between print sheets and corresponds to a print sheet type. 
     For example, as shown in  FIG.  6   , in case of page images with A4R or Letter R size (in case of page images of 150 pages per minute), five print sheets are transported in one belt period, and the flushing is performed at the flushing opening parts  31 - 1 ,  31 - 3  and  31 - 6 . Here a distance between the flushing opening parts  31 - 1  and  31 - 3 , a distance between the flushing opening parts  31 - 3  and  31 - 6 , and a distance between the flushing opening parts  31 - 6  and  31 - 1  are not identical, i.e. different from each other. Therefore, in this case, the aforementioned distance S(m) changes in accordance with the time number m of the flushing. 
     For example, as shown in  FIG.  6   , in case of page images with A4 or Letter size (in case of page images of 120 pages per minute), four print sheets are transported in one belt period, and the flushing is performed at the flushing opening parts  31 - 1  and  31 - 4 . Here a distance from the flushing opening part  31 - 1  to the flushing opening part  31 - 4 , and a distance from the flushing opening part  31 - 4  to the flushing opening part  31 - 1  are identical to each other. Therefore, in this case, the aforementioned distance S(m) does not change in accordance with the time number m of the flushing, and is therefore constant. 
     For example, as shown in  FIG.  6   , in case of page images with A3, B4 or Legal size (in case of page images of 90 pages per minute), three print sheets are transported in one belt period, and the flushing is performed at the flushing opening parts  31 - 1 ,  31 - 2 , and  31 - 5 . Here a distance between the flushing opening parts  31 - 1  and  31 - 2 , a distance between the flushing opening parts  31 - 2  and  31 - 5 , and a distance between the flushing opening parts  31 - 5  and  31 - 1  are identical to each other. 
     For example, as shown in  FIG.  6   , in case of page images with 13 inch by 19.2 inch size (in case of page images of 60 pages per minute), two print sheets are transported in one belt period, and the flushing is performed at the flushing opening parts  31 - 1  and  31 - 4 . 
       FIG.  7    shows a diagram that indicates another example of the transportation belt  2  shown in  FIG.  1   . For example, as shown in  FIG.  7   , flushing opening parts  41 - 1  to  41 -N in the transportation belt  2  may be arranged with a regular interval along a rotational direction (i.e. secondary scanning direction) of the belt  2 , and may be also used as the sheet suction holes. In this case, for example, as shown in  FIG.  7   , flushing opening parts  41   a  are selected with a regular interval among the flushing opening parts  41 - 1  to  41 -N, and used for the flushing. 
     The following part explains a behavior of the image forming apparatus  10 . 
     When printing an image, the control unit  81  controls the print engine  10   a  and causes the print engine  10   a  to eject ink from nozzles of the inkjet recording units  1   a  to  1   d  onto a print sheet at ink ejection timings of the ink to be ejected for pixels in the image. The ink ejection timing repeatedly comes with the aforementioned ejection period, and ink is ejected for a pixel at an ink ejection timing corresponding to the pixel. 
     Further the control unit  81  determines flushing timings on the basis of a print sheet type and the like, controls the print engine  10   a , and causes the print engine  10   a  to eject ink from nozzles of the inkjet recording units  1   a  to  1   d  toward the flushing opening parts  31 - i  or  41 - i  at the ink ejection timings. 
     Subsequently, the ejection timing control unit  81   a  counts up the number of the ink ejection timings P(m) when printing, and as mentioned, repeatedly derives the first and second correction amounts C1 and C2, updates the ejection period every time when deriving the first and/or second correction amounts C1 and/or C2, and adjusts the ink ejection timings. 
     As mentioned, in Embodiment 1, the transportation belt  2  includes the flushing opening part  31 - i  or  41 - i . The print engine  10   a  repeatedly performs ink flushing to the flushing opening part  31 - i  or  41 - i  at a predetermined timings. Further the ejection timing control unit  81   a  derives an adjustment amount (the aforementioned second correction amount C2) for the ink ejection timing of the print engine  10   a  on the basis of: a number of the ink ejection timings P(m) in a period from a previous ((m−1)-th) flushing time to a current (m-th) flushing time, a distance S(m) from the flushing opening part  31 - i  or  41 - i  for the flushing at the previous flushing time to the flushing opening part  31 - j  or  41 - j  for the flushing at the current flushing time, and a print resolution R. 
     Thus, the ink ejection timings are adjusted on the basis of timings of the ink flushing using the flushing opening parts  31 - i  or  41 - i  formed in the transportation belt  2 , and therefore, as mentioned, even if speed fluctuation occurs of the transportation belt  2  due to the driving system from the motor or the roller to the transportation belt  2 , an error due to this speed fluctuation is detected as the second correction amount C2 and the ink ejection timings are properly adjusted. Consequently an image is formed with a favorable image quality at a relatively low cost, without using high resolution encoder or the like. 
     Embodiment 2 
     In Embodiment 2, the ejection timing control unit  81   a  derives the adjustment amount (the second correction amount C2) so as to be an integral multiplication of a clock period of a predetermined clock signal, stores a rounding error W(m) that occurs when deriving the adjustment amount as the integral multiplication, and derives the adjustment amount at a next adjustment timing (next flushing timing) in consideration with the stored rounding error W(m). 
     Specifically, in accordance with the following formulas, the ejection timing control unit  81   a  derives the second correction amount C2 using the rounding error W(m−1) of the previous flushing timing, and derives and stores the rounding error W(m) of the current flushing timing.
 
 C 2=CLK*INT(( C 20+ W ( m− 1))/CLK)
 
Here,  C 20=( P ( m )− Q ( m ))* T 0/ Q ( m ).
 
 W ( m )=( C 20+ W ( m− 1))− C 2
 
     Here W(m) is a rounding error at the current flushing, CLK is a clock period of a clock signal for a control signal that specifies the ink ejection timings, and INT(X) indicates the integer part of X. If X is less than 1, then INT(X) gets 0. 
     If a value of (C20+W(m−1)) is less than the clock period, then C2 and W(m) may be calculated as C2=0 and W(m)=C20+W(m−1), and otherwise, if not, then C2 and W(m) may be calculated as C2=C20+W(m−1) and W(m)=0 or W(m)=C2−CLK*INT((C20+W(m−1))/CLK). An initial value W(0) of the rounding error is set as 0. 
     T0 is sufficiently longer than the clock period, and a fraction does not occur when T0 is converted to a clock number. For example, if the clock frequency is 100 MHz (i.e. the clock period is 10 ns) and T0 is 55 micro seconds, then T0 is expressed as 5500 clocks. Further, as mentioned, C2 is set as a multiple of the clock period CLK, and even though a fraction thereby occurs when generating the control signal that specifies the ink ejection timings in synchronization with the clock signal, the fraction is considered at a next adjustment timing, and consequently if the second correction amount C2 is small, the adjustment on the ink ejection timings is performed in consideration with the second correction amount C2. 
     Other parts of the configuration and behaviors of the image forming apparatus in Embodiment 2 are identical or similar to those in Embodiment 1, and therefore not explained here. 
     As mentioned, in Embodiment 2, even if a value of the second correction amount C2 is small, the ink ejection timings are properly adjusted. 
     It should be understood that various changes and modifications to the embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims. 
     For example, in the aforementioned Embodiment 1 or 2, the updating of the ejection period U may be performed at the flushing timing (i.e. at a timing in outside of the page image). In this case, the page image is not affected by fluctuation of the ejection period U. 
     Further, in Embodiment 1 or 2, the ejection period U may be derived as a clock number.