Patent Publication Number: US-7911652-B2

Title: Methods and systems for determining banding compensation parameters in printing systems

Description:
BACKGROUND 
     The present exemplary embodiment relates to document processing systems. It finds particular application in conjunction with sensing and control of banding and will be described with a particular reference thereto. However, it is to be appreciated that the present exemplary embodiment is also amenable to other like applications. 
     The image quality defect known as banding is a periodic modulation of color (some aspect of lightness, hue, and saturation) in the image on a printed medium that runs in the marking process direction. Banding generally occurs across the full width of an image, and may vary in amplitude in time and in the direction perpendicular to the marking process direction, i.e., the cross-process direction. Banding can be caused by a number of fluctuations that occur within the subsystems of a marking engine such as, for example, laser polygon Raster Output Scanner (ROS) facet-to-facet reflectance variation, intensity and spot size variation in a multibeam ROS, ROS polygon wobble, non-uniform motion of certain subsystems, gap variations between moving surfaces, and non-uniform photoreceptor wear and/or charging. 
     A typical approach to eliminate banding defects is to require the manufacture of parts/subsystems to meet tight tolerances which results in high costs. Alternative approaches include using active compensation schemes. In one compensation scheme, banding defects are sensed with optical sensors in the developed image on the photoreceptor. The development field is actuated according to a feedback control strategy in order to prevent the formation of the bands. In such an approach, accurate knowledge of banding frequency, amplitude and phase is critical at the time of the compensation, this knowledge being gained through sensing. Typically, the sensing is performed by sensing imaged targets at the photoreceptor or in the print media path. However, such sensing of the targets is performed in the midst of customer&#39;s jobs, thus using up extra printing cycles and reducing the overall productivity of the printing system. 
     There is a need for methods and apparatuses that overcome the aforementioned problems and others. 
     CROSS REFERENCE TO RELATED APPLICATIONS 
     The following applications, the disclosures of each being totally incorporated herein by reference are mentioned: 
     U.S. application Ser. No. 10/793,902, filed Mar. 8, 2004, entitled “METHOD AND APPARATUS FOR CONTROLLING NON-UNIFORM BANDING AND RESIDUAL TONER DENSITY USING FEEDBACK SYSTEM,” by Howard A. Mizes, et al.; 
     U.S. application Ser. No. 10/852,243, filed May 25, 2004, entitled “MEASUREMENT AND CONTROL OF HIGH FREQUENCY BANDING IN A MARKING SYSTEM,” by Howard A. Mizes, et al.; 
     U.S. application Ser. No. 10/917,676, filed Aug. 13, 2004, entitled “MULTIPLE OBJECT SOURCES CONTROLLED AND/OR SELECTED BASED ON A COMMON SENSOR,” by Robert M. Lofthus, et al.; 
     U.S. application Ser. No. 10/999,326, filed Nov. 30, 2004, entitled “SEMI-AUTOMATIC IMAGE QUALITY ADJUSTMENT FOR MULTIPLE MARKING ENGINE SYSTEMS,” by Robert E. Grace, et al.; 
     U.S. application Ser. No. 11/084,280, filed Mar. 18, 2005, entitled “SYSTEMS AND METHODS FOR MEASURING UNIFORMITY IN IMAGES,” by Howard Mizes; 
     U.S. application Ser. No. 11/090,502, filed Mar. 25, 2005, entitled IMAGE QUALITY CONTROL METHOD AND APPARATUS FOR MULTIPLE MARKING ENGINE SYSTEMS,” by Michael C. Mongeon; 
     U.S. application Ser. No. 11/095,378, filed Mar. 31, 2005, entitled “IMAGE ON PAPER REGISTRATION ALIGNMENT,” by Steven R. Moore, et al.; 
     U.S. application Ser. No. 11/109,558, filed Apr. 19, 2005, entitled “SYSTEMS AND METHODS FOR REDUCING IMAGE REGISTRATION ERRORS,” by Michael R. Furst et al.; 
     U.S. application Ser. No. 11/115,766, Filed Apr. 27, 2005, entitled “IMAGE QUALITY ADJUSTMENT METHOD AND SYSTEM,” by Robert E. Grace; 
     U.S. application Ser. No. 11/170,873, filed Jun. 30, 2005, entitled “COLOR CHARACTERIZATION OR CALIBRATION TARGETS WITH NOISE-DEPENDENT PATCH SIZE OR NUMBER”, by R. Victor Klassen; and 
     U.S. application Ser. No. 11/189,371, filed Jul. 26, 2005, entitled “PRINTING SYSTEM”, by Steven R. Moore et al. 
     CROSS REFERENCE TO RELATED PATENTS 
     The following patent, the disclosure of which being totally incorporated herein by reference is mentioned: 
     U.S. Pat. No. 5,900,901 to Costanza, issued May 1999, entitled “Method and apparatus for compensating for raster position errors in output scanners.” 
     REFERENCES 
     U.S. Pat. No. 4,746,940 to Lee, entitled “Line scanner to reduce banding,” issued May 1988, describes a control system for an electrophotographic exposure apparatus which is characterized by a film sheet transport which carries a film sheet past a first and a second spaced position where at the same portion of the film sheet is exposed to an imaging beam each having the same image information. 
     U.S. Pat. No. 4,884,083 to Loce, entitled “Printer compensated for vibration-generated scan line errors,” issued November 1989, describes a printing system employing a raster output scanning device that is compensated for the effects of motion of the medium upon which an image is being printed. 
     U.S. Pat. No. 4,989,019 to Loce, entitled “Multi-beam scanning system compensated for banding, issued January 1991, describes a multi-beam laser ROS print system which is adapted to minimize banding in output prints. 
     U.S. Pat. No. 5,315,322 to Bannai, entitled “Image forming apparatus with anti-banding implementation,” issued May 1994, describes an electrophotographic copier, laser printer, facsimile transceiver or similar image forming apparatus of the type having a rotary polygonal mirror. 
     U.S. Pat. No. 5,248,997 to Summers, entitled “Facet reflectance correction in a polygon scanner,” issued September 1993, describes a technique for correcting facet reflectance differences to effect uniform laser light power output for all scanner facets in a laser imaging apparatus which includes a multifaceted polygon scanner. 
     U.S. Pat. No. 5,729,277 to Morrison, issued March 1998, entitled “System and method for modifying an output image signal to compensate for drum velocity variations in a laser printer,” describes a system and method of correcting aberrations in an output image of an image transfer apparatus, the aberrations being due to variations in a velocity of a scanning surface in the image transfer apparatus. 
     U.S. Pat. No. 5,760,817 to Foote, issued June 1998, entitled “Laser printer with apparatus to reduce banding by servo adjustment of a scanned laser beam,” issued June 1998 describes a print apparatus which includes a photoconductor and a mechanical system for moving the photoconductor past a scan line exposure station. 
     U.S. Pat. No. 5,920,336 to Lawton, issued July 1999, entitled “Beam deflecting for resolution enhancement and banding reduction in a laser printer,” describes a system and method of deflecting a laser beam in a laser printer for providing enhanced resolution and reduced banding effects. 
     U.S. Pat. No. 6,023,286 to Nowak, entitled “Moving mirror motion quality compensation,” issued Feb. 8, 2000 describes correcting motion quality induced color banding problems resulting from photoreceptor motion defects in a color imaging device having a laser based multifaceted polygon and a rotating cylindrical mirror whose rotation is set by a controlled rotation inducing element. 
     U.S. Pat. No. 6,025,922 to Marsden, entitled “Reduction of banding in printed images,” issued February 2000, describes a method and apparatus for adding pseudo-random noise and bias to an input pixel value to reduce banding effects and to produce additional highlights in the output. 
     U.S. Pat. No. 6,057,867 to Chan, entitled “Laser printer with piezoelectric apparatus to reduce banding by adjustment of a scanned laser beam,” describes a print apparatus which includes a photoconductor and a mechanical system for moving the photoconductor past a scan line exposure station. 
     U.S. Pat. No. 6,055,005 to Appel, entitled “Color printer with jitter signature matching”, issued Apr. 25, 2000 describes correcting color banding problems resulting from facet-to-facet jitter in a color imaging device having a multifaceted polygon are corrected by starting each color separation using the same facet. 
     US Patent Application Publication No. 20020159791 to Chen, entitled “Systems and methods for reducing banding artifact in electrophotographic devices using drum velocity control”, published Oct. 31, 2002, describes an electrophotographic device which uses a closed loop controller that receives a feedback signal from an encoder connected to the OPC drum to improve the rotational velocity control of the drum. 
     However, the above described references do not describe methods and apparatuses for sensing the banding in non image areas. 
     BRIEF DESCRIPTION 
     According to one aspect, a method is disclosed. A test target is written in a non image zone at set time intervals. The test target is sensed. At least one of frequency, amplitude and phase of banding is determined, which banding is inherent in a printing device, based on the sensed test target. At least one banding compensation parameter is determined based at least on one of the determined frequency, amplitude and phase of banding. Characteristics of producing an image based on the determined banding compensation parameter are adjusted to compensate the banding inherent in the printing device. 
     According to another aspect, a system is disclosed. A sensor senses a first test target. A banding parameters determining processor initially determines one or more frequencies of banding based on the sensed first test target and initially estimates values of amplitude and phase corresponding to each initially determined banding frequency. A second test target is written in a non image zone and sensed by the sensor. A banding parameters updating processor determines a change in at least one of the initially estimated amplitude and phase based on the written second test target and updates at least one of the initially estimated amplitude and phase based on the determined change. 
     According to another aspect, a method is disclosed. Banding parameters are periodically fully characterized. A first test target is written. The first test target is sensed. One or more frequencies of banding are initially determined based on the sensed first test target. Values of amplitude and phase corresponding to each initially determined banding frequency are initially estimated. The banding parameters are updated at predetermined time intervals. A second test target is written in a non image zone. The second test target is sensed. A change in at least one of the initially estimated amplitude and phase is determined based on the sensed second test target. At least one of the initially estimated amplitude and phase is one of monitored and updated based on the determined change. Banding compensation imaging parameters are adjusted based on the banding parameters update. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a diagrammatic illustration of a document processing system; 
         FIG. 2  is a block diagram of a control methodology approach; 
         FIG. 3  is a diagrammatic illustration of test targets located in image and non-image areas; and 
         FIG. 4  is an example of a low frequency banding detected by an intermittent sampling. 
     
    
    
     DETAILED DESCRIPTION 
     With reference to  FIG. 1 , an example printing or document processing system  6  includes first, second, . . . , nth marking engine processing units  8   1 ,  8   2 ,  8   3 , . . . ,  8   n  each including an associated first, second, . . . , nth marking engines or devices  10 ,  12 ,  14  and associated entry and exit inverter/bypasses  16 ,  18 . In some embodiments, marking engines are removable. For example, in  FIG. 1 , an integrated marking engine and entry and exit inverter/bypasses of the processing unit  8   4  are shown as removed, leaving only a forward or upper paper path  22 . In this manner, for example, the functional marking engine portion can be removed for repair, or can be replaced to effectuate an upgrade or modification of the printing system  6 . While three marking engines  10 ,  12 ,  14  are illustrated (with the fourth marking engine being removed), the number of marking engines can be one, two, three, four, five, or more. Providing at least two marking engines typically provides enhanced features and capabilities for the printing system  6  since marking tasks can be distributed amongst the at least two marking engines. Some or all of the marking engines  10 ,  12 ,  14  may be identical to provide redundancy or improved productivity through parallel printing. Alternatively or additionally, some or all of the marking engines  10 ,  12 ,  14  may be different to provide different capabilities. For example, the marking engines  10 ,  12  may be color marking engines, while the marking engine  14  may be a black (K) marking engine. 
     The illustrated marking engines  10 ,  12 ,  14  employ xerographic printing technology, in which an electrostatic image is formed and coated with a toner material, and then transferred and fused to paper or another print medium by application of heat and pressure. However, marking engines employing other printing technologies can be provided, such as marking engines employing ink jet, or so forth. The processing units of the printing system  6  can also be other than marking engines; such as, for example, a print media feeding source or feeder  24  which includes associated print media conveying components  26 . The media feeding source  24  supplies paper or other print media for printing. Another example of the processing unit is a finisher  28  which includes associated print media conveying components  30 . The finisher  28  provides finishing capabilities such as collation, stapling, folding, stacking, hole-punching, binding, postage stamping, or so forth. 
     The print media feeding source  24  includes print media sources or input trays  40 ,  42 ,  44 ,  46  connected with the print media conveying components  26  to provide selected types of print media. While four print media sources are illustrated, the number of print media sources can be one, two, three, four, five, or more. Moreover, while the illustrated print media sources  40 ,  42 ,  44 ,  46  are embodied as components of the dedicated print media feeding source  24 , in other embodiments one or more of the marking engine processing units may include its own dedicated print media source instead of or in addition to those of the print media feeding source  24 . Each of the print media sources  40 ,  42 ,  44 ,  46  can store sheets of the same type of print media, or can store different types of print media. For example, the print media sources  42 ,  44  may store the same type of large-size paper sheets, print media source  40  may store company letterhead paper, and the print media source  46  may store letter-size paper. The print media can be substantially any type of media upon which one or more of the marking engines  10 ,  12 ,  14  can print, such as high quality bond paper, lower quality “copy” paper, overhead transparency sheets, high gloss paper, and so forth. 
     Since multiple jobs arrive at the finisher  28  during a common time interval, the finisher  28  includes two or more print media finishing destinations or stackers  50 ,  52 ,  54  for collecting sequential pages of each print job that is being simultaneously printed by the printing system  6 . Generally, the number of the print jobs that the printing system  6  can simultaneously process is limited to the number of available stackers. While three finishing destinations are illustrated, the printing system  6  may include two, three, four, or more print media finishing destinations. The finisher  28  deposits each sheet after processing in one of the print media finishing destinations  50 ,  52 ,  54 , which may be trays, pans, stackers and so forth. While only one finishing processing unit is illustrated, it is contemplated that two, three, four or more finishing processing units can be employed in the printing system  6 . 
     Bypass routes in each marking engine processing unit provide a means by which the sheets can pass through the corresponding marking engine processing unit without interacting with the marking engine. Branch paths are also provided to take the sheet into the associated marking engine and to deliver the sheet back to the upper or forward paper path  22  of the associated marking engine processing unit. 
     The printing system  6  executes print jobs. Print job execution involves printing selected text, line graphics, images, Magnetic Ink Character Recognition (MICR) notation, or so forth on front, back, or front and back sides or pages of one or more sheets of paper or other print media. In general, some sheets may be left completely blank. In general, some sheets may have mixed color and black-and-white printing. Execution of the print job may also involve collating the sheets in a certain order. Still further, the print job may include folding, stapling, punching holes into, or otherwise physically manipulating or binding the sheets. 
     Print jobs can be supplied to the printing system  6  in various ways. A built-in optical scanner  70  can be used to scan a document such as book pages, a stack of printed pages, or so forth, to create a digital image of the scanned document that is reproduced by printing operations performed by the printing system  6 . Alternatively, one or more print jobs  72  can be electronically delivered to a system controller  74  of the printing system  6  via a wired connection  76  from a digital network  80  that interconnects example computers  82 ,  84  or other digital devices. For example, a network user operating word processing software running on the computer  84  may select to print the word processing document on the printing system  6 , thus generating the print job  72 , or an external scanner (not shown) connected to the network  80  may provide the print job in electronic form. While a wired network connection  76  is illustrated, a wireless network connection or other wireless communication pathway may be used instead or additionally to connect the printing system  6  with the digital network  80 . The digital network  80  can be a local area network such as a wired Ethernet, a wireless local area network (WLAN), the Internet, some combination thereof, or so forth. Moreover, it is contemplated to deliver print jobs to the printing system  6  in other ways, such as by using an optical disk reader (not illustrated) built into the printing system  6 , or using a dedicated computer connected only to the printing system  6 . 
     The printing system  6  is an illustrative example. In general, any number of print media sources, media handlers, marking engines, collators, finishers or other processing units can be connected together by a suitable print media conveyor configuration. While the printing system  6  illustrates a 2×2 configuration of four marking engines, buttressed by the print media feeding source on one end and by the finisher on the other end, other physical layouts can be used, such as an entirely horizontal arrangement, stacking of processing units three or more units high, or so forth. Moreover, while in the printing system  6  the processing units have removable functional portions, in some other embodiments some or all processing units may have non-removable functional portions. It is contemplated that even if the marking engine portion of the marking engine processing unit is non-removable, associated upper or forward paper paths  22  through each marking engine processing unit enables the marking engines to be taken “off-line” for repair or modification while the remaining processing units of the printing system continue to function as usual. 
     In some embodiments, separate bypasses for intermediate components may be omitted. The “bypass path” of the conveyor in such configurations suitably passes through the functional portion of a processing unit, and optional bypassing of the processing unit is effectuated by conveying the sheet through the functional portion without performing any processing operations. Still further, in some embodiments the printing system may be a stand alone printer or a cluster of networked or otherwise logically interconnected printers, with each printer having its own associated print media source and finishing components including a plurality of final media destinations. 
     Although several media path elements are illustrated, other path elements are contemplated which might include, for example, inverters, reverters, interposers, and the like, as known in the art to direct the print media between the feeders, printing or marking engines and/or finishers. 
     The controller  74  controls the production of printed sheets, the transportation over the media path, and the collation and assembly as job output by the finisher. 
     With continuing reference to  FIG. 1  and further reference to  FIGS. 2 and 3 , in a full characterization mode or control methodology approach  100 , a banding parameters determining processor or algorithm or means  102  determines banding parameters such as at least one of a frequency, phase, and amplitude of banding. More specifically, a test pattern or target is created. The test pattern is a banding sensitive test pattern and designed based on design criteria as known in the art and described, for example, in the patent application Ser. No. 10/852,243, entitled “Measurement and Control of High Frequency Banding in a Marking System” by Mizes et al., identified above. One example of such test pattern is a periodic spatial representation, in which the periodic pattern is arranged in a process direction Y. For example, a first or initial or full or initialization test pattern or target or targets  104  is written  110  in the first marking device  10  and sensed  112  by one or more optical sensors. The first test target  104 , for example, is disposed within one or more image areas  114  and includes one, two, three or more test targets. The measurements, for example, are taken off the image media and/or the photoreceptor. The sensors, for example, are disposed inside the corresponding marking device  10 , i.e., in situ. Sensing of the first test target  104  may be performed by optical sensors that can be either array-type optical sensors or point optical sensors. According to various alternative embodiments, one or more optical sensors  116  could be located outside the marking engine such as in the upper print path  22 . In one embodiment, the first test target  104  is disposed within a non-image area such as in an interdocument zone  120 , inboard zone  122 , and/or outboard zone  124 . The interdocument zone  120  is located between each two consecutive image areas  114  and extends in a cross-process direction X. The inboard and outboard zones  122 ,  124  are located opposing one another and each extends parallel to the process direction Y and perpendicular to the cross-process direction X outside of the image areas  114  adjacent corresponding first and second outer edges  126 ,  128  of each image area  114 . The measurements are taken from the photoreceptor or the image media such as sheets of paper. In one embodiment, the test target is printed onto the paper that contains a desired print job. The paper is oversized and later is trimmed to a required page size thereby eliminating the target or targets. One, two, three or more sensing targets located in one or more of each of the interdocument zone  120 , inboard zone  122  and outboard zone  124  are used. One or more frequencies of banding of the first marking device  10  are determined  130  by a use of algorithms known in the art. At least one of phase and amplitude of the determined banding frequencies is estimated  130 . The determined banding frequencies, and corresponding estimated amplitude and phase are stored  132  in a banding parameters memory  136 . Although described with reference to the first marking engine  10 , the full characterization mode  100  is performed on all or selected marking engines of the printing system  6 . The determined banding parameters are supplied to a feedback controller  142  in nearly real-time. The feedback control system utilizes methods and algorithms known in the art to determine  144  banding compensation parameters and compensate  146  for banding, as, for example, controlling the laser intensity in the laser printing system. 
     In one embodiment, one or more of banding frequencies is known a priori. For example, the banding frequency may be known from a manufacturer&#39;s data, service record, and the like. Such a known frequency is used to estimate phase and amplitude of banding. 
     With continuing reference to  FIGS. 1-3 , in a maintenance mode or control methodology approach  148 , a banding parameters updating processor or algorithm or means  150  updates at least one of the banding parameters determined or estimated in the full characterization mode  100 . More specifically, while a banding frequency may be relatively constant over time, the amplitude and phase of banding can drift substantially. According to various embodiments of the present application, the full characterization mode  100  of banding is performed at infrequent time intervals, while more frequent measurements are taken to monitor and/or update, for example, one of the parameters such as amplitude or phase of banding. The banding frequency is updated less frequently on an as needed basis. More specifically, an intermittent or second or monitoring test target or targets  152  are disposed within the non-image area such as in at least one of the interdocument zone  120 , inboard zone  122 , and outboard zone  124 . Of course, it is contemplated that more than one second test target  152  can be positioned in any of the interdocument, inboard and outboard zones  120 ,  122 ,  124 . The intermittent test targets  152  can be of the same design as the full test target  104  or can be of a different design. One or more intermittent test targets  152  are written  160  and sensed  162 . The measurements are taken from the photoreceptor or the image media such as sheets of paper. In one embodiment the intermittent test target is printed onto the paper that contains a desired print job. The paper is oversized and later is trimmed to a required page size thereby eliminating the target or targets. One, two, three or more sensing targets are used. Phase and amplitude of the determined banding frequencies are estimated  170 . The amplitude and phase are correspondingly updated  172  in the banding parameters memory  136 . In this manner, accurate estimates of the banding amplitude and phase are maintained throughout the marking process and are accurate at the time of feedback compensation. The banding frequency is updated as required. 
     With reference to  FIG. 4 , one or more of the determined banding frequencies is a low frequency  180 . In one embodiment, where the inboard and outboard zones  122 ,  124  are not available, the sensing is performed over a number of the test targets  152  which are disposed in two, three or more interdocument zones  120 . Since the low frequency  180  is generally determined in the full characterization mode  100 , the amplitude and phase of the low frequency banding are estimated by using intermittent sampling methods and algorithms known in the art, such as methods based on filtering or those used in radar signal processing. In this manner, portions of a band are sensed in successive test targets positioned in successive interdocument zones  120 . The amplitude and phase of the low frequency of banding are determined. In another embodiment, where a width of one interdocument area  120  is not wide enough to sense and sample a complete period of banding to estimate the amplitude and phase of a low frequency banding component, the sampling is complemented by the inboard and outboard sampling zones  122 ,  124 . E.g., a combination of targets is sensed and measured. For example, the targets can be disposed in one or more of each of the interdocument zone  120 , inboard zone  122 , and outboard zone  124   
     In one embodiment, a combination of targets is used such that the targets are disposed in two or more interdocument, inboard and outboard areas  120 ,  122 ,  124 . A combination of targets facilitates a determination whether a full characterization mode  100  needs to be performed  178 , e.g. whether the spatial variation has changed significantly since last full characterization mode  100  was performed. For example, a parameter is measured which is compared to a reference value. If the parameter value exceeds the reference value, a triggering device or means  180  automatically triggers  182  the full characterization mode  100 . As another example, a message may be sent or displayed to a user to start the full characterization mode  100 . The user manually triggers the triggering device  180  such as a push button or a software option to start the full characterization mode  100 . 
     It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.