JP2006015519A - Image forming apparatus and its management method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve such a problem that it is difficult to totally cover data obtained from experiments in a laboratory because user environments, job setting conditions and the like in which an image forming apparatus is actually used are various. <P>SOLUTION: When a failure or a trouble of no consumables occurs, it is determined on the basis of diagnostic data whether or not the trouble is a wear system trouble by change with time. When the trouble is the wear system trouble, a difference between a user set value at the previous trouble occurrence time and a user set value at the present trouble occurrence time is stored. When the user sets a set value to execute a job (step S21), if the set value exceeds a value of the difference (step S22), a warning message is generated even if the wear system trouble is not brought about (step S23). <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to an image forming apparatus such as a copying machine, a printer, and a facsimile machine and a management method thereof, and more particularly to an image forming apparatus having functions of failure diagnosis and consumable management and a management method thereof.

  In image forming apparatuses such as copying machines, printers, and facsimile machines, logging data indicating usage / setting conditions, used recording paper / document information, cumulative number of sheets, and image / conveyance quality information is sent to the host to predict parts replacement time. A remote maintenance support system that predicts the maintenance time is known (for example, see Patent Document 1).

  On the other hand, conventionally, in order to detect troubles such as a jam (paper jam) in the apparatus main body of the image forming apparatus and the consumption of consumables, the threshold parameters obtained by experiments are stored in the ROM or nonvolatile memory of the apparatus main body. The threshold parameter is compared with the actual detection sensor value, the number of printed sheets of the user, and the like.

JP 2000-305886 A

  However, there are various user environments and job setting conditions in which the image forming apparatus is actually used, and it is difficult to cover all of the data obtained from experiments in the laboratory. In addition, there is a limitation on the memory capacity of the storage device built in the device body (for example, reduction of memory capacity due to reduction in production cost), and threshold parameters that take into consideration all usage conditions are prepared in the device body in advance. It is impossible to leave. In addition, it is difficult to accurately perform troubles and preliminary predictive diagnosis of consumables using only the information indicating the usage status such as the number of copies for each paper size and the number of times of copying in black and white / color.

  The present invention has been made in view of the above-described problems, and an object of the present invention is to provide an image forming apparatus capable of early detection of occurrence of wear-related troubles due to changes over time and signs of consumable consumption, with high accuracy. It is to provide the management method.

  In order to achieve the above object, the present invention stores diagnostic data for failure diagnosis or consumable management when it is detected that a failure or no consumable has occurred based on a predetermined threshold. Based on the stored diagnostic data, it is determined whether failure or no consumables is a wear-related trouble due to aging. When it is determined that the wear-related trouble has occurred, the difference between the setting value for the job execution by the user at the time of the previous trouble occurrence and the setting value for the job execution by the user at the time of the current trouble is saved, and When the set value for executing the job exceeds the stored difference value, a warning message is issued regardless of whether or not the wear trouble has occurred.

  In the image forming apparatus, first, detection of occurrence of a failure or no consumable is performed based on a predetermined threshold value (threshold value for warning (prediction) detection). In addition, when a failure or no consumables occurs, the determination unit determines whether the failure or no consumables is a wear-related problem due to aging based on the diagnostic data stored in the storage unit. In the case of a wear system trouble, the difference between the user set value at the time of the previous trouble occurrence and the user set value at the time of the current trouble occurrence is stored in the storage means. When the setting value is set when the user performs the job, if the setting value exceeds the difference value, the wear-related trouble has not occurred regardless of whether or not the wear-related trouble has occurred. Also generate a warning message.

  According to the present invention, when a setting value is set when a user performs a job, a warning message is generated when the setting value exceeds the difference value, even if no wear-related trouble has occurred. This makes it possible to detect the occurrence of wear-related troubles due to changes over time and the sign of consumable consumption at an early stage with high accuracy, thereby reducing the downtime of the apparatus.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

  FIG. 1 is a schematic configuration diagram showing, for example, a tandem digital color copying machine to which the present invention is applied. As is apparent from FIG. 1, the digital color copying machine according to this application example includes an image reading unit 10, an image forming unit 20, a paper feeding unit 30, and the like, and an operation having a display function on the upper surface side of the apparatus main body, for example. A panel unit (user I / F (interface) display unit) 40 is included.

  In the image reading unit 10, the image of the document 50 placed on the platen glass 11 passes through the mirror system 13 as image light that is reflected light from the document surface based on the irradiation light from the illumination lamp 12. The lens 14 forms an image on an imaging surface of an optical sensor, for example, a CCD (Charge Coupled Device) image sensor 15. Then, when the original image is a color image, for example, the CCD image sensor 15 reads the reflectance information of the original 50 as R (red), G (green), and B (blue) signals, and R, G, B Each signal is output.

  The image forming unit 20 includes image forming engines 21Y, 21M, 21C, and 21K for each color material of Y (yellow), M (magenta), C (cyan), and K (black) as an image output device. . These image forming engines 21Y, 21M, 21C, and 21K are arranged horizontally and in series in the order of Y, M, C, and K, for example, from the right side of the drawing, that is, from the upstream side in the sheet conveyance direction.

  In the image forming engine 21Y, an on-duty time of a laser beam is determined for each pixel around the photosensitive drum 22Y as an image carrier in accordance with a Y signal, and the photosensitive drum 22Y is exposed to expose an electrostatic latent image. For developing an electrostatic latent image on an exposure source (image writing device) 23Y, a charger 24Y for uniformly charging the surface of the photosensitive drum 22Y, and the photosensitive drum 22Y into a toner image by an electrophotographic process. A developing device 25Y, a transfer device 26Y for transferring a toner image onto a sheet (recording paper), a cleaner 27Y for collecting residual toner after transfer, and the like are disposed. The developing device 25Y contains a cartridge (not shown) that stores toner.

  Similar to the image forming engine 21Y, an exposure source 23M, a charger 24M, a developing device 25M, a transfer device 26M, a cleaner 27M, and the like are disposed around the photosensitive drum 22M of the image forming engine 21M. An exposure source 23C, a charger 24C, a developing device 25C, a transfer device 26C, a cleaner 27C, and the like are disposed around the drum 22C. An exposure source 23K and a charger 24K are disposed around the photosensitive drum 22K of the image forming engine 21K. A developing device 25K, a transfer device 26K, a cleaner 27K, and the like are arranged.

  In the tandem digital color copying machine including the image reading unit 10 and the pixel forming unit 20 having the above-described configuration, first, a Y (yellow) signal is converted into an optical signal by the exposure source 23Y, and the photosensitive drum is irradiated with the laser beam. An electrostatic latent image corresponding to the original image is formed on 22Y. The Y latent image is developed into a toner image by the developing device 25Y. Then, the transfer unit 26Y transfers the toner image to the Y electrostatic latent image on the sheet fed from the sheet tray 31 of the sheet feeding unit 30 and conveyed by the sheet conveying belt 60.

  Subsequently, the exposure source 23M outputs a light signal of M (magenta), and the toner image of M is applied to the sheet conveyed by the conveying belt 60 through the steps of forming and developing the electrostatic latent image of M. Is transferred by the transfer machine 26M. In the same manner, C (cyan) and K (black) latent images are formed, developed, and transferred. In this way, the transfer of four colors is sequentially performed on the sheet conveyed by the conveyance belt 60. When the transfer of the fourth color is completed, the sheet is sent to the fixing device 28, where the toner image is fused and fixed, and a series of image forming processes is completed.

[First Embodiment]
FIG. 2 is a block diagram showing an example of the configuration of the control system in the digital color copying machine according to the first embodiment of the present invention. As shown in FIG. 2, the control system 80 according to this example includes a controller 81, a nonvolatile memory 82 as storage means and storage means, a jam (paper jam) detection sensor group 83, an accumulation counter group 84, and the like. Yes.

  The controller 81 is constituted by, for example, a CPU, controls the entire digital color copying machine, and receives various setting values (job execution volume) set by the user in executing the job in the operation panel unit (user interface unit) 40. In addition, a function that detects the occurrence of a failure or no consumable trouble based on a predetermined threshold (threshold for warning (prediction) detection), and whether a trouble or no consumable is a wear-related trouble due to changes over time based on diagnostic data described later For example, a function (notification means) for issuing a warning message to the user through the display screen of the operation panel unit 40.

  The nonvolatile memory 82 stores various parameters used when controlling the entire apparatus. This parameter includes the warning detection threshold (predetermined threshold). The non-volatile memory 82 stores diagnostic data for failure diagnosis and consumable management each time a failure or trouble without consumables occurs.

  Further, when the controller 81 determines that the failure or no consumables is a wear-related trouble due to a change with time, the setting value (hereinafter referred to as “user”) The difference between the setting value and the user setting value at the time of the current trouble is stored. The “previous” and “current” mentioned here are based on the occurrence of a wear-related trouble.

  That is, if a wear-related trouble due to a change with time occurs during job execution, the user set value at that time is stored in the non-volatile memory 82 as the current set value, and when the previous wear-related trouble occurs, the non-volatile memory 82 is stored. The controller 81 calculates a difference from the previous user setting value stored in the memory and stores the difference in the nonvolatile memory 82.

  The jam detection sensor group 83 includes a plurality of jam detection sensors provided at appropriate locations in the paper feed path by the paper transport belt 60, the transport rollers, and the like. The data is given to the controller 81 as diagnostic data for diagnosis and consumable management. The integration counter group 84 includes an integration counter that integrates the number of printed sheets for each paper size, an integration counter that integrates the number of printed sheets for each paper quality, an integration counter that integrates the number of printed sheets for each paper tray, and the like. Is provided to the controller 81 as diagnostic data for fault diagnosis and consumable management.

  Here, the user environment information of the paper size, paper quality, and paper tray is taken as an example of the diagnostic data, but is not limited to this, and user environment information such as density, resolution, temperature and humidity is also possible.

  Next, a series of processing procedures executed under the control of the controller 81 when a failure or a trouble with no consumables occurs will be described with reference to the flowchart of FIG.

  First, the controller 81 determines whether or not a trouble such as a failure or no consumable has occurred, based on a predetermined threshold (warning detection threshold) (step S11). Here, a case where a jam occurs as a trouble will be described as an example. When the trouble is a jam, the occurrence of the jam is detected based on the conveyance timing information for each jam detection sensor given from the jam detection sensor group 83.

  Specifically, for each jam detection sensor of the jam detection sensor group 83, a temporal threshold is set at the timing when the paper (recording paper) passes through each sensor position, and the paper detects the sensor position within the threshold. If it does not pass, it is detected that a jam has occurred. Therefore, when a jam occurs, the threshold for the timing when the sheet passes through the sensor position becomes the warning detection threshold.

  When the controller 81 determines that a failure or a trouble with no consumables has occurred, diagnostic data for failure diagnosis or consumable management is stored in the nonvolatile memory 82 (step S12), and then stored in the nonvolatile memory 82. Based on the diagnosis data, it is determined whether or not the trouble with no failure or no consumable is a wear-related trouble due to aging (step S13). This determination result is also stored in the nonvolatile memory 82 together with the diagnostic data.

  Here, when a jam occurs as a trouble, as the diagnosis data, as shown in FIG. 4, the history ID 1 to n of the jam ID = 1, the wear-type jam = Yes, and the past jam detection sensors. (N is determined by the number of jam detection sensors) is stored in the nonvolatile memory 82. Note that, as shown in FIG. 5, each integration counter of the integration counter group 85 performs a count operation for each print operation (every job execution), so that the count value of each integration counter is also stored as a diagnostic data in a nonvolatile memory. 82.

  When the controller 81 determines that the trouble with no trouble or no consumables is a wear-type trouble, the user set value at the time of this trouble occurrence, that is, the paper size and print set by the user on the operation panel unit 40 when the current job is executed. The setting values such as the number of sheets and the image quality are stored in the nonvolatile memory 82 (step S14), and then the user setting values stored in the nonvolatile memory 82 at the time of the previous trouble occurrence and the current trouble occurrence A difference from the user setting value is obtained, and the difference is stored in the nonvolatile memory 82 (step S15).

  As described above, a series of processes executed when a failure or a trouble with no consumables occurs is completed. On the other hand, based on the processing results of the above-described series of processing, warning detection (prediction detection) of occurrence of a failure or trouble without consumables is performed for each job execution.

  A processing procedure for detecting a warning of trouble occurrence will be described with reference to the flowchart of FIG. The process for detecting the warning of the occurrence of the trouble is also executed under the control of the controller 81.

  The controller 81 determines whether or not setting values (user setting values) such as the paper size, the number of prints, and the image quality are input from the operation panel unit 40 by the user (step S21), and the user setting values are input. Then, the difference value stored in the nonvolatile memory 82, that is, the difference value between the user setting value at the time of the previous trouble occurrence and the user setting value at the time of the current trouble occurrence obtained in step S15. It is judged whether or not (step S22).

  And if the current user setting value exceeds the value of the difference between the user setting value at the time of the previous trouble occurrence and the user setting value at the time of the current trouble occurrence, regardless of the occurrence of the wear-related trouble, That is, even if no wear-related trouble has occurred, a warning message indicating that the wear-related trouble is likely to occur, for example, is generated, and the warning message is displayed on the display screen of the operation panel unit 40, for example. Inform the user to that effect (step S23).

  In this example, the warning message is displayed on the display screen of the operation panel unit 40 to notify the user that the wear-out trouble is likely to occur. However, a plurality of digital color copiers are connected to the network. If a management system managed by the service center is established via the network, it is possible to send a warning message to the service center through the network so that it is easy to cause wear-related problems. is there.

  When the current user setting value exceeds the value of the difference between the user setting value at the time of the previous trouble occurrence and the user setting value at the time of the current trouble occurrence, the controller 81 is further stored in the nonvolatile memory 82. The threshold value for warning detection is changed by a predetermined amount so that the detection of the occurrence of failure or no consumables in step S11 is accelerated, that is, the warning detection conditions from the next time are made stricter (step S24).

  Taking a case where a jam has occurred as a problem, as shown in FIG. 7, among the jam 1 warning detection threshold data to the jam N warning detection threshold data stored in the nonvolatile memory 82 as the warning detection threshold, The threshold data corresponding to the jam detection sensor in which a jam has occurred this time is adjusted by a predetermined amount so that the detection conditions for the next warning become stricter.

  Note that here, when the current user setting value exceeds the difference between the user setting value at the time of the previous trouble occurrence and the user setting value at the time of the current trouble occurrence, the warning detection threshold is set to the next warning value. However, the value of the difference stored in the non-volatile memory 82 is set so that the warning message is generated earlier, that is, the detection condition for the occurrence of a wear-related trouble from the next time. It is also possible to change the predetermined amount so as to be severe.

  As described above, when a failure or no consumables occurs, it is determined whether the failure or no consumables is a wear-related trouble due to aging based on the diagnostic data. The difference between the user setting value at the time of the trouble occurrence and the user setting value at the time of the current trouble is saved, and when the user sets the setting value when executing the job, the setting value exceeds the difference value above. In this case, a warning message is generated even if no wear-related trouble has occurred, so that it is possible to detect wear-related troubles due to changes over time and signs of consumable consumption early and accurately. The downtime of the color copying machine can be reduced.

  In particular, when the current user setting value exceeds the difference between the user setting value at the time of the previous trouble occurrence and the user setting value at the time of the current trouble occurrence, the warning detection threshold is set to the next warning detection condition. By changing the value of the above difference so that the detection conditions for the signs of occurrence of wear-related troubles from the next time become stricter, the occurrence of wear-related troubles due to changes over time and signs of consumable consumption It can be detected earlier.

  By the way, the timing of occurrence of wear-related troubles differs depending on the user environment, such as the environment in which an image forming apparatus such as a digital color copying machine is installed or the job mode. It can be difficult to detect at the timing. In view of this point, a digital color copying machine according to a second embodiment of the present invention, which will be described below, has been made.

[Second Embodiment]
FIG. 8 is a conceptual diagram showing an image forming system including a digital color copying machine according to the second embodiment of the present invention. In FIG. 8, the apparatus 1 corresponds to the digital color copying machine according to the first embodiment, and the apparatus 2 corresponds to another apparatus other than the digital color copying machine. In the first embodiment, it is assumed that the nonvolatile memory 82 (see FIG. 2) as a storage unit is fixedly provided in the apparatus main body as a main body memory. In addition, a configuration having an expansion memory 85 that can be attached / detached to / from the apparatus main body is employed. The expansion memory 85 is also a nonvolatile memory.

  By executing the job with the extended memory 85 attached to the apparatus 1, a failure diagnosis and consumable management are performed in the extended memory 85 each time a failure or no consumable trouble occurs together with a warning detection threshold. When the wear-related trouble further occurs, the difference data (the wear-related trouble occurrence history) between the previous user set value and the current user set value is stored.

  The data stored in the expansion memory 85 is different by removing the expansion memory 85 from the device 1 and attaching it to the device 2, reading the data stored in the expansion memory 85 and storing it in the main body memory in the device 2. It can be shared between the devices 1 and 2. Specifically, for example, when multiple digital color copiers are installed in an office, the user environment is basically the same in the same office where the digital color copier is installed and the job mode. Therefore, it is possible to share information among a plurality of digital color copiers.

  As a result, it is only necessary to prepare one extended memory 85 for a plurality of digital color copiers in order to store trouble occurrence histories, analysis and diagnostic data. As a result, the cost burden on the user when introducing a plurality of digital color copiers can be reduced.

  In addition, when the information obtained by the device 1 is read and stored in the device 2 via the extended memory 85 and then the job is executed by the device 2, the first execution is performed based on the data read from the extended memory 85. Warning detection of trouble occurrence is performed according to the procedure described in the embodiment.

  Then, the difference between the user setting value in the device 2 read and stored from the extended memory 85 (the difference between the user setting value in the previous trouble occurrence in the device 1 and the user setting value in the current trouble occurrence) ) Exceeds the value, the warning message is generated even if no wear-related trouble has occurred, and the warning detection threshold value read from the extended memory 85 and saved is used as the next warning detection condition. Change to become more severe. In addition, when the user set value in the apparatus 2 exceeds the difference value read and stored from the extended memory 85, the detection condition for the sign of occurrence of a wear-related trouble from the next time becomes strict. It is also possible to change the predetermined amount so as to be.

  In the present embodiment, the diagnosis data is shared between a plurality of apparatuses via the expansion memory 85 that can be attached / detached to / from the apparatus main body. However, as shown in FIG. Are connected to each other via a network, the diagnostic data stored in the diagnostic data storage memory 86 (corresponding to the non-volatile memory 82 in FIG. 2) of the apparatus 1 is transferred via the network. It is also possible to share with the device 2.

  As mentioned above, by sharing diagnostic data of digital color copiers that are used by the same user or in a similar environment between copiers, the environment where the digital color copier is installed, job mode, etc. Since it is possible to accurately detect a wear-related trouble whose occurrence is affected by the user environment and warnings without consumables, the downtime of the digital color copying machine can be reduced.

  In the above embodiment, the case where the present invention is applied to a tandem digital color copying machine has been described as an example. However, the present invention is not limited to this application example, and other types of copying machines such as a multiple transfer system, Is applicable not only to copying machines but also to image forming apparatuses in general, such as printers and facsimile machines.

1 is a schematic configuration diagram showing a tandem digital color copying machine to which the present invention is applied. 1 is a block diagram illustrating an example of a configuration of a control system in a digital color copying machine according to a first embodiment of the present invention. It is a flowchart which shows the process sequence at the time of trouble generation | occurrence | production of a failure or no consumables. It is a figure which shows an example of the diagnostic data recorded for every jam generation. It is a figure which shows the content of the integration counter made to count for every print. It is a flowchart which shows the process sequence for the warning detection of trouble occurrence. It is a figure which shows the threshold value data for the warning detection of jam generation. It is a conceptual diagram which shows the image forming system containing the digital color copying machine which concerns on 2nd Embodiment of this invention. It is a conceptual diagram of the system which concerns on the modification of 2nd Embodiment.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Image reading part, 11 ... Platen glass, 14 ... Lens, 15 ... CCD image sensor, 20 ... Image formation part, 21Y, 21M, 21C, 21K ... Image formation engine, 22Y, 22M, 22C, 22K ... Photosensitive drum, 23Y, 23M, 23C, 23K ... exposure source, 24Y, 24M, 24C, 24K ... charger, 25Y, 25M, 23C, 25K ... developer, 26Y, 26M, 26C, 26K ... transfer device, 28 ... fixing device, 30 ... Paper feeding section, 40 ... Operation panel section (user I / F display section), 50 ... Document, 60 ... Paper transport belt, 80 ... Control system, 81 ... Controller, 82 ... Non-volatile memory, 83 ... Jam detection sensor group 84 ... Integral counter group, 85 ... Extended memory, 86 ... Diagnostic data storage memory

Claims (9)

Storage means for storing diagnostic data for fault diagnosis or consumable management when it is detected that a failure or no consumable has occurred with reference to a predetermined threshold;
Determining means for determining whether a failure or no consumable is a wear-related trouble due to aging based on the diagnostic data stored in the storage means;
When the determination unit determines that the wear-related trouble has occurred, a storage for storing a difference between a setting value when the user performs the job when the previous trouble occurs and a setting value when the user performs the job when the current trouble occurs Means,
And a notification means for issuing a warning message regardless of whether or not the wear-related trouble has occurred when a set value for executing a job by a user exceeds the difference value stored in the storage means. An image forming apparatus. The image forming apparatus according to claim 1, wherein when the current set value exceeds the difference value, the predetermined threshold value is changed to a side where detection of occurrence of a failure or no consumable item is accelerated. The image forming apparatus according to claim 1, wherein when the current set value exceeds the difference value, the difference value is changed to a side where the warning message is generated earlier. The image forming apparatus according to claim 1, wherein the storage unit stores an integrated value for user environment information at the time of job execution together with the predetermined threshold and the diagnostic data. The predetermined threshold value and the diagnostic data stored in the storage unit, and the difference value stored in the storage unit are shared with other devices. Image forming apparatus. The storage means and the storage means are expansion memories that can be attached / detached to / from the apparatus main body,
The other apparatus reads and stores the predetermined threshold value, the diagnostic data, and the difference value from the extended memory removed from the apparatus main body, and the set value when the job is executed by the user is stored in the extended memory. When the value of the difference read out and stored from the memory is exceeded, the predetermined threshold value read out and stored from the extended memory is changed to a side where the detection of occurrence of failure or no consumables is accelerated. The image forming apparatus according to claim 5. The storage means and the storage means comprise an extended memory that can be attached / detached to / from the apparatus main body,
The other apparatus reads and stores the predetermined threshold value, the diagnostic data, and the difference value from the extended memory removed from the apparatus main body, and the set value when the job is executed by the user is stored in the extended memory. 6. The image forming apparatus according to claim 5, wherein when the difference value read out and stored from the storage device exceeds the difference value, the difference value is changed to an earlier generation side of the warning message. The predetermined threshold value and the diagnostic data stored in the storage unit, and the difference value stored in the storage unit are shared with other devices via a network. The image forming apparatus according to claim 5. A first step of storing diagnostic data for fault diagnosis or consumable management when it is detected that a failure or no consumable has occurred with reference to a predetermined threshold;
A second step of determining whether failure or no consumable is a wear-related trouble due to a change over time based on the diagnostic data stored in the first step;
Saves the difference between the setting value for the job execution by the user when the previous trouble occurred and the setting value for the job execution by the user at the time of the current trouble when it is determined in the second step that the wear type trouble has occurred A third step,
And a fourth step of issuing a warning message regardless of whether or not the wear-out trouble has occurred when a set value for the job execution by the user exceeds the difference value stored in the third step. And a method of managing an image forming apparatus.

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