JP2006201633A - Unit-recycling system for image forming apparatus, and program for automatically determining replacement part - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an image forming apparatus with a unit-recycling system capable of improving efficiency in unit recycling, and to provide a program for automatically determining replacement parts. <P>SOLUTION: The unit recycling system is used for an image forming apparatus, in which a unit composing an image forming means is detachable from the body of the apparatus and a fresh unit is used by replacing the old one, if necessary. In the unit recycling system, in the event that image formation is abnormal, collected information about the abnormal state is stored, together with the individual determination information of the unit. The abnormal state information and the individual determination information are managed together with reference information about reasons for unit replacement, which is inputted by a person replacing the unit. Before the unit is recycled, the abnormal state information, the individual determination information, and the reference information are utilized. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a unit reproduction system and an automatic replacement part determination program for an image forming apparatus, and more particularly to a unit reproduction system and an automatic replacement part determination program for an image formation apparatus that can improve unit reproduction efficiency.

In an image forming apparatus, a large number of parts are used, each of which has a lifetime. In particular, the life of parts of the image forming system and the fixing system related to image formation is often shorter than that of the machine body. Therefore, maintenance work (= part replacement) is necessary when the lifetime of such parts comes. In addition, even if the life has not come, if some abnormality occurs in the apparatus, replacement work for parts that cause the abnormality occurs.
For example, Patent Document 1 proposes a technique for notifying a consumable end state and information necessary for replacement or reuse through printing or transmission / reception output. In the technique of Patent Document 2, the management of equipment including the operation status of the image forming apparatus and the process cartridge, and the settlement of expenses caused by parts supply, recycling recovery processing, and the like is performed.
Further, in the technique of Patent Document 3, when an abnormality occurs in the image forming process, the cause and the situation are diagnosed by a self-diagnostic program without the necessity of the user's own investigation, and the repairer is repaired by this data. It is assumed that the cause of the failure will be grasped in advance, and quick and reliable trouble repair will be realized.
JP 2002-006693 A JP 2001-251464 A JP 09-120247 A

By the way, conventionally, these parts replacement work is often performed by the service person near the machine body used by the user, but the replacement work takes time, and as a result, the machine stop time is lengthened. It was. In view of such a problem, in recent years, there has been an increasing number of cases in which replacement work is performed on a unit basis without performing part replacement work on the part of the user, and the replaced unit is brought back to each service station and replaced. .
Further, a system for providing a unit regeneration base, collecting the replaced units, and performing a part replacement operation in a lump is beginning to spread. With the widespread use of such systems, machine downtime during maintenance has been dramatically reduced. But this is another problem.
When the replaced units are collected at the recycling base, it becomes difficult to grasp the features of the collected units. Of course, it suffices to attach a report that records the machine usage status (print counter, etc.) at the time of replacement and the reason for replacement, but it takes time to create these reports. Furthermore, in the case of a maintenance kit or the like that is exchanged by the user, it is difficult to request the user to create a report thoroughly.
Accordingly, the present invention has been made in consideration of the above-described circumstances, and can store unit management information and manage it to improve unit regeneration efficiency and an image forming apparatus unit regeneration system and replacement parts. An object is to provide an automatic judgment program.

In order to solve the above problems, the invention according to claim 1 is an image forming apparatus in which a unit constituting the image forming means is configured to be detachable from the apparatus main body, and the unit is appropriately replaced with a new one. In the unit reproduction system, storage means for storing abnormality status information about the abnormality collected when there is an abnormality in image formation together with individual unit identification information of the unit, and an exchange operator inputs at the time of replacement of the unit Management means for managing the abnormal situation information and the individual discrimination information stored in the storage means together with reference information relating to the reason for replacement of the unit, and the management means is stored in the storage means before the reproduction of the unit. The unit is managed based on the stored abnormal situation information, the individual discrimination information, and the reference information.
According to a second aspect of the present invention, in the unit reproduction system of the image forming apparatus, the unit constituting the image forming means is configured to be detachable from the apparatus main body, and the unit is replaced with a new one as appropriate. Storage means for storing the abnormality status information about the abnormality collected when there is abnormality in the unit together with the individual identification information of the unit, and a reference regarding the reason for replacement of the unit that is input by the replacement operator when replacing the unit Management means for managing the abnormal situation information and the individual discrimination information stored in the storage means together with information in a database server, and the management means is stored in the storage means before the reproduction of the unit. The unit is managed based on the abnormal situation information, the individual discrimination information, and the reference information.
According to a third aspect of the present invention, a unit reproduction system of an image forming apparatus that prints out the reference information is a main feature.
According to a fourth aspect of the present invention, a unit reproduction system of an image forming apparatus having a program for automatically determining a part to be replaced from the reference information is a main feature.

According to a fifth aspect of the present invention, a unit reproduction system of an image forming apparatus capable of changing the reference information input permission setting is a main feature.
According to a sixth aspect of the present invention, the unit constituting the image forming means of the image forming apparatus is configured to be detachable from the apparatus main body, and used when the unit is regenerated after the unit is appropriately replaced with a new one. An automatic replacement part determination program for storing abnormality status information about abnormalities collected when there is an abnormality in image formation together with information for individual determination of the unit, and input by a replacement operator when replacing the unit The abnormal situation information and the individual discrimination information are managed together with reference information on the reason for replacement of the unit by a database server, and the parts to be replaced are automatically determined from the abnormal situation information, the individual discrimination information and the reference information. The main feature is a replacement part automatic judgment program for discriminating into two.
According to a seventh aspect of the present invention, the unit reproduction system of the image forming apparatus that can change the setting of whether to input the reference information is a main feature.
Further, in the invention according to claim 8, an image in which the input / output setting of the reference information is managed by the database server together with the individual discrimination information and the abnormality status information, and the information is used before the unit reproduction. The main feature is the unit regeneration system of the forming apparatus.
According to a ninth aspect of the present invention, there is provided a replacement part automatic determination program used in the unit reproduction system of the image forming apparatus according to the eighth aspect, wherein the individual determination information, the abnormal state information, and the reference information The main feature is a replacement part automatic determination program for automatically determining a part to be replaced from input enable / disable setting information.

  According to the present invention, it is possible to feed back to the regeneration process information other than what the machine can discriminate about the situation at the time of unit replacement, and the efficiency of unit regeneration can be improved.

The best mode for carrying out the present invention will be described below in detail with reference to the drawings. First, an outline of the overall configuration of a digital copying machine as an image forming apparatus in a unit reproduction system, which is the best mode for carrying out the present invention, will be described with reference to FIG. Sheets are sent out one by one from the selected sheet feeding tray out of the plurality of sheet feeding trays 2, 4, 6, 8 provided at the lower part of the apparatus to the registration roller pair 10 in order from the top sheet.
The sheet is fed out, and an electrostatic latent image is formed on the photosensitive member 16 by the image writing device 14 based on the image information read by the image reading device 12. The electrostatic latent image is visualized as a toner image by the developing device 18. The sheet is temporarily stopped by the registration roller pair 10 and then conveyed upward at a predetermined timing and sent between the photoconductor 16 and the transfer roller 20 to transfer the toner image. The sheet onto which the image has been transferred is further conveyed upward from the transfer unit and sent to the fixing device 22 where the image is fixed by heat and pressure.

The sheet on which the image is fixed is sent to one of the inner 1 bin tray 26, the relay unit 28, and the automatic duplex unit 30 through the paper discharge device 24. The paper sent to the relay unit 28 is sent to a paper discharge tray 96 formed on the upper surface of the unit or a finisher 94 as a paper post-processing device. The paper sent to the finisher 94 is directly output to the paper discharge tray 96 when post-processing such as binding processing is not specified, and is post-processed when the post-processing execution is specified. Discharged. The sheet conveyance path from the registration roller pair 10 to the fixing device 22 is set to be substantially vertical. After the sheet is sent upward from the fixing device 22, the direction is changed and the sheet is discharged to the inner 1 bin tray 26 and the like.
What is unitized in this digital copying machine is a “photosensitive unit” in which the photoconductor 16 and the developing device 18 are combined and a “fixing unit” in which the fixing device 22 is unitized. In addition to the photoconductor 16, the photoconductor unit includes components such as a charging member, a developing sleeve, a toner concentration sensor, a toner conveying screw, and a cleaning member. The fixing unit includes components such as a heater, a fixing roller (or belt), a pressure roller, a thermistor, and a thermostat (or a thermal fuse).
The unit has a life as a unit, and the count reference is the number of prints or the number of image formation. When the life counter for each unit exceeds a predetermined value, a message prompting replacement is displayed on the operation unit by making the machine inoperable. The replacement warning message may be displayed on the PC screen if there is a printer function. When this replacement warning message is displayed, the user contacts the service station, and the service person replaces the corresponding unit. If the replacement is possible by the user, it is necessary to display a notice message and prompt the preparation of a new unit before making the machine inoperable.
The exchanged unit is sent to the reproduction site by the service person or the user. These units have a full lifetime as a unit, but their lifetime is tailored to the component with the shortest lifetime, so some individual components are still usable. Therefore, it can be used again by replacing the short-life component in the regeneration process.

So far, we have described units that have reached the end of their life, but not all units that are replaced will end their life. If some abnormality occurs in the unit and it cannot be removed, the unit must be replaced. These units cannot be reproduced in the regeneration process as described above. Abnormality occurs because it is not always a short-life component. Therefore, when regenerating a unit that has been replaced due to an abnormality, if information on the cause of the abnormality is attached, the unit that caused the abnormality can be reused by replacing the part that caused the abnormality together with the short-life component. Is possible.
However, it is difficult to accurately determine the cause of the abnormality because it depends on the skill of the service person. Therefore, as in this example, it is important to attach information about the abnormal situation as reference information. If a part to be replaced at the time of reproduction is set in advance according to the type of abnormality, the part to be replaced can be immediately discriminated from the abnormality state information attached to the unit. That is, it is possible to efficiently regenerate both the unit that has reached the end of its life and the unit that has not.
FIG. 2 shows a configuration example of a control unit of a digital copying machine (example of a multi-function machine). In the control unit 31, a CPU 32 having a ROM 33, a RAM 34, and a non-volatile RAM 35 is connected to an image reading device 36, a latent image forming unit 37, a high voltage power supply 38 for image formation, a fixing unit 39, a driving unit 40, a paper feeding unit 41, and an operation. A panel unit 42, a PC interface 43, a network interface 44, and a modem 45 are connected.
Among these, the PC interface 43 is connected to a user's PC outside the image forming apparatus main body, the network interface 44 is connected to an office LAN or the like, and the modem 45 is connected to a telephone line. The CPU 32 controls the above input / output devices according to a control program written in the ROM 33 in advance. Data input / output in this control is temporarily stored in the RAM 34.

First, when a user or a service person newly installs a new unit in the digital copying machine, it is necessary to make the digital copying machine recognize the unit serial number before performing a printing operation. As a method of recognizing
a) Have a user or service person enter keys from the operation unit of the digital copying machine.
b) The sheet on which the replacement unit serial number information (individual discrimination information) is printed is read by an image reading device of a digital copying machine.
c) A barcode sticker of serial number information is pasted on the replacement unit and read by a dedicated reader in the digital copying machine.
However, since technology related to ID chips has been developed in recent years,
d) A contact type ID chip is mounted on the exchange unit and read by a dedicated reader in the digital copying machine.
e) A non-contact type ID chip is mounted on the exchange unit and read by a dedicated reader in the digital copying machine.
There are methods.
As described above, since various methods can be used for the storage means, they are not illustrated. The unit serial number recognized by the digital copying machine by these methods is stored in an area allocated for storing the serial number for the corresponding part in the nonvolatile RAM 35 so that the information is not lost even if the main power is turned off. The
Usually, the digital copying machine has a function of counting the number of prints, and the counter value is stored in the RAM 34 or the nonvolatile RAM 35 in the control unit, and the counter value increases by a predetermined increment every time one sheet is printed. It is like that. In this example, a counter value storage area for each unit is provided on the non-volatile RAM 35 in addition to the print number counter from the start of use of the digital copying machine.

When a new unit is mounted on the digital copying machine, the printed sheet counter of the digital copying machine itself maintains the value as it is, but the counter for the replaced unit is cleared to zero. When the unit is used to output an image from the digital copying machine, the counter for each unit stores the number of used sheets for the currently used unit.
When the unit is replaced, the digital copier is made aware of this. When the service person has exchanged, it is possible to input “which unit has been exchanged” from the operation unit, but it is desirable that the user exchange unit (maintenance kit) can automatically detect the exchange.
Thus, when the digital copying machine recognizes that a certain unit has been replaced, the processing shown in the flowchart of FIG. 3 is performed. First, the serial number and counter value of the replaced unit are stored in a buffer (not shown), and the counter itself is cleared to 0 (steps S1 to S2). Next, it is determined whether or not the unit life has been reached (step S3). If it has reached the end of its service life, the process is terminated. If not, it is determined that some sort of abnormality has occurred and it has been replaced, and information about the abnormality is collected.
First, the serviceman call history due to abnormality in self-diagnosis is referred to (step S4). Next, the jam history is referred to (step S5). Finally, information about abnormalities that cannot be determined by the machine is collected as reference information, but since there is only a method for contacting a service person or a user after that, a screen prompting input is displayed on the operation unit (see FIG. 4). . Abnormalities that cannot be determined by the machine are mainly “abnormal images”, “abnormal noise”, “paper wrinkles”, “fixing failure”, etc., and a button for selecting these is displayed on the screen (step S6). If “abnormal image” is selected, a button for inputting a more detailed situation (background dirt, blurring, streaks, density unevenness, etc.) is displayed (step S7). Image type information is stored (step S8).
The reference information stored in the above process is stored in the machine as individual unit information, such as a serial number, and individual identification information such as a serial number, and fed back to the unit regeneration process. To do.

Next, Example 2 will be described. The second embodiment is a case where the information on the reason for unit replacement stored in the machine body at the time of unit replacement is transmitted and stored in a database server installed at a service base in the first embodiment. In the examples shown in the second and subsequent examples, the description of the same parts as those in the first example is omitted.
As a transmission method to the database server,
f) Direct access to the database server using a telephone line.
g) Connect to the Internet using a telephone line and access via the network.
h) Access via the network using the network interface.
i) Use the PC interface to access via the user's PC through a telephone line or network connected to the PC.
j) Access through a wireless communication line by connecting a mobile phone terminal or the like.
The method can be considered.
FIG. 5 is a work flow diagram showing an example of the reproduction process of the photosensitive unit. First, in the disassembling / cleaning step 61, the photosensitive unit is disassembled to remove parts, and the remaining toner and waste toner are cleaned / removed. Then, in the part selection step 62, the part removed from the photosensitive unit is inspected to determine whether or not it can be reused. The part judged to be unusable is discarded, and a new part is put on the process instead. It is done. Here, means for accessing the database server 70 and means for displaying information obtained from the database server 70 (PC 71) are prepared in the part selection step 62 in the reproduction step. In this case, access via a network is preferable in terms of efficiency.
In addition to the PC 71, PCs 72 to 74 are connected to the database server 70 as shown in FIG.
In the next reassembly step 63, the photosensitive unit is returned to its original form using the parts sent from the previous step. Toner filling and the like are also performed in this step. In the image inspection step 64, the photoconductor unit is mounted on the jig digital copying machine, a test image is output, and the presence or absence of an abnormal image is checked. If there is an abnormality, it is sent to the repairing process 65, the cause of the abnormality is analyzed, the part causing the abnormality is replaced and repaired, and the process is returned to the image inspection process again. In the characteristic value measurement 66, the characteristic value of the unit is measured. Finally, in the packing / shipping process 67, the history of the process up to that time is checked, and if there is no problem, packing / shipping is performed.

  Next, Example 3 will be described. The third embodiment is an example in which the information on the reason for unit replacement stored in the machine body at the time of unit replacement is printed out in the first embodiment. As the print format, a barcode or a two-dimensional code can be considered. The paper output in this way is collected together with the unit. The work flow of the regeneration process of Example 3 is shown in FIG. In the component sorting step 62, a reading / display unit 91 for reading and displaying the information at the time of unit replacement printed on the paper is prepared.

  Next, Example 4 will be described. In the fourth embodiment, in the second and third embodiments, the means for displaying the information at the time of replacement of the unit recovered in the regeneration process includes a program for determining a part to be replaced based on the information. It is. As a result, in the component selection step 52, the name of the component that needs to be replaced is immediately displayed.

Next, Example 5 will be described. In the fifth embodiment, the display possibility of the unit replacement reason input screen can be changed in the first to fourth embodiments. Examples of the display permission / inhibition setting pattern include the following.
k) It is set at the time of shipment according to the character of the machine (whether the machine has a lot of user maintenance).
l) Settings can be changed by service personnel.
Note that if the setting is not displayed, only abnormal information that can be determined by the machine is collected, and this must be fed back to the reproduction process.

  Next, Example 6 will be described. In the sixth embodiment, even if information is downloaded from the database server in the reproduction process in the second embodiment, it is not efficient if it takes time to determine a part to be replaced. Therefore, this is a replacement part automatic determination program that automatically determines a part to be replaced based on the individual unit identification information, abnormality status information, and reference information (unit replacement reason information). By introducing this program, the time required for determining the part to be replaced can be greatly reduced.

Next, Example 7 will be described. In the seventh embodiment, the replacement reason input screen is displayed whenever the predetermined number of sheets has passed even if there is no abnormality in the second embodiment. This is a case corresponding to a case where the frequency of inputting is increased and the user feels bothersome. In preparation for such a case, in this example, it is possible to change the display availability setting of the input screen for reference information (reason for unit replacement). The following display possibility setting patterns are conceivable.
a) It is set at the time of shipment according to the characteristics of the machine (whether the machine has a lot of user maintenance).
b) Settings can be changed by service personnel.
As a result, the unit replacement reason information input screen display setting according to the user usage status and the character of the machine becomes possible.

  Next, Example 8 will be described. In the eighth embodiment, in response to the fact that only the abnormal situation information that can be determined by the machine itself is collected when the setting is made so that the unit replacement reason input screen is not displayed in the seventh embodiment, the unit replacement reason input screen display permission setting is also set. This is a case where the information is reflected in the replacement part determination as a management target of the database server. In this example, it is possible to construct a unit reproduction system that takes into account setting changes in accordance with usage conditions in the field.

Subsequently, Example 9 will be described. Embodiment 9 is a replacement part automatic determination program for determining replacement parts in consideration of the unit individual determination information and abnormality status information in addition to the reference information (reason for unit replacement) input screen display enable / disable setting in the eighth embodiment. It is. Since there is no unit replacement reason information, the accuracy is lower than in the example of the sixth embodiment. However, the level is determined and displayed as “replacement-required part” and “replacement-recommended part” accordingly. For parts that are determined to be “recommended for replacement”, whether or not they can be replaced is examined by visual inspection or characteristic value measurement. As a result, even when there is no unit replacement reason information, the unit can be efficiently reproduced.
As described above, in the unit regeneration system and the replacement part automatic determination program that are the best mode for carrying out the present invention, information other than what the machine can discriminate about the situation at the time of unit replacement is used in the regeneration process. Feedback can be performed, and the efficiency of unit reproduction can be improved.

1 is a schematic diagram of the overall configuration of a digital copying machine in a unit reproduction system that is the best mode for carrying out the present invention. FIG. 2 is a block diagram illustrating a configuration example of a control unit of a digital copying machine. 6 is a flowchart showing the operation of the digital copying machine after unit replacement recognition. The figure which shows the example of the input screen displayed on an operation part. FIG. 5 is a work flow diagram illustrating an example of a reproduction process of a photoreceptor unit. FIG. 10 is a work flow diagram of a regeneration process according to the third embodiment.

Explanation of symbols

2, 4, 6, 8 Paper feed tray, 10 Registration roller pair, 12 Image reading device, 14 Image writing device, 16 Photoconductor, 18 Developing device, 20 Transfer roller, 22 Fixing device, 24 Paper discharge device, 26 Inner 1 Bin tray, 28 relay unit, 30 automatic duplex unit, 31 control unit, 32 CPU, 33 ROM, 34 RAM, 35 nonvolatile RAM, 36 image reading device, 37 latent image forming unit, 38 high voltage electric wire for image formation, 39 fixing unit, 40 Drive unit, 41 Paper feed unit, 42 Operation panel, 43 PC interface, 44 Network interface, 45 Modem, 61 Disassembly / cleaning process, 62 Parts selection process, 63 Assembly process, 64 Image inspection process, 65 Repair process, 66 Characteristics Value measurement, 67 Packing / shipping process, 70 Database server -, 71, 72, 73, 74 PC, 91 Reading / display means, 94 finisher, 96 discharge tray

Claims (9)

In the unit reproduction system of the image forming apparatus, the unit constituting the image forming means is configured to be detachable from the apparatus main body, and the unit is appropriately replaced with a new one.
Storage means for storing abnormality status information about the abnormality collected when there is an abnormality in image formation together with information for individual determination of the unit, and the reason for replacement of the unit that is input by a replacement operator when replacing the unit Management means for managing the abnormal situation information and the individual discrimination information stored in the storage means together with the reference information regarding the management information, and the management means stores the abnormal situation stored in the storage means before the reproduction of the unit. A unit reproduction system for an image forming apparatus, wherein the unit is managed based on information, the individual discrimination information, and the reference information. In the unit reproduction system of the image forming apparatus, the unit constituting the image forming means is configured to be detachable from the apparatus main body, and the unit is appropriately replaced with a new one.
Storage means for storing abnormality status information about the abnormality collected when there is an abnormality in image formation together with information for individual determination of the unit, and the reason for replacement of the unit that is input by a replacement operator when replacing the unit Management means for managing the abnormal situation information and the individual discrimination information stored in the storage means together with the reference information on the database server, the management means in the storage means before the reproduction of the unit A unit reproduction system of an image forming apparatus, wherein the unit is managed based on the stored abnormal condition information, the individual discrimination information, and the reference information. The unit reproduction system of the image forming apparatus according to claim 1,
A unit reproduction system of an image forming apparatus, wherein the reference information is printed out. In the unit reproduction system of the image forming device according to claim 2 or 3,
A unit reproduction system for an image forming apparatus, comprising a program for automatically discriminating a part to be exchanged from the reference information. In the unit reproduction system of the image forming device according to any one of claims 1 to 4,
A unit reproduction system of an image forming apparatus, wherein the reference information input permission setting can be changed. A replacement part automatic determination program used when the unit constituting the image forming unit of the image forming apparatus is configured to be detachable from the apparatus main body, and the unit is appropriately replaced with a new one, and then the unit is regenerated.
Reference information relating to the reason for replacement of the unit, which is stored by the replacement operator when the unit is replaced, is stored together with the individual discrimination information of the unit collected when there is an abnormality in image formation. In addition, the abnormal situation information and the individual discrimination information are managed by a database server, and a part to be exchanged is automatically discriminated from the abnormal situation information, the individual discrimination information, and the reference information. Automatic component judgment program. The unit reproduction system of the image forming apparatus according to claim 2,
A unit reproduction system of an image forming apparatus, wherein the reference information input permission setting can be changed. The unit reproduction system for an image forming apparatus according to claim 7,
The unit reproduction system of the image forming apparatus, wherein the database server manages the reference information input permission setting together with the individual discrimination information and the abnormality status information, and uses the information before the unit reproduction. . 9. A replacement part automatic determination program used in a unit reproduction system of an image forming apparatus according to claim 8, wherein a part to be replaced is automatically determined based on the individual discrimination information, the abnormal state information, and the input information availability setting information of the reference information. A replacement part automatic determination program characterized in that it is automatically determined.

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