JP2010211147A - Image forming apparatus and prediction program - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an image forming apparatus capable of accurately predicting the replacement time of a consumable good used for a print output ensuring good print quality, and to provide a prediction program. <P>SOLUTION: A replacement time analysis part 19 determines setting information for consumable goods based on environmental data of a printing environment, and forms a prediction expression for predicting the replacement time of a consumable good when the consumable good is set based on the setting information. The replacement time of the consumable good is calculated by executing the formed prediction expression. Further, the next adjustment time is determined according to the printing state, whereby an optimum replacement time of the consumable good according to the printing state is calculated. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to an image forming apparatus and a prediction program.

  Printing processing by an image forming apparatus or the like is performed using a predetermined printing material by operating various components in the printing processing process. Among these components and printing materials, there are consumables that need to be replaced or replenished as the use state advances. Examples of consumables include a photoreceptor, toner, a transfer mechanism, and a fixing mechanism.

  These consumables have different lifetimes such as the number of prints that can be used (number of prints) and elapsed time due to differences in their functions and applications, and it is necessary to replace the consumables to prevent the print processing function from stopping. It is necessary to accurately predict the correct time.

  In the prior art disclosed in Patent Document 1, the estimated amount of toner consumption based on the image formation signal is verified by the amount of toner detected based on the optical density of the inspection toner image, and unnecessary toner replenishment is obtained. It is possible to prevent such a situation and a situation where the toner runs out.

  Using such a technique, the lifetime of consumables is accurately predicted and the convenience of the apparatus is improved, but this lifetime varies greatly depending on the use environment.

  In Patent Document 2, by controlling each parameter that determines the operation of the color stabilization control as a set, it is possible to achieve optimal image stabilization that matches the change in the situation. Is published.

JP-A-10-123820 JP 2003-228201 A

  SUMMARY OF THE INVENTION An object of the present invention is to provide an image forming apparatus and a prediction program that can accurately predict the replacement time of consumables used for print output that ensures good print quality.

  In order to achieve the above object, the invention of claim 1 adjusts the setting means for detecting the environmental data in the printing environment, and the setting information of each consumable used for the print output based on the environmental data detected by the detecting means. A setting information adjusting unit; and a prediction formula creating unit that creates a prediction formula for predicting a replacement time that requires replacement of the consumable by printing out based on the setting information adjusted by the setting information adjusting unit; Replacement time prediction means for predicting the replacement time of the consumables based on the prediction formula created by the prediction formula creation means.

  According to a second aspect of the present invention, in the first aspect of the invention, a print history storage unit that stores a print history relating to a print output performed based on the setting information adjusted by the setting information adjustment unit, and the print history storage. Determining means for determining the adjustment time of the setting information performed by the setting information adjusting means based on the print history stored by the means.

  According to a third aspect of the present invention, in the second aspect of the present invention, the adjustment information management unit includes an adjustment condition management unit that manages an adjustment condition for adjusting the setting information by the setting information adjustment unit, and the determination unit includes the print history. When the print history stored in the storage means satisfies the adjustment condition managed by the adjustment condition management means, the adjustment time is determined.

  According to a fourth aspect of the present invention, in the first or second aspect of the present invention, the apparatus includes a detecting unit that detects replacement of the consumable item, and the setting information adjusting unit detects the replacement of the consumable item by the detecting unit. The setting information of the consumable item is adjusted based on the environmental data detected by the detecting means.

  According to a fifth aspect of the present invention, in the invention of the second or third aspect, the adjustment condition management means adjusts conditions based on a print history stored by the print history storage means and environmental data detected by the detection means. The determination unit determines that the adjustment time is satisfied when at least one of the print history and the environmental data for the adjustment condition managed by the adjustment condition management unit is satisfied.

  According to a sixth aspect of the present invention, in the third aspect of the present invention, the adjustment condition management unit manages an adjustment condition according to an implementation status of the print output based on a print history managed by the print history management unit.

  According to a seventh aspect of the invention, in the sixth aspect of the invention, the adjustment condition management unit manages an adjustment condition based on an average number of printed sheets based on a print history managed by the print history management unit.

  According to an eighth aspect of the present invention, in any one of the first to seventh aspects of the present invention, the measuring means for measuring the actual remaining amount with respect to the total usable amount of each of the consumables, and the printing managed by the printing history managing means. Comparing the remaining usable amount calculating means for calculating the remaining usable amount of the consumable based on the history, the actual remaining amount measured by the measuring means and the remaining usable amount calculated by the remaining usable amount calculating means And a difference calculation means for calculating the difference, and when the difference is calculated by the difference calculation means, the prediction expression generation means generates a prediction expression composed of a coefficient derived from the difference and a correction term. To do.

  The invention according to claim 9 is based on setting information adjusting means for adjusting setting information of each consumable used for print output based on environmental data in a printing environment, and setting information adjusted by the setting information adjusting means. Prediction formula creation means for creating a prediction formula for predicting the replacement time when the consumables need to be replaced by print output, replacement time prediction for predicting the replacement time of the consumables by the prediction formula created by the prediction formula creation means It functions as a means.

  According to the first aspect of the present invention, there is an effect that it is possible to accurately predict the replacement time of the consumables used for the print output ensuring good print quality.

  According to the second aspect of the present invention, it is possible to adjust the setting information at an optimal time according to the printing status, and it is possible to accurately predict the replacement time of the consumables.

  According to the third aspect of the present invention, it is possible to adjust the setting information according to the adjustment condition based on the print history, and it is possible to accurately predict the replacement time of the consumables.

  According to the fourth aspect of the present invention, by changing to a new consumable item, the setting information is adjusted according to the consumable item, and the replacement time of the consumable item by the print output based on the setting information is accurately determined. There is an effect that it can be predicted.

  According to the fifth aspect of the present invention, it is possible to adjust the setting information of the consumables according to the adjustment conditions according to the printing environment, and to provide an optimum printing environment and to set the replacement time of the consumables based on the printing environment. It has the effect of being able to predict accurately.

  According to the sixth aspect of the present invention, it is possible to adjust the setting information at an optimal timing according to the print output implementation status.

  According to the seventh aspect of the present invention, it is possible to adjust the consumable setting information at an optimal timing based on the average number of printed sheets per day or unit time.

  Further, according to claim 8, there is an effect that it is possible to predict the replacement time of the consumables based on the more accurate usage amount.

  In addition, according to the ninth aspect, there is an effect that it is possible to accurately predict the replacement time of the consumables used for the print output ensuring the good print quality.

1 is an example of a diagram illustrating a configuration of an image forming apparatus configured by applying an image forming apparatus and a prediction program according to an embodiment of the present invention. 5 is a flowchart showing a detailed processing flow when a consumable unit is attached to the image forming apparatus according to the embodiment of the present invention. 12 is another flowchart showing a detailed processing flow when the consumable unit is mounted on the image forming apparatus according to the embodiment of the present invention. The figure which shows an example of adjustment conditions. The flowchart which shows the flow of the process which applies adjustment conditions. 9 is a flowchart showing a detailed processing flow when the image forming apparatus according to the embodiment of the present invention has reached the adjustment time of consumables setting information. 9 is a flowchart showing a detailed processing flow when the image forming apparatus according to the embodiment of the present invention has an adjustment condition for consumables setting information. 6 is a graph showing a consumption state of consumables in a printing process performed by the image forming apparatus in the embodiment of the present invention. 1 is an example of a diagram illustrating a configuration of an image forming apparatus configured by applying an image forming apparatus and a prediction program according to an embodiment of the present invention. 6 is a flowchart showing a flow of processing performed by the image forming apparatus according to the embodiment of the present invention. 9 is a flowchart showing a detailed processing flow when the image forming apparatus according to the embodiment of the present invention has an adjustment timing of consumables setting information. The figure which shows an example of adjustment conditions. The figure which shows an example of a printing history.

  Hereinafter, an embodiment of an image forming apparatus and a prediction program according to the present invention will be described in detail with reference to the accompanying drawings.

  FIG. 1 is an example of a diagram illustrating a configuration of an image forming apparatus configured by applying an image forming apparatus and a prediction program according to an embodiment of the present invention.

  In FIG. 1, the image forming apparatus includes a controller 10 that performs print control on print data requested to be printed, and an engine 20 that prints out the print data that is print-controlled by the controller 10.

  The controller 10 includes a CPU 11, a RAM 12, a ROM 13, a display unit 14, a storage unit 15, a timing unit 16, a system control unit 17, an engine interface unit 18, and a replacement time analysis unit 19, and the engine 20 includes a CPU 21, RAM 22, ROM 23, engine control unit 24, environmental sensor 25-1, density sensor 25-2, charging control unit 26, charging unit 26A, exposure control unit 27, exposure unit 27A, developing machine control unit 28, developing unit 28A, toner A cartridge 28B, a transfer machine controller 29, a transfer unit 29A, a fixing machine controller 30, and a fixing unit 30A are provided.

  When the controller 10 receives a print data print request via a communication interface (not shown) or the like, the CPU 11 executes a print processing program stored in the ROM 13 using the RAM 12 as a work area based on the print control processing in the system control unit 17. And print data in a print output processing format by the engine 20 is generated. Print instructions for the generated print data are sent to the engine 20 via the engine interface 18.

  In the engine 20 in response to the print instruction, the engine control unit 24 receives the print data instructed to be printed by the engine interface 18, and the CPU 21 stores a processing program stored in the ROM 23 using the RAM 22 as a work area based on the instruction from the engine control unit 24. By executing the above, image development, conversion, gradation expression processing, and the like are performed.

  The engine control unit 24 controls the charging control unit 26, the exposure control unit 27, the developing device control unit 28, the transfer device control unit 29, and the fixing device control unit 30 to perform print output processing corresponding to the print data instructed to be printed. Is done.

  The charging control unit 26 controls the charging unit 26A based on the charging setting information to charge the photosensitive drum, and the exposure control unit 27 controls the exposure unit 27A based on the exposure setting information. Then, an exposure process is performed to remove the charges charged on the photosensitive drum by irradiating the laser on the basis of the print data. The developing machine control unit 28 controls the developing unit 28A based on the development setting information, thereby causing the toner, which is a printing material, to adhere from the toner cartridge 28B to the photosensitive drum subjected to the exposure processing by the exposure control unit 27. Then, the transfer machine control unit 29 controls the transfer unit 29A based on the transfer setting information to transfer the toner attached to the photosensitive drum to a printing medium to which a positive charge is applied. Then, the fixing device control unit 30 controls the fixing unit 30A based on the fixing setting information to fix the toner transferred to the printing medium by applying heat.

  Then, the print medium is discharged to a discharge tray by being transported through the paper transport path, and printed out.

  At this time, the charging unit 26A, the exposure unit 27A, the developing unit 28A, the toner cartridge 28B, the transfer unit 29A, and the fixing unit 30A are examples of consumables, and the charge setting that is information that sets the usage form of these consumables. The information, exposure setting information, development setting information, transfer setting information, and fixing setting information are collectively referred to as “consumable setting information”.

  When printing is performed in this manner, the number of printed sheets and consumable setting information used for the printing are stored in the storage unit 15 as a printing history.

  When a consumable used for such a printing process is newly installed, a control unit (charging control unit 26, exposure control unit 27, developing device control unit 28, transfer device control unit 29) for each consumable product is installed. The fixing device control unit 30) detects this and notifies the engine control unit 24 of this fact.

  Upon receiving the notification, the engine control unit 24 sends a detection notification to the replacement time analysis unit 19 via the engine interface unit 18 of the controller 10.

  When the replacement time analysis unit 19 receives environmental information such as temperature / humidity detected by the environmental sensor 25-1 together with the detection notification of the wearing of the consumables, the replacement time analyzing unit 19 detects the wearing of the consumables attached based on the environmental information. The consumables setting information for which the usage form is set is determined.

  The consumable setting information is information indicating a usage form of the consumable to be referred to when processing using each consumable. For example, when the consumable is a charging unit, the consumable setting of the charging unit is set. This is information on the charge amount, charge area, etc. of the charge indicated by the charge setting information, and if the consumable is the toner cartridge 28B, it is information on the toner concentration transferred by the toner cartridge, and the consumable If is a development unit, it is information relating to gradation expression reproducibility.

  The process for determining the consumable item setting information is a process that is performed based on environmental information such as temperature and humidity. For example, the consumable item setting information is a process for setting consumable item setting information that is determined in advance corresponding to the temperature and humidity information. .

  When the consumable item setting information is determined in this way, the replacement time analyzing unit 109 further supplies the consumable item determined by the above determination process together with the consumable item setting information set before the consumable item setting information is determined. The setting information is stored in the storage unit 15 as an adjustment history for consumables.

  In addition, the replacement timing analysis unit 109 converts the consumables setting information to each control unit (charging control unit 26, exposure control unit 27, developing unit control unit 28, transfer unit control unit 29, fixing unit control) that constitutes the engine 20. Part 30).

  Subsequently, the replacement time analysis unit 19 creates a prediction formula for predicting the replacement time of the consumable when the consumable is used based on the determined consumable setting information. This prediction formula creation procedure and an example thereof will be described below with reference to FIG.

  When the prediction formula for predicting the replacement time of the consumables is created by the replacement time analysis unit 19, processing for predicting the replacement time of the consumables is performed using the prediction formula, and information on the predicted replacement time is stored in the storage unit 15. Save to memory.

  Then, the next adjustment time (hereinafter also referred to as adjustment timing) of the consumables setting information is satisfied when a certain operation time has elapsed from the present time or when a predetermined adjustment condition, for example, an adjustment condition as shown in FIG. 4 is satisfied. It is decided when. Information on this next adjustment timing is also stored in the storage unit 15.

  The adjustment condition shown in FIG. 4 includes a main condition and two sub conditions. The sub condition is satisfied, and the adjustment condition is satisfied by satisfying one of the sub conditions.

  In the subordinate condition, an item for determining the next adjustment timing is specified by satisfying the subordinate condition. In the example shown in FIG. 4, “the number of printed sheets has reached 1000” is shown as the main condition, and “the next adjustment is performed when the average temperature of the printing environment is 20 ° C. or more” as the first subordinate condition. The minimum interval until the time is 2 days "is shown, and the second subordinate condition is" If the average temperature of the printing environment is less than 20 degrees, the minimum interval until the next adjustment time is 1 day " "It is shown.

  That is, when the number of printed sheets indicated in the main condition reaches 1000, and the average temperature of the printing environment indicated by the subordinate condition is 20 degrees or more, the next adjustment timing is set to be two days after the current date. It is shown. In addition, when the number of printed sheets indicated in the main condition reaches 1000, and the average temperature of the printing environment indicated by the sub condition is less than 20 degrees, the next adjustment timing should be one day after the current date. It is shown.

  In this way, the next adjustment timing is determined.

  Next, a procedure for creating the prediction formula shown above and an example thereof will be described with reference to FIG.

  FIG. 8 is a graph showing the consumption state of consumables in the printing process performed by the image forming apparatus according to the embodiment of the present invention.

  The graph shown in FIG. 8 is created based on the print history information stored in the storage unit 15, and the horizontal axis indicates the life of the consumables such as the number of printed sheets and the number of printings. The remaining usable ratio is shown.

  The remaining usable ratio of the consumables shown on the vertical axis is the total amount of consumables used and the total amount of consumables calculated by the replacement time analysis unit 19 based on the total number of printed pages managed as the print history and the consumable setting information. It is a ratio calculated from the usable amount.

  In FIG. 8, the ratio of the remaining usable amount on the vertical axis in a state where unused consumables are mounted is “100%”, and the remaining usable amount that needs to be replaced due to the life of the consumables is shown. A state in which the ratio is “0 (zero)%” is shown.

  Furthermore, the states calculated as the adjustment timing of the next consumable setting information are shown as “P1 adjustment timing 1”, “P2 adjustment timing 2”, and “P3 adjustment timing 3”.

  In this “P1 adjustment timing 1”, the total number of printed sheets after printing is “c1”, and the remaining usable ratio of consumables at the time when the total number of printed sheets “c1” is printed is “p3”. Is shown. In “P2 adjustment timing 2”, the total number of prints after printing is “c2”, and the remaining usable ratio of consumables at the time when the total number of prints “c2” is printed is “p2”. It is shown that. Further, in “P3 adjustment timing 3”, the total number of printed sheets after printing is “c3”, and the remaining usable ratio of the consumables at the time when the total number of printed sheets “c3” is printed is “p1”. It is shown that.

  Then, the point that the remaining usable ratio of the consumables becomes “0%” by the straight line connecting “P1 adjustment timing 1” and the state in which the unused consumables are mounted “P0 at the start of use of consumables” is “L0” Life is 0 ”. This “L0 life 0” is the replacement time of consumables in “P0 start of use of consumables” to “P1 adjustment timing 1”.

  Further, the remaining usable rate of consumables is “0%” by a straight line connecting “P2 adjustment timing 2” and “P1 adjustment timing 1” determined as the next adjustment timing at the time of “P1 adjustment timing 1”. This point is “L1 life 1”, and this “L1 life 1” is the replacement time of consumables in “P1 adjustment timing 1” to “P2 adjustment timing 2”.

  Furthermore, the remaining usable rate of consumables is “0%” by a straight line connecting “P3 adjustment timing 3” and “P2 adjustment timing 2” determined as the next adjustment timing at the time of “P2 adjustment timing 2”. This point is “L2 life 2”, and this “L2 life 2” is the replacement time of consumables in “P2 adjustment timing 2” to “P3 adjustment timing 3”.

  An example of a consumable prediction formula calculated based on the graph shown in FIG. 8 is shown below.

  In the graph shown in FIG. 8, when the remaining amount of consumables on the vertical axis is “v” and the number of printed sheets on the horizontal axis is “c”, there is a linear function relationship between the adjustment timings. This is due to connecting the adjustment timings with a straight line, and means that the interval between the adjustment timings becomes shorter as the number of adjustment timings increases.

  In the section between an arbitrary adjustment timing “n” and the adjustment timing “n + 1” next to the adjustment timing “n”, the following relationship (Formula 1) is established.

  However, the coefficient “αn” is obtained by the following (Formula 2). Incidentally, the coefficient “αn” indicates the rate of change of the straight line between the adjustment timings “n” and “n + 1” in the graph of FIG.

  This (Equation 2) indicates that it is determined by the temperature “t” and the humidity “h”, which are the use environment at the adjustment timing “Pn”. That is, the change rate represented by “αn” is changed by changing the temperature and humidity.

  (Formula 1) is determined by the number of printed sheets “cn” and the remaining amount “vn” at the adjustment timing “Pn”.

  Furthermore, “Vn” indicating the intercept of the vertical axis indicating the remaining ratio of the consumables can be expressed by the following (Equation 3), and “Ln” indicating the intercept of the horizontal axis indicating the number of printable sheets is It can be expressed by the following (Formula 4).

  This (Equation 4) indicates the consumable item replacement time at the adjustment timing “Pn”.

  In addition, it is necessary to consider the effects of differences in user usage.

  For example, comparing the case of printing an image-centric document and the case of printing a character-centric document, the amount of toner consumed per unit sheet is greater when printing an image-centric document, indicating the user. Using the parameter “u”, it is expressed as the following (Formula 5).

  Further, if the difference between the calculated remaining amount data and the actual value detected by the sensor or the like is “Δ (delta)” due to the mechanism characteristic unique to the apparatus, this difference “Δ (delta)” is expressed by the following (formula 6). ).

  This (Formula 6) is expressed as a function of the usage environment temperature “t”, humidity “h”, and user usage status “u”.

  In this case, the relationship between the remaining amount of consumables “v” and the number of printed sheets “c” (Formula 1) is expressed as the following (Formula 7).

  Such a prediction formula is created.

  Further, the number of printed sheets “c (n + 1)” at the adjustment timing “P (n + 1)”, that is, the next adjustment execution timing at “Pn” is the usage environment such as the temperature “t” and the humidity “h” and the usage status “ As a function of “u”, it is expressed as (Formula 8) below.

  It is also possible to calculate the adjustment timing using such a calculation formula.

  Next, the flow of processing for calculating the replacement time for consumables will be described.

  FIG. 2 is a flowchart showing a detailed processing flow when the consumable unit is mounted in the image forming apparatus according to the embodiment of the present invention.

  In FIG. 2, when a consumable unit is mounted and mounted in the apparatus (201), processing is started, consumable setting information (printing parameters) in the mounted consumable unit is initialized (202), and consumable. The coefficient and the correction term based on the consumable item set in the prediction formula for predicting the replacement time of the item are also initialized (203).

  As an example of the initialization process of the consumables setting information, there is a process of changing to the initial value of the consumables setting information in the consumables unit stored in advance by the ROM or the like of the image forming apparatus. As an example of the initialization process of the coefficient and the correction term, there is a process of changing to a prediction formula including a coefficient and a correction term specified in advance.

  Next, an initial operation of the consumable unit is executed (204). As this operation, for example, when the consumable unit is a toner cartridge, the operation of filling the image forming apparatus with toner corresponds to this, and when the consumable unit is a developing unit, charging and exposure are performed. The operation of operating each development mechanism to enable the print output processing corresponds to this.

  In this way, when the initial operation is completed, environmental information of temperature and humidity is subsequently detected by an environmental sensor including a temperature and humidity sensor (205). The consumable item setting information based on the detected environment information is determined, and the consumable item setting information in the consumable item unit is updated (206).

  The consumable item setting information determination process at this time is a process for setting consumable item setting information based on the environment information, and is determined based on, for example, consumable item setting information stored for each detected temperature and humidity range.

  When the consumables setting information is determined in this way, coefficients constituting a prediction formula for predicting the replacement time of consumables when the consumables are used (print preparation, print output, etc.) based on the consumables setting information Then, a correction term is determined (207).

  An example of this coefficient is “αn” shown in the above (Formula 2), and an example of the correction term is “Δ” shown in the above (Formula 7).

  Subsequently, by executing the prediction formula based on the coefficient and the correction term, the replacement time in the consumable unit is calculated and predicted (208), and this replacement time is stored (209).

  Then, the next adjustment timing of the consumables setting information is determined to be when a certain operation time has elapsed from the present time (210). If the consumable unit is a toner cartridge by adjusting the consumable setting information at this time, the toner density is adjusted. If the consumable unit is a developing unit, the gradation expression reproducibility is adjusted.

  FIG. 6 is a flowchart showing a detailed processing flow when the image forming apparatus according to the embodiment of the present invention has reached the adjustment time of consumables setting information.

  In FIG. 8, when the predetermined consumable setting information adjustment time Pn is reached, the processing shown in FIG. 6 is started.

  First, the set consumables setting information is saved (601). Next, environmental information of temperature and humidity is detected by an environmental sensor composed of a temperature / humidity sensor or the like (602).

  Then, consumable setting information is determined based on the detected environment information, and the consumable setting information in the consumable unit is updated (603).

  Based on the consumables setting information updated in this way, the engine adjustment processing of the image forming apparatus is performed (604).

  As the engine adjustment processing, adjustment in toner print density and gradation expression reproduction is performed. In addition to adjusting the charging amount of the developing machine based on the consumables setting information, adjustments can be made based on the transfer voltage set in the consumables setting information and the temperature setting of the fixing device. To do.

  Next, coefficients and correction terms that constitute a prediction formula for predicting the replacement time of consumables when the consumables are used (print preparation, printout, etc.) based on the consumables setting information that has undergone engine adjustment processing Is calculated and determined (605).

  Subsequently, by executing the prediction formula based on the coefficient and the correction term, the replacement time in the consumable unit is calculated and predicted (606), and the replacement time is stored (607).

  Further, the next adjustment time of the consumables setting information is determined (608).

  FIG. 3 is another flowchart showing the detailed processing flow when the consumable unit is mounted in the image forming apparatus according to the embodiment of the present invention.

  The flowchart shown in FIG. 3 is similar to the flowchart shown in FIG. 2. In FIG. 2, the next adjustment time of the consumables setting information is determined by passing a certain operation time from the current time. In the example shown, it is a process for determining the next adjustment time of the consumable setting information by satisfying a predetermined adjustment condition.

  In FIG. 3, when a consumable unit is mounted and mounted on the apparatus (301), processing is started, consumable setting information (printing parameters) in the mounted consumable unit is initialized (302), and consumable. The coefficient and the correction term based on the consumable item set in the prediction formula for predicting the replacement time of the item are also initialized (303).

  As an example of the initialization process of the consumables setting information, there is a process of changing to the initial value of the consumables setting information in the consumables unit stored in advance by the ROM or the like of the image forming apparatus. As an example of the initialization process of the coefficient and the correction term, there is a process of changing to a prediction formula including a coefficient and a correction term specified in advance.

  Next, an initial operation of the consumable unit is executed (304). As this operation, for example, when the consumable unit is a toner cartridge, the operation of filling the image forming apparatus with toner corresponds to this, and when the consumable unit is a developing unit, charging and exposure are performed. The operation of operating each development mechanism to enable the print output processing corresponds to this.

  In this way, when the initial operation is completed, environmental information of temperature and humidity is subsequently detected by an environmental sensor composed of a temperature and humidity sensor or the like (305). Then, consumable setting information corresponding to the detected environment information is determined, and the consumable setting information in the consumable unit is updated (306).

  The consumable item setting information determination process at this time is a process for setting consumable item setting information based on the environment information, and is determined based on, for example, consumable item setting information stored for each detected temperature and humidity range.

  When the consumables setting information is determined in this way, coefficients constituting a prediction formula for predicting the replacement time of consumables when the consumables are used (print preparation, print output, etc.) based on the consumables setting information The correction term is calculated and determined (307).

  Subsequently, by executing the prediction formula based on the coefficient and the correction term, the replacement time in the consumable unit is calculated and predicted (308), and this replacement time is stored (309).

  Then, it is determined that the next adjustment timing of the consumable setting information satisfies the adjustment condition as shown in FIG. 4 (310).

  FIG. 4 is a diagram illustrating an example of the adjustment condition.

  In the example shown in FIG. 4, two subordinate conditions are shown in addition to the main condition, and the relationship between these conditions is applied by the flow shown by the flowchart shown in FIG.

  The main condition is that “the number of printed sheets has reached 1000 sheets”, and the first sub-condition is “if the average temperature of the printing environment is 20 ° C. or more, the minimum interval until the next adjustment time is 2 The second subordinate condition is that “if the average temperature of the printing environment is 20 ° C. or higher, the minimum interval until the next adjustment period is one day”.

  Although there is no superiority or inferiority between the subordinate conditions, the present invention is not limited to this, and a configuration may be adopted in which priority is provided between the subordinate conditions and the condition is judged from the subordinate conditions having a higher priority.

  That is, in FIG. 5, it is determined whether or not the main condition is satisfied (501). If the main condition is not satisfied (NO in 501), the adjustment time of the consumables setting information is determined as not satisfying the adjustment condition. Not performed. If the main condition is satisfied (YES in 501), it is subsequently determined whether the sub condition is satisfied.

  It is determined whether subordinate condition 1 is satisfied (502). If subordinate condition 1 is not satisfied (NO in 502), it is subsequently determined whether subordinate condition 2 is satisfied (503). If NO is satisfied (NO in 503), the adjustment time of the consumables setting information is not determined as in the case where the main condition is not satisfied.

  On the other hand, if any one of the sub-conditions is satisfied in the determination whether the sub-condition 1 is satisfied (502) or the determination whether the sub-condition 2 is satisfied (503), the consumable setting information is determined. Perform the process.

  FIG. 7 is a flowchart showing a detailed processing flow when the image forming apparatus according to the embodiment of the present invention has the consumables setting information adjustment condition.

  In FIG. 7, the process is started when the adjustment condition of the consumables setting information by the process as shown in FIG. 3 is satisfied.

  First, the set consumables setting information is stored (701). Next, environmental information such as temperature and humidity is detected by an environmental sensor including a temperature and humidity sensor (702).

  Then, consumable setting information corresponding to the detected environment information is determined, and the consumable setting information in the consumable unit is updated (703).

  The consumable item setting information determination process at this time is a process for setting consumable item setting information based on the environment information, and is determined based on, for example, consumable item setting information stored for each detected temperature and humidity range.

  Based on the consumables setting information updated in this way, the engine adjustment processing of the image forming apparatus is performed (704). As the engine adjustment processing, adjustment in toner print density and gradation expression reproduction is performed. In addition to adjusting the charging amount of the developing machine based on the consumables setting information, adjustments can be made based on the transfer voltage set in the consumables setting information and the temperature setting of the fixing device. To do.

  Next, coefficients and correction terms that constitute a prediction formula for predicting the replacement time of consumables when the consumables are used (print preparation, printout, etc.) based on the consumables setting information that has undergone engine adjustment processing Is calculated and determined (705).

  Subsequently, by executing the prediction formula based on the coefficient and the correction term, the replacement time in the consumable unit is calculated and predicted (706), and this replacement time is stored (707).

  Then, an adjustment condition for the next consumable setting information is determined (708).

  In the first embodiment, the remaining usable rate of the consumable is calculated from the print state based on the consumable setting information. In the second embodiment, the remaining usable amount of the consumable is measured by a sensor or the like. An example of calculating the remaining usable ratio is shown below.

  FIG. 9 is an example of a diagram illustrating a configuration of an image forming apparatus configured by applying the image forming apparatus and the prediction program according to the embodiment of the present invention.

  In FIG. 9, the image forming apparatus includes a controller 10 that performs print control on print data requested to be printed, and an engine 20 that prints out the print data that is print-controlled by the controller 10.

  The controller 10 includes a CPU 11, a RAM 12, a ROM 13, a display unit 14, a storage unit 15, a timing unit 16, a system control unit 17, an engine interface unit 18, and a replacement time analysis unit 19, and the engine 20 includes a CPU 21, RAM 22, ROM 23, engine control unit 24, environmental sensor 25-1, density sensor 25-2, charging control unit 26, charging unit 26A, exposure control unit 27, exposure unit 27A, developing machine control unit 28, developing unit 28A, toner A cartridge 28B, a transfer machine control unit 29, a transfer unit 29A, a fixing machine control unit 30, a fixing unit 30A, and a remaining usable amount measuring unit 31 are provided.

  When the controller 10 receives a print data print request via a communication interface (not shown) or the like, the CPU 11 executes a print processing program stored in the ROM 13 using the RAM 12 as a work area based on the print control processing in the system control unit 17. And print data in a print output processing format by the engine 20 is generated. Print instructions for the generated print data are sent to the engine 20 via the engine interface 18.

  In the engine 20 in response to the print instruction, the engine control unit 24 receives the print data instructed to be printed by the engine interface 18, and the CPU 21 stores a processing program stored in the ROM 23 using the RAM 22 as a work area based on the instruction from the engine control unit 24. By executing the above, image development, conversion, gradation expression processing, and the like are performed.

  The engine control unit 24 controls the charging control unit 26, the exposure control unit 27, the developing device control unit 28, the transfer device control unit 29, and the fixing device control unit 30 to perform print output processing corresponding to the print data instructed to be printed. Is done.

  The charging control unit 26 controls the charging unit 26A based on the charging setting information to charge the photosensitive drum, and the exposure control unit 27 controls the exposure unit 27A based on the exposure setting information. Then, an exposure process is performed to remove the charges charged on the photosensitive drum by irradiating the laser on the basis of the print data. The developing machine control unit 28 controls the developing unit 28A based on the development setting information, thereby causing the toner, which is a printing material, to adhere from the toner cartridge 28B to the photosensitive drum subjected to the exposure processing by the exposure control unit 27. Then, the transfer machine control unit 29 controls the transfer unit 29A based on the transfer setting information to transfer the toner attached to the photosensitive drum to a printing medium to which a positive charge is applied. Then, the fixing device control unit 30 controls the fixing unit 30A based on the fixing setting information to fix the toner transferred to the printing medium by applying heat.

  Then, the print medium is discharged to a discharge tray by being transported through the paper transport path, and printed out.

  At this time, the charging unit 26A, the exposure unit 27A, the developing unit 28A, the toner cartridge 28B, the transfer unit 29A, and the fixing unit 30A are examples of consumables, and the charge setting that is information that sets the usage form of these consumables. The information, exposure setting information, development setting information, transfer setting information, and fixing setting information are collectively referred to as “consumable setting information”.

  When printing is performed in this manner, the number of printed sheets and consumable setting information used for the printing are stored in the storage unit 15 as a printing history.

  When a consumable used for such a printing process is newly installed, a control unit (charging control unit 26, exposure control unit 27, developing device control unit 28, transfer device control unit 29) for each consumable product is installed. The fixing device control unit 30) detects this and notifies the engine control unit 24 of this fact.

  Upon receiving the notification, the engine control unit 24 sends a detection notification to the replacement time analysis unit 19 via the engine interface unit 18 of the controller 10.

  When the replacement time analysis unit 19 receives environmental information such as temperature / humidity detected by the environmental sensor 25-1 together with the detection notification of the wearing of the consumables, the replacement time analyzing unit 19 detects the wearing of the consumables attached based on the environmental information. The consumables setting information for which the usage form is set is determined.

  The consumable setting information is information indicating a usage form of the consumable to be referred to when processing using each consumable. For example, when the consumable is a charging unit, the consumable setting of the charging unit is set. This is information on the charge amount, charge area, etc. of the charge indicated by the charge setting information, and if the consumable is the toner cartridge 28B, it is information on the toner concentration transferred by the toner cartridge, and the consumable If is a development unit, it is information relating to gradation expression reproducibility.

  The process for determining the consumable item setting information is a process that is performed based on environmental information such as temperature and humidity. For example, the consumable item setting information is a process for setting consumable item setting information that is determined in advance corresponding to the temperature and humidity information. .

  When the consumable item setting information is determined in this way, the replacement time analyzing unit 109 further supplies the consumable item determined by the above determination process together with the consumable item setting information set before the consumable item setting information is determined. The setting information is stored in the storage unit 15 as an adjustment history for consumables.

  In addition, the replacement timing analysis unit 109 converts the consumables setting information to each control unit (charging control unit 26, exposure control unit 27, developing unit control unit 28, transfer unit control unit 29, fixing unit control) that constitutes the engine 20. Part 30).

  Subsequently, the replacement time analysis unit 19 creates a prediction formula for predicting the replacement time of the consumable when the consumable is used based on the determined consumable setting information. The procedure for creating the prediction formula and an example thereof are the same as those shown in the first embodiment.

  When a prediction formula for predicting the replacement time of consumables is created by the replacement time analysis unit 19, the replacement time analysis unit 19 calculates the remaining usable amount based on the print history stored in the storage unit 15. Subsequently, the remaining usable amount (actual remaining amount) of the consumables measured by the remaining usable amount measuring unit 31 is acquired from the engine control unit 24, and the acquired remaining usable amount (actual remaining amount) is calculated. Compare the possible amount and calculate the difference.

  When the calculated difference is “0 (zero)”, a prediction formula for predicting the replacement time of the consumables is created based on the print history stored in the storage unit 15. If the calculated difference is not “0 (zero)”, a coefficient and a correction term for correcting this difference in a prediction formula for predicting the replacement time of the consumables created based on the print history stored in the storage unit 15. Is added to create a prediction formula considering the difference.

  A process for predicting the replacement time of consumables is performed using the prediction formula thus created, and information on the predicted replacement time is stored and stored in the storage unit 15.

  Then, the next adjustment timing of the consumable setting information is determined when a certain operation time has elapsed from the present time or when a predetermined adjustment condition, for example, an adjustment condition as shown in FIG. 4 is satisfied. Information on this next adjustment timing is also stored in the storage unit 15.

  FIG. 10 is a flowchart showing a flow of processing performed by the image forming apparatus according to the embodiment of the present invention.

  In FIG. 10, when a consumable unit is mounted and mounted on the apparatus (201), processing is started, consumable setting information (printing parameters) in the mounted consumable unit is initialized (202), and consumable. The coefficient and the correction term based on the consumable item set in the prediction formula for predicting the replacement time of the item are also initialized (203).

  As an example of the initialization process of the consumables setting information, there is a process of changing to the initial value of the consumables setting information in the consumables unit stored in advance by the ROM or the like of the image forming apparatus. As an example of the initialization process of the coefficient and the correction term, there is a process of changing to a prediction formula including a coefficient and a correction term specified in advance.

  Next, an initial operation of the consumable unit is executed (204). As this operation, for example, when the consumable unit is a toner cartridge, the operation of filling the image forming apparatus with toner corresponds to this, and when the consumable unit is a developing unit, charging and exposure are performed. The operation of operating each development mechanism to enable the print output processing corresponds to this.

  In this way, when the initial operation is completed, environmental information of temperature and humidity is subsequently detected by an environmental sensor including a temperature and humidity sensor (205). The consumable item setting information based on the detected environment information is determined, and the consumable item setting information in the consumable item unit is updated (206).

  The consumable item setting information determination process at this time is a process for setting consumable item setting information based on the environment information, and is determined based on, for example, consumable item setting information stored for each detected temperature and humidity range.

  When the consumable setting information is thus determined, the remaining usable amount of the consumable is calculated from the print history in the print output, and then the remaining usable amount (actual remaining) of the consumable is measured by a sensor or the like. (1001). When the consumable is toner, the remaining amount of toner is measured.

  After measuring the remaining usable amount (actual remaining amount), the remaining usable amount (actual remaining amount) is compared with the calculated remaining usable amount, and the difference is calculated. If there is a difference, this difference is taken into account, and a coefficient that constitutes a prediction formula that predicts the replacement time of the consumable when the consumable is used (print preparation, print output, etc.) based on the consumable setting information Then, a correction term is determined (207).

  Subsequently, by executing the prediction formula based on the coefficient and the correction term, the replacement time in the consumable unit is calculated and predicted (208), and this replacement time is stored (209).

  Then, the next adjustment timing of the consumable setting information is determined (210).

  FIG. 11 is a flowchart illustrating a detailed processing flow when the image forming apparatus according to the embodiment of the present invention has reached the adjustment time of consumables setting information.

  In FIG. 8, when the predetermined consumable setting information adjustment time Pn is reached, the processing shown in FIG. 11 is started.

  First, the set consumables setting information is saved (1101). Next, environmental information of temperature and humidity is detected by an environmental sensor composed of a temperature and humidity sensor or the like (1102).

  Then, consumable setting information is determined based on the detected environment information, and the consumable setting information in the consumable unit is updated (1103).

  Based on the consumable setting information updated in this manner, the engine adjustment processing of the image forming apparatus is performed (1104).

  As the engine adjustment processing, adjustment in toner print density and gradation expression reproduction is performed. In addition to adjusting the charging amount of the developing machine based on the consumables setting information, adjustments can be made based on the transfer voltage set in the consumables setting information and the temperature setting of the fixing device. To do.

  Next, the remaining usable amount (actual remaining amount) of the consumables is measured by a sensor or the like (1105), the remaining usable amount (actual remaining amount) is compared with the calculated remaining usable amount, and the difference is calculated. calculate. If there is a difference, this difference is taken into account, and a coefficient that constitutes a prediction formula that predicts the replacement time of the consumable when the consumable is used (print preparation, print output, etc.) based on the consumable setting information Then, a correction term is determined (1106).

  Subsequently, by executing a prediction formula based on the coefficient and the correction term, the replacement time in the consumable unit is calculated and predicted (1107), and this replacement time is stored (1108).

  Further, the next adjustment time of the consumable setting information is determined (1109).

  In the first embodiment and the second embodiment, the prediction formula is created and the replacement time of the consumable is calculated. However, in the third embodiment, the optimum use based on the usage form of the consumable in the print output is used. Calculate the replacement time.

  The storage unit 15 shown in FIG. 1 is in a state where a print history as shown in FIG. 13 is stored.

  FIG. 13 shows print histories in each of the three image forming apparatuses. The print histories include a [print number per day] item 1301, a [cumulative print number] item 1302, and an [average print number until the relevant day]. ] Item 1303.

  FIG. 13A shows a print history recorded by a general print output, and FIG. 13B shows a print with a relatively small number of prints per day compared to the print history shown in FIG. FIG. 13C shows a print history in which the number of printed pages per day varies depending on the day.

  In the case of such a print history, the storage unit 15 shown in FIGS. 1 and 9 stores and saves the adjustment conditions for the print form indicated by the print history. For example, the adjustment condition shown in FIG. 12 indicates that “the number of printed sheets from the previous adjustment has exceeded 10 times the average number of printed sheets of the printer” as the main condition, and no sub-condition is provided. The adjustment conditions are shown.

  That is, the adjustment timing of the consumables setting information is determined according to the average number of printed sheets shown in the three print histories shown in FIG.

  The embodiment described above is one embodiment of the present invention, and is not limited to these examples, and can be implemented with appropriate modifications within a range not changing the gist thereof.

  In the present invention, the program is executed from a recording medium (CD-ROM, DVD-ROM, etc.) storing a program for executing the above-described operation in an image forming system having a communication function or configuring the above-described means. It is also possible to configure an image forming system that executes the above-described processing by installing the above in a computer and executing it. A computer constituting the image forming system is connected to a central processor unit (CPU), a read only memory (ROM), a random access memory (RAM), and a hard disk via a system bus. The CPU performs processing using the RAM as a work area according to a program stored in the ROM or the hard disk.

  The medium for supplying the program may be a communication medium (a medium for temporarily or fluidly holding the program such as a communication line or a communication system). For example, the program may be posted on an electronic bulletin board (BBS: Bulletin Board Service) of a communication network and distributed via a communication line.

10 Controller 10
11 CPU
12 RAM
13 ROM
DESCRIPTION OF SYMBOLS 14 Display part 15 Memory | storage part 16 Time measuring part 17 System control part 18 Engine interface part 19 Replacement time analysis part 20 Engine 21 CPU
22 RAM
23 ROM
24 Engine Control Unit 25-1 Environmental Sensor 25-2 Density Sensor 26 Charging Control Unit 26A Charging Unit 27 Exposure Control Unit 27A Exposure Unit 28 Developing Machine Control Unit 28A Developing Unit 28B Toner Cartridge 29 Transfer Machine Control Unit 29A Transfer Unit 30 Fixing Machine Control unit 30A Fixing unit 31 Remaining usable amount measuring unit

Claims (9)

Detection means for detecting environmental data in the printing environment;
Setting information adjusting means for adjusting setting information of each consumable used for print output based on the environmental data detected by the detecting means;
A predictive formula creating means for creating a predictive formula for predicting a replacement time when the consumable needs to be replaced by printing out based on the set information adjusted by the set information adjusting means;
An image forming apparatus comprising: a replacement time prediction unit that predicts a replacement time of the consumables based on a prediction formula created by the prediction formula creation unit. A print history storage unit for storing a print history relating to a print output performed based on the setting information adjusted by the setting information adjustment unit;
The image forming apparatus according to claim 1, further comprising: a determining unit that determines an adjustment timing of the setting information performed by the setting information adjusting unit based on a printing history stored by the printing history storage unit. An adjustment condition management means for managing an adjustment condition for adjusting the setting information by the setting information adjustment means,
The determining means includes
The image forming apparatus according to claim 2, wherein the adjustment time is determined when the print history stored in the print history storage unit satisfies the adjustment condition managed by the adjustment condition management unit. Detecting means for detecting replacement of the consumables,
The setting information adjustment means includes:
The image forming apparatus according to claim 1, wherein when the detection unit detects replacement of a consumable item, the setting information of the consumable item is adjusted based on environmental data detected by the detection unit. The adjustment condition management means includes:
Managing adjustment conditions based on the print history stored by the print history storage means and the environmental data detected by the detection means;
The determining means includes
The image forming apparatus according to claim 2, wherein the adjustment time is determined to satisfy at least one of the print history and the environmental data for the adjustment condition managed by the adjustment condition management unit. The adjustment condition management means includes:
The image forming apparatus according to claim 3, wherein an adjustment condition is managed according to an implementation status of the print output based on a print history managed by the print history management unit. The adjustment condition management means includes:
The image forming apparatus according to claim 6, wherein an adjustment condition based on an average number of printed sheets based on a print history managed by the print history management unit is managed. Measuring means for measuring the actual remaining amount with respect to the total usable amount of each consumable;
A remaining usable amount calculating means for calculating a remaining usable amount of the consumable based on a printing history managed by the printing history managing means;
Comparing the actual remaining amount measured by the measuring means and the remaining usable amount calculated by the remaining usable amount calculating means, and comprising difference calculating means for calculating the difference,
The prediction formula creating means includes:
The image forming apparatus according to claim 1, wherein, when the difference is calculated by the difference calculation unit, a prediction formula including a coefficient derived from the difference and a correction term is created. Computer
Setting information adjusting means for adjusting setting information of each consumable used for print output based on environmental data in the printing environment;
A predictive formula creating means for creating a predictive formula for predicting a replacement time when the consumable needs to be replaced by print output based on the setting information adjusted by the setting information adjusting means;
A prediction program that functions as a replacement time prediction unit that predicts the replacement time of the consumables based on the prediction formula created by the prediction formula creation unit.

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