JP2016007706A - Image forming device, control method, and program - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an image forming device which improves estimation accuracy of a remaining toner amount, and reduces an error of a remaining amount value detected by a remaining amount sensor and an estimated remaining toner amount.SOLUTION: An image forming device of forming an image by using a recording material includes: acquisition means which acquires a remaining amount of the recording material; calculation means which calculates a consumed amount of the recording material on the basis of a dot count value in raster data and a consumption coefficient indicating the consumed amount of the recording material on each dot; estimation means which estimates the remaining amount of the recording material on the basis of the consumed amount of the recording material calculated by the calculation means; and correction means which corrects the consumption coefficient on the basis of the remaining amount of the recording material acquired by the acquisition means and the remaining amount of the recording material estimated by the estimation means. A toner consumption coefficient is corrected on the basis of an error between a current value and a sensor value in receiving the sensor.

Description

  The present invention relates to an image forming apparatus, a control method, and a program.

  The image forming apparatus forms an image on a sheet using a recording material such as toner. Generally, the recording material is accommodated in an accommodating portion such as a cartridge.

  Conventionally, a technique for predicting the remaining amount of toner in a cartridge based on a dot count value of raster data is known (Patent Document 1). Specifically, the toner consumption amount is calculated based on the dot count value of the raster data, and the toner remaining amount is calculated by subtracting the current toner consumption amount from the current toner remaining amount. Here, the toner consumption amount is generally calculated by multiplying the dot count value of the raster data by a toner consumption coefficient predetermined for each apparatus.

JP 2006-343621 A

  In general, a fixed value is used as the toner consumption coefficient.

  However, the toner consumption amount is not always proportional to the dot count value of the raster data.

  For example, when the printing rate in the image data changes, the toner consumption amount per dot used when calculating the remaining amount of toner based on the dot count also changes. In addition, the loading amount varies depending on differences in image type (image frequency), printing frequency, temperature, humidity, and the like. For this reason, a deviation occurs in the predicted value of the remaining amount of toner calculated based on the dot count. However, when this deviation is large, there is a problem that if the remaining amount value to be notified is corrected using the method of Patent Document 1, the remaining amount value to be notified changes greatly and may cause confusion for the user.

  The present invention has been made to solve the above-described problem, and improves the prediction accuracy of the remaining amount of toner and reduces the error between the predicted remaining toner amount and the remaining amount value detected by the remaining amount sensor. Objective.

  An image forming apparatus according to the present invention is an image forming apparatus that forms an image using a recording material, and includes an acquisition unit that acquires the remaining amount of the recording material, a dot count value in raster data, and a recording for each dot. A calculation unit that calculates a consumption amount of the recording material based on a consumption coefficient indicating a consumption amount of the material; and a remaining amount of the recording material is predicted based on the consumption amount of the recording material calculated by the calculation unit And a correcting unit that corrects the consumption coefficient based on the remaining amount of the recording material acquired by the acquiring unit and the remaining amount of the recording material predicted by the predicting unit. It is characterized by.

  The error between the predicted toner remaining amount and the remaining amount value detected by the remaining amount sensor is reduced.

Block diagram showing configuration of image forming apparatus Block diagram showing the configuration of the controller Block diagram showing the configuration of the print engine Flow chart showing control of toner remaining amount detection (first half) Flow chart showing control of toner remaining amount detection (second half) FIG. 5 is a diagram illustrating a change in the current value of the remaining amount of toner (first embodiment). Flowchart showing details of toner consumption coefficient update processing (first embodiment) FIG. 10 is a diagram illustrating a change in the current value of the remaining amount of toner (second embodiment). Flowchart showing details of toner consumption coefficient update processing (second embodiment) FIG. 10 is a diagram illustrating a change in the current value of the remaining amount of toner (fourth embodiment). Flowchart showing details of update processing of toner consumption coefficient (fifth embodiment) Flowchart showing details of update processing of toner consumption coefficient (sixth embodiment) Diagram showing the relationship between frequency and error

[First Embodiment]
FIG. 1 is a block diagram illustrating a configuration of the image forming apparatus.

  The data processing apparatus 101 (for example, PC) generates image data and transmits the image data to the image forming apparatus 102.

  An image forming apparatus 102 (for example, a laser printer) receives image data from the data processing apparatus 101 and forms an image on a sheet based on the image data. Note that the image forming apparatus 102 may be a multifunction machine having a scanner function, a FAX function, and the like.

  The UI 301 is a user interface, and includes a display unit that transmits various information to the user and an operation unit that receives various operations from the user. The display unit displays a current value of the remaining amount of toner, which will be described later. The current value of the remaining amount of toner may be transmitted to an external apparatus such as the data processing apparatus 101 via the external I / F and displayed on a display unit included in the external apparatus such as the data processing apparatus 101.

  The controller 302 generates bitmap data based on the PDL data, and transmits the bitmap data to the print engine 303. Details of the controller 302 will be described later with reference to FIG.

  The print engine 303 forms an image on a sheet using toner in electrophotography based on the bitmap data received from the controller 302. The image forming method may be other than the electrophotographic method, for example, an ink jet method. In this case, the electrophotographic recording material is toner, but the ink jet recording material is ink.

  The controller 302 and the print engine 303 are separate, but may be integrated.

  FIG. 2 is a block diagram showing the configuration of the controller.

  The CPU 401 develops a program stored in the ROM 402 in the RAM 403 and executes the program to control the image forming apparatus 102. Further, as will be described later, the CPU 401 uses the toner consumption amount converted from the dot count counted by the dot count unit 409 and the toner remaining amount sensor value notified from the print engine 303 based on the toner remaining amount sensor value. Calculate the remaining amount. The CPU 401 displays the calculated remaining toner amount on the UI 301 via the panel I / F 405 or notifies the data processing apparatus 101 via the external I / F 404.

  The ROM 402 stores a program executed by the CPU 401 and the like.

  The RAM 403 stores programs and the like developed from the ROM 402. The RAM 403 also stores PDL data, intermediate data generated by interpreting the PDL data, bitmap data generated by rendering the intermediate data, and various temporary processing statuses and log information necessary for other processing. Remember.

  The external I / F 404 connects the data processing apparatus 101 and the controller 302 to each other and relays data communication between them, that is, data transmission and reception.

  The panel I / F 405 connects the UI 301 and the controller 302 to each other, and relays data communication between them, that is, data transmission and reception.

  The engine I / F 406 connects the print engine 303 and the controller 302 to each other and relays data communication between them, that is, data transmission and reception.

  The DMAC 407 receives an instruction from the CPU 401 and performs data access to the RAM 403, that is, data writing or reading.

  The rendering unit 408 expands the intermediate data into bitmap data.

  The dot count unit 409 counts the number of dots that consume toner when performing image formation among the dots included in the developed bitmap data. Specifically, the number of dots of colors other than white is counted. For example, in the case of monochrome printing, the number of dots corresponds to K (black). In the case of color printing, the number of dots corresponds to one of Y (yellow), M (magenta), C (cyan), and K (black). Note that the CPU 401 and the rendering unit 408 may count the number of dots.

  The EEPROM 410 stores setting information of the image forming apparatus 102 and the like.

  The bus 411 connects the components in the controller 302 to each other.

  FIG. 3 is a block diagram showing the configuration of the print engine.

  The CPU 501 expands the program stored in the ROM 502 in the RAM 503 and executes the program to control the print engine 303.

  The ROM 502 stores a program executed by the CPU 501 and the like.

  The RAM 503 stores programs and the like developed from the ROM 502.

  The toner remaining amount sensor 504 measures the remaining amount of toner contained in the cartridge 509. As a method for detecting the remaining amount of toner in the sensor, for example, there are a magnetic permeability detection method, a magnet method, a piezoelectric vibration method, a transmitted light method, and the like. For example, when the remaining amount of toner reaches a predetermined value such as 20% or 0%, the sensor detects the value as a sensor value. That is, 100% is detected when the remaining amount of toner is 100% to 21%, 20% when the remaining amount of toner is 20% to 1%, and 0% when the remaining amount of toner is 0%. Note that the sensor may be provided in the cartridge 509.

  The drive control unit 505 drives various motors necessary when the image forming unit 508 forms an image.

  A status change detection unit 506 detects a status change such as a jam or cover open in the image forming apparatus. The status change detection unit 506 also detects replacement of the cartridge 509. The change in status may be detected by the CPU 501.

  A controller I / F 507 connects the controller 302 and the print engine 303 to each other and relays data communication between them, that is, data transmission and reception.

  Based on the bitmap data received from the controller 302, the image forming unit 508 forms an image on a sheet using toner in an electrophotographic system.

  The cartridge 509 is a so-called process cartridge that can be attached to the image forming apparatus 102 as a storage unit that stores toner, and stores toner and the like used when the image forming unit 508 forms an image. The cartridge 509 has a nonvolatile storage medium in which cartridge information is stored. The cartridge information includes, for example, information indicating whether or not the cartridge is new, color information indicating the color of the cartridge, toner remaining amount information indicating the current toner remaining amount of the cartridge, and the like. The cartridge 509 is connected to the bus 510, but may be connected to the CPU 501 through a dedicated line.

  A bus 510 connects the components in the print engine 303 to each other.

  4 and 5 are flowcharts showing control for detecting the remaining amount of toner.

  The control shown in the flowchart on the left side is realized in the controller 302 by the CPU 401 expanding and executing the control program stored in the ROM 402 in the RAM 403. The control shown in the flowchart on the right side is realized by causing the print engine 303 to have the CPU 501 expand and execute the control program stored in the ROM 502 on the RAM 503.

  First, the CPU 501 determines whether or not the cartridge 509 has been replaced (S201). This is determined by detecting that a cartridge 509 is newly installed in the image forming apparatus 102. The attachment of the cartridge 509 is recognized by the status change detection unit 506 detecting the attachment of the cartridge 509 and notifying the CPU 501. The mounting of the cartridge 509 may be detected by opening or closing a cover provided to replace the cartridge 509, or may be detected by a button or a switch whose hardware on / off state changes according to the attachment / detachment of a component. May be. If YES in S201, the process proceeds to S202. If NO in S201, the process waits.

  Next, the CPU 501 transmits a cartridge replacement notification indicating that the cartridge 509 has been replaced to the controller 302 via the controller I / F 507 (S202).

  Next, the CPU 401 determines whether a cartridge replacement notification has been received from the print engine 303 via the engine I / F 406 (S101). If YES in S101, the process proceeds to S102. If NO in S101, the process waits.

  Next, the CPU 401 transmits a cartridge information request for requesting cartridge information of the cartridge 509 to the print engine 303 via the engine I / F 406 (S102).

  Next, the CPU 501 determines whether a cartridge information request has been received from the controller 302 via the controller I / F 507 (S203). If YES in S203, the process proceeds to S204. If NO in S203, the process waits.

  Next, the CPU 501 transmits cartridge information of the cartridge 509 to the controller 302 via the controller I / F 507 (S204).

  Next, the CPU 401 determines whether cartridge information has been received from the print engine 303 via the engine I / F 406 (S103). If YES in S103, the process proceeds to S104. If NO in S103, the process waits.

  Next, the CPU 401 executes a toner consumption coefficient update process (S121). Details of the toner consumption coefficient update processing will be described later with reference to FIG.

  Next, the CPU 401 initializes the current value of the remaining amount of toner based on the cartridge information (S104). Here, the current value of the remaining amount of toner is a value that the controller 302 recognizes as the remaining amount of toner in the cartridge 509 and is a value displayed to the user via the UI 301. Specifically, the initialization of the current value of the remaining amount of toner refers to the cartridge information, and if the cartridge is found to be new, the current value of the remaining amount of toner is set to 100%. If it is not known that the cartridge is new, the current value of the remaining amount of toner is set to a value corresponding to the remaining amount of toner information included in the cartridge information described above. The current value of the remaining amount of toner is held in the RAM 403 or the like.

  Next, the CPU 401 determines whether or not a job to be subjected to image formation is input from the data processing apparatus 101 via the external I / F 404 (S105). Here, examples of the job include a PDL print job, a copy job, and a FAX reception print job. If YES in S105, the process proceeds to S106. If NO in S105, the process proceeds to S111.

  Next, the CPU 401 executes image processing necessary for image formation based on the job (S106). Here, the image processing includes processing for controlling the rendering unit 408 to develop print data and generate raster data.

  Next, the CPU 401 transmits the raster data generated by the image processing to the print engine 303 via the engine I / F 406 (S107).

  Next, the CPU 401 acquires a dot count value measured at the time of raster data generation from the dot count unit 409 (S108). The dot count value may be acquired on a page basis or on a job basis.

  Next, the CPU 401 calculates a predicted value of the remaining amount of toner based on the dot count value acquired in S108 (S109). Specifically, first, (dot count value [dot] at the time of execution of printing of the current job or page) × (toner consumption [g / dot] for each dot) = (toner consumption by execution of current job [ g]). Here, the toner consumption amount for each dot may be stored in the ROM 402 in advance, or may be included in the cartridge information received in S103. Next, a calculation of (current toner remaining amount [g]) − (toner consumption amount [g] of current job execution) = (new toner remaining amount [g]) is performed. Next, a calculation of (new toner remaining amount [g]) / (toner remaining amount [g] when the cartridge is not used) = (predicted value of new toner remaining amount [%]) is performed. Here, the remaining amount of toner in the unused state of the cartridge may be stored in the ROM 402 in advance, or may be included in the cartridge information received in S103.

  A specific formula for calculating the toner consumption amount using the dot count is as follows.

C _d = A _d × D (Expression 1)
C _d : Toner consumption [g] calculated using dot count
A _d : Toner consumption coefficient (toner consumption per dot) [g / dot]
D: Print page dot counter [dot]
Next, the CPU 401 updates the current value of the remaining amount of toner with the predicted value calculated in S109 (S110).

  On the other hand, the CPU 501 determines whether or not raster data is received from the controller 302 via the controller I / F 507 (S205). If YES in S205, the process proceeds to S206. If NO in S205, the process proceeds to S208.

  Next, the CPU 501 controls the image forming unit 508 to execute image formation based on the raster data (S206).

  Next, the CPU 501 acquires a sensor value of the remaining toner amount from the remaining toner sensor 504 (S207). The sensor value acquisition timing may be a timing at which image formation is completed in units of pages or a timing at which image formation is completed in units of jobs. The sensor value acquisition timing may be set every time a predetermined time elapses.

  Next, the CPU 501 determines whether or not the sensor value acquired this time has changed from the sensor value acquired last time (S208). If YES is obtained in S208, the process proceeds to S209. If NO in S208, the process returns to S205.

  Next, the CPU 501 transmits a sensor value change notification indicating that the sensor value has changed to the controller 302 via the controller I / F 507 (S209).

  Next, the CPU 401 determines whether or not a sensor value change notification has been received from the print engine 303 via the engine I / F 406 (S111). If YES in S111, the process proceeds to S112. If NO in S111, the process returns to S105.

  Next, the CPU 401 transmits a sensor value request for requesting a sensor value to the print engine 303 via the engine I / F 406 (S112).

  Next, the CPU 501 determines whether a sensor value request has been received from the controller 302 via the controller I / F 507 (S210). If YES is obtained in S210, the process proceeds to S211. If NO at S210, the system waits.

  Next, the CPU 501 transmits the sensor value to the controller 302 via the controller I / F 507 (S211).

  Next, the CPU 401 determines whether or not the sensor value is received from the print engine 303 via the engine I / F 406 (S113). If YES in S113, the process proceeds to S114. If NO in S113, the process waits.

  Next, the CPU 401 executes a toner consumption coefficient update process (S122). Details of the toner consumption coefficient update processing will be described later with reference to FIG.

  Next, the CPU 401 updates the current value of the remaining amount of toner with the sensor value received in S113 (S114). At this time, the sensor value acquired this time is stored in the RAM 403 or the like. If the previously acquired sensor value is held, it is updated with the sensor value acquired this time.

  Next, the CPU 401 refers to the current value of the remaining amount of toner and determines whether or not the remaining amount of toner has become zero (S115). If YES in S115, the process ends. If NO in S115, the process returns to S105.

  On the other hand, the CPU 501 refers to the sensor value of the remaining amount of toner and determines whether the remaining amount of toner has become zero (S212). If YES in S212, the process ends. If NO in S212, the process returns to S205.

  FIG. 6 is a diagram illustrating the transition of the current value of the remaining amount of toner.

  Reference numeral 200 denotes an actual toner remaining amount transition. Here, the actual toner remaining amount is an accurate value of the remaining toner amount that actually exists. For example, the actual toner remaining amount is directly obtained unless the sensor is very accurate over the entire area. Is very difficult.

  Reference numerals 201 to 203 denote changes in the sensor value of the remaining toner amount.

  Reference numeral 210 denotes a possible value of the sensor value for the remaining amount of toner. In this embodiment, this value is set to 100%, 20%, and 0%, but other values may be used.

  Reference numeral 250 denotes a transition of the current value of the remaining amount of toner.

  P251 corresponds to the case where the current value of the remaining amount of toner is initialized in S104 after the cartridge replacement.

  In the period from P251 to P252, until the sensor value (20%) of the remaining toner amount is received, the predicted value of the remaining toner amount is calculated and the current value of the remaining toner amount is updated in the loop of S105 to S111. Corresponding to when.

  The section from S252 to S253 corresponds to when the current value of the toner remaining amount is updated with the sensor value (20%) in S104 when the sensor value (20%) of the toner remaining amount is received. At this time, the user is notified of the toner LOW (the remaining amount of toner has decreased).

  In the period from P253 to P254, the predicted value of the remaining amount of toner is calculated and the current value of the remaining amount of toner is updated in the loop of S105 to S111 until the sensor value (0%) of the remaining amount of toner is received. Corresponding to when.

  The section from S254 to S255 corresponds to when the current value of the toner remaining amount is updated with the sensor value (0%) in S104 when the sensor value (0%) of the toner remaining amount is received. At this time, the user is notified of toner OUT (toner remaining amount is exhausted).

  FIG. 7 is a flowchart (first embodiment) showing details of the toner consumption coefficient update process.

  First, the CPU 401 determines whether or not the toner cartridge has been replaced (S301). If the process proceeds from S121 to this flowchart, the determination is YES. On the other hand, if the process proceeds from S122 to this flowchart, the determination is NO. If YES is obtained in S301, the process proceeds to S303. If NO in S301, the process proceeds to S302.

  If NO in S301, the CPU 401 calculates a correction value for the toner consumption coefficient based on the current value and the sensor value (S302). The formula for calculation is as follows.

B = (RS _{pre -RS cur} ) / (RS _pre -RC) ... (Formula 2)
B: Correction value of toner consumption coefficient RS _cur : _Remaining sensor remaining value [g]
RS _pre : Sensor remaining value [g] acquired last time
RC: Current remaining amount value (toner remaining amount value calculated according to the predicted toner consumption value) [g]
Here, the correction value B of the toner consumption factor, minus the current remaining value RC sensor remaining value RS _cur from the toner cartridge capacity RS _pre, i.e. the sensor remaining value is consumed until the change Calculated as a value divided by the estimated total toner consumption. This will be described with reference to FIG. Consider a case where the sensor remaining amount value RS _cur acquired in P253 is 200 [g], the sensor remaining amount value RS _pre acquired in P251 is 1000 [g], and the current remaining amount value RC is 400 [g]. In this case, the actual toner consumption (RS _{pre -RS cur} ) detected by the sensor is 800 [g], whereas the total amount of toner predicted to be consumed until the sensor remaining value changes. The consumption (RS _pre -RC) is predicted to be 600 [g]. That is, it is predicted that the toner is consumed (600/800) times the actual consumption amount. Therefore, the toner consumption amount is predicted by multiplying (800/600), which is the reciprocal of (600/800), by the toner consumption coefficient. By doing so, the toner consumption amount and the actual toner consumption amount substantially coincide with each other, and the error (difference) decreases. Therefore, the correction value B of the toner consumption coefficient is calculated by Equation 2. Further, the correction value of the toner consumption coefficient in P255 is calculated in the section from P253 to P255. That is, RS _cur is 0 [g], the sensor remaining amount value RS _pre acquired in P253 is 200 [g], and the current remaining amount value RC is 20 [g]. Here, the calculation method of the correction value of the toner consumption coefficient is merely an example, and may be calculated using another calculation method.

If YES in S301, the CPU 401 sets the toner consumption coefficient correction value B to 1 without using Equation 2 (S303). That is, the toner consumption factor _{A d} without changing accept the ones stored in the EEPROM 410. In this way, when the image forming apparatus 102 has never used a toner cartridge, the toner consumption amount can be calculated using the default toner consumption coefficient. If the toner consumption coefficient has been updated more than once, even if the toner cartridge is replaced, the toner consumption coefficient updated on the toner cartridge before replacement is continuously used to calculate the toner consumption. can do. As a result, it is possible to maintain a state in which the toner consumption prediction accuracy is high even after replacement of the toner cartridge. For example, the prediction of toner consumption at the time of transition from P251 to P252 in FIG. 6 changes along the line 200 indicating the transition of the ideal notification remaining amount value. Therefore, when the acquired sensor remaining amount value changes from 100% to 20%, the correction amount to be corrected is reduced, and the drop from P252 to P253 is reduced.

  Next, the CPU 401 stores the correction value B of the toner consumption coefficient calculated in S302 or S303 in the EEPROM 410 (S304).

Next, CPU 401 multiplies the correction value B of the toner consumption coefficient calculated in step S202 into a toner consumption coefficient _{A d,} and updates the toner consumption factor _{A d} (S305).

Thus, by updating the toner consumption factor A _d in P253 in FIG. 6, for example, P253 from the prediction of the toner consumption amount when transitioning to P254 in FIG. 6, line indicating the transition of the ideal notice remaining value It changes so that it may follow 200. Therefore, the correction amount to be corrected is reduced when the acquired sensor remaining amount value changes from 20% to 0%.

[Second Embodiment]
In the first embodiment, the example in which the correction value of the toner consumption coefficient is calculated from the total toner consumption obtained in the interval from P251 to P252 in FIG. 6 and the remaining sensor value acquired in P253 has been described.

  In the present embodiment, an example of calculating a correction value of a toner consumption coefficient in consideration of a plurality of sections will be described with reference to FIGS.

  FIG. 8 is a diagram illustrating the transition of the current value of the remaining amount of toner (second embodiment).

  Reference numeral 600 denotes a line indicating a transition of an ideal notification remaining amount value on the assumption that the same consumption amount as the physical consumption can be acquired.

  Reference numerals 601 to 604 are lines showing examples of changes in the remaining sensor value notified from the printer engine 303.

  Reference numeral 610 denotes an example of points of the remaining sensor value (%) that can be notified from the printer engine 303. In this example, the remaining sensor values that can be notified from the printer engine 303 are 100%, 60%, 30%, and 0%, and 30% is set as a low level threshold value.

  Reference numeral 650 denotes a line indicating the transition of the remaining toner value. 650 starts from the point of P651 and shifts each point of P652 to P656 to the point of P657 that notifies 0% as the remaining amount of toner.

  P651 is a state immediately after the cartridge replacement.

  The interval from P651 to P652 indicates that the remaining sensor value acquired from the printer engine 302 does not change from 100%, and thus changes based on the prediction of toner consumption.

  The transition from P652 to P653 is due to the correction of the remaining toner amount to be notified according to the change in the remaining sensor value acquired from the printer engine 303 from 100% to 60%. Here, in P653, the toner consumption coefficient is updated by the toner consumption coefficient update process.

  The section from P653 to P654 indicates that the sensor remaining amount value acquired from the printer engine 303 does not change from 60%, and thus changes based on the prediction of toner consumption. Here, originally, in the section from P653 to P654, the toner consumption coefficient is updated in P653, so that the deviation from the line 600 indicating the transition of the ideal notification remaining amount value becomes small.

  Here, when the error between the remaining amount of toner calculated from the predicted value of the toner consumption amount in the section from P653 to P654 and the remaining amount of sensor is equal to or greater than a predetermined value, the following may be considered.

・ Environmental changes such as temperature and humidity ・ Changes in trends in data to be printed (including changes in users)
Therefore, when the toner consumption coefficient is updated in P655, the correction value B of the toner consumption coefficient is obtained from the whole data including the previous section and the current section rather than obtaining the correction value B of the toner consumption coefficient from the data of only the current section. It is possible to obtain a more universal toner consumption coefficient.

  As described above, the toner consumption coefficient update process considering the case where the error between the remaining toner value (current remaining amount value) calculated from the predicted value of the toner consumption amount in the section from P653 to P654 and the remaining sensor value is equal to or greater than a predetermined value. Is shown in FIG.

  The transition from P654 to P655 is due to the fact that the remaining amount of toner to be notified is corrected according to the change in the remaining amount of sensor acquired from the printer engine 303 from 60% to 30%.

  A section from P655 to P656 indicates that the remaining sensor value acquired from the printer engine 303 does not change from 30%, and thus changes based on the prediction of toner consumption.

  The transition from P656 to P657 is due to the correction of the remaining toner amount to be notified according to the change in the remaining sensor value acquired from the printer engine 303 from 30% to 0%.

  FIG. 9 is a flowchart (second embodiment) showing details of the toner consumption coefficient update process.

  In FIG. 9, the same steps as those in FIG.

  First, the CPU 401 calculates an error between the current remaining amount value and the sensor remaining amount value during the current section (S401).

  Next, the CPU 401 determines whether or not the error calculated in S401 is a predetermined value or more (S402).

When it is determined in S402 that the value is equal to or greater than the predetermined value, the CPU 401 calculates the correction value of the toner consumption coefficient by combining the previous section and the current section (S403). At this time, for example, in the example of FIG. 8, the remaining sensor value at P651 is 1000 [g], the remaining sensor value at P653 is 600 [g], the remaining sensor value at P655 is 300 [g], and the current remaining value at P654 is The quantity value is 280 [g]. In _S403, the _{RS cur} 300 _[g], the sensor remaining value acquired the _{RS pre} with P651 1000 [g], a current remaining value RC as 280 [g], the toner consumption coefficient correction value B, Calculation is performed using Equation 2. In this way, the toner consumption coefficient correction value B and the toner consumption coefficient reflecting the prediction error of the toner consumption amount in the previous section can be calculated as compared with the calculation method in the first embodiment. it can.

If it is determined in S402 that the value is less than the predetermined value, the CPU 401 calculates a correction value for the toner consumption coefficient only in the current section (S404). At this time, in the example of FIG. 8, for example, RS _pre is set to the remaining sensor value 600 [g] acquired in P653, and other values are calculated with the same values as in S403.

  In the present embodiment, when the error between the current remaining amount value and the sensor remaining amount value is greater than or equal to a predetermined value during the current interval, the correction value of the toner consumption coefficient is calculated by combining the previous interval and the current interval. Of course, all the sections may be calculated together. For example, when the sensor remaining amount value is acquired in P657, if the error between the current remaining amount value and the sensor remaining amount value in the interval from P655 to P656 is equal to or greater than a predetermined value, the toner consumption coefficient is corrected in the interval from P651 to P656. A value may be calculated.

  Further, the present embodiment may be applied not only to the same toner cartridge but also to, for example, the last section of the toner cartridge used last time and the first section of the toner cartridge newly started to be used.

[Third Embodiment]
In the first and second embodiments, when the sensor remaining amount value can be acquired from the printer engine 303, the correction value of the toner consumption coefficient is calculated and the toner consumption coefficient is updated.

  However, depending on the type of printer engine, there may be a case where the remaining sensor value can be acquired even when the toner consumption is small. For example, in the example of FIG. 8, it is assumed that there is an engine that can acquire the sensor remaining amount value even when the toner remaining amount is 90%. In this case, in the first and second embodiments, the toner consumption coefficient is updated when the remaining sensor value is 90%. However, at the stage where the toner is reduced by only 10%, the number of samples of the printed data and the user is small, and it is considered that the tendency of toner consumption in the image forming apparatus is not grasped.

  In the third embodiment, in consideration of the above points, the toner consumption coefficient is not updated when the remaining sensor value can be acquired at a stage where it can be determined that the number of samples of printed data or users is small. To do.

[Fourth Embodiment]
In the first to third embodiments, the sensor remaining value that can be acquired from the printer engine 303 has been described as being discrete as shown in FIGS.

  However, depending on the printer engine, there is an engine that can acquire the sensor remaining value every 1% when the toner remaining value decreases to some extent. In this case, the transition of the remaining amount of toner is as shown in FIG.

  FIG. 10 is a diagram illustrating a transition of the current value of the remaining amount of toner (fourth embodiment).

  This is a diagram showing a case where the remaining sensor value can be acquired every 1% after the remaining toner value becomes 30% or less in FIG. The difference between FIG. 8 and FIG. 10 is only that the remaining sensor value is decreased every 1% in 703 in FIG. 10 while 603 in FIG. 8 is fixed at 30%. Here, since the sensor remaining amount value can be acquired every 1% in the section from P755 to P756 in FIG. 10, it is possible to display the correct toner remaining amount value without predicting the toner consumption amount.

  However, in the third embodiment, the toner consumption amount is predicted and the toner consumption coefficient is updated even when the toner consumption amount is not predicted as in the section from P755 to P756.

  By doing so, the toner consumption coefficient can be continuously updated until the toner cartridge is replaced, and the prediction accuracy of the toner consumption is improved. By using the toner consumption coefficient even after replacement of the toner cartridge, it is possible to predict the toner consumption amount in the section from P751 to P752 with high accuracy.

[Fifth Embodiment]
In the first to fourth embodiments, one of the sensor remaining values that can be acquired from the printer engine 303 (20% in FIG. 6 and 30% in FIG. 8) is set to the toner low level.

  When performing automatic toner delivery, it is common to deliver at the timing when the toner low level is detected. However, the timing at which the toner cartridge is automatically sent varies depending on the user. For example, it is convenient that a user who does not want to run out of toner cartridge inventory is automatically sent early, and a user who does not want to have much stock of toner cartridges is automatically sent later. In order to respond to such a user's request, there is a case in which the user can arbitrarily change the timing of automatic shipping, that is, the timing of notifying the user that the toner level is low. The percentage of toner remaining in timing control is determined by what percentage. For example, in the example of FIG. 6, the sensor remaining value of the toner low level that can be acquired from the printer engine 303 is 20%. However, if the user wants to ship the toner cartridge early, the remaining toner value is 25. Suppose you set to automatically ship when the percentage is reached. In this case, whether or not the toner remaining amount value has reached 25% is determined from the calculation result based on the toner consumption amount prediction performed by the controller 302, not the sensor remaining amount value that can be acquired from the printer engine 303.

  Therefore, in the fifth embodiment, the correction value of the toner consumption coefficient used for the toner consumption amount prediction is calculated in consideration of the change of the automatic shipping timing set by the user.

  FIG. 11 is a flowchart (fifth embodiment) showing details of the toner consumption coefficient update process.

  In FIG. 11, the same steps as those in FIG.

  First, the CPU 401 acquires from the EEPROM 410 a remaining toner value for automatically sending out the toner cartridge set by the user (S501). This value is set in advance from the user via the UI 301.

  Next, the CPU 401 determines whether or not the current remaining amount value is smaller than the sensor remaining amount value notified from the printer (S502).

  In the case of YES in S502, the CPU 401 determines whether or not the toner remaining amount value for automatic toner cartridge dispatch set by the user is greater than the toner LOW value (20% in the example of FIG. 6) notified from the printer (see FIG. 6). S503).

  In the case of No in S502, the CPU 409 determines whether or not the toner remaining amount value for automatic toner cartridge shipment set by the user is smaller than the value of toner Low notified from the printer (20% in the example of FIG. 5) (S504). ).

  Next, the correction value of the toner consumption coefficient is recalculated using the correction coefficient (S505).

  If both S502 and S503 are YES, the user does not want to run out of toner cartridge inventory, and the toner consumption is predicted to be larger than the actual consumption. At this time, since the current remaining amount value becomes the toner remaining amount value for performing the automatic shipping set by the user earlier than the actual toner consumption, the automatic shipping is performed at an early timing, and the toner cartridge is out of stock. This is consistent with the user's intention of not wanting to. If the toner coefficient is updated and the toner coefficient is corrected too much, the timing at which the current remaining amount value becomes the toner remaining amount value for automatic shipping set by the user is later than the actual toner consumption. End up. If it becomes so, the timing of automatic dispatch will also become late and will be in the state contrary to a user's intention.

  The recalculation formula is, for example, as follows.

B = B ÷ C (Formula 3)
B: Correction value of toner consumption coefficient C: Correction coefficient Here, the correction coefficient is a coefficient that can take an arbitrary value less than 1, and may be stored in the EEEPOM 410 or the like in advance or set by the user. You may do it. When both S502 and S503 are YES, the correction value B of the toner consumption coefficient is smaller than 1. By dividing the correction value B of the toner consumption coefficient by the correction coefficient C of less than 1, the correction amount of the toner consumption coefficient is relaxed. In this embodiment, the correction coefficient is set to 0.9 in order to perform correction appropriately while maintaining the tendency of toner consumption prediction that matches the user's intention.

  On the other hand, if NO in S502 and YES in S504, the user thinks that the user does not want to have a stock of toner cartridges, and the toner consumption is predicted to be smaller than the actual consumption. At this time, the timing at which the current remaining amount value becomes the toner remaining amount value for automatic shipping set by the user is later than the actual toner consumption. As a result, the timing for carrying out the self-propelled shipping is delayed, which is consistent with the user's intention of not wanting to hold the toner cartridge inventory.

  In this case as well, the toner consumption coefficient correction value is corrected with the correction coefficient in the process of S505, and the calculation formula is as follows.

B = B × C (Formula 4)
B: Correction value of toner consumption coefficient C: Correction coefficient In this case, the correction value B of the toner consumption coefficient is larger than 1. By multiplying the correction value B of the toner consumption coefficient by the correction coefficient C less than 1, the correction amount of the toner consumption coefficient is relaxed.

[Sixth Embodiment]
FIG. 12 is a flowchart (sixth embodiment) showing details of the toner consumption coefficient update process.

  In FIG. 12, the same steps as those in FIG.

  If NO in S301, the CPU 401 calculates an error δ between the current value and the sensor value (S601).

  The error in the remaining amount value of toner is calculated by the following calculation formula.

δ _n = A · D _n −S
δ: Error between sensor value and predicted value A: Toner consumption coefficient D _n : Dot counter [K dot] for each print page
S: Sensor Value Next, the CPU 401 stores the error δ calculated in S601 in the EEPROM 410. (S602).

  In the case of YES in S301, the CPU 401 totals the error values stored in S602 and calculates the standard deviation of errors (S603). The standard deviation is calculated by the following formula.

_{n = m}
Av = Σδ _n / m
^{n = 1}
m: Number of stored errors δ Av: Average value of errors between sensor values and predicted values δ: Errors between stored sensor values and predicted values
_{n = m}
s = Σ (δ _n −Av) ^{2
n = 1}
s: Standard deviation δ: Error between stored sensor value and predicted value Av: Average value of error between sensor value and predicted value m: Number of stored errors δ Next, the CPU 401 has a constant standard deviation calculated in S603. It is determined whether the value is equal to or less than the value (S604).

  If YES in S604, the CPU 401 determines that there is a tendency in the user environment, and extracts a certain range of error δ from the median as shown in FIG. 13A (S605).

  In the case of NO in S604, the CPU 401 determines that the user's usage environment is not so characteristic, and extracts the entire range of error δ as shown in FIG. 13B (S606).

Next, the CPU 401 calculates the average value of the errors extracted in S605 or S606. (S607)
Next, the CPU 401 updates the toner consumption coefficient based on the average value of errors calculated in S607 (S608). Specifically, the toner consumption coefficient is corrected so that the average error value is canceled out.

[Other Embodiments]
The present invention is also realized by executing the following processing.

  That is, software (program) that realizes the functions of the above-described embodiments is supplied to a system or apparatus via a network or various storage media, and a computer (or CPU, MPU, or the like) of the system or apparatus reads the program. It is a process to be executed.

Claims (10)

An image forming apparatus that forms an image using a recording material,
Obtaining means for obtaining the remaining amount of the recording material;
Calculation means for calculating a consumption amount of the recording material based on a dot count value in the raster data and a consumption coefficient indicating a consumption amount of the recording material for each dot;
Predicting means for predicting the remaining amount of the recording material based on the consumption of the recording material calculated by the calculating means;
Correction means for correcting the consumption coefficient based on the remaining amount of the recording material acquired by the acquisition unit and the remaining amount of the recording material predicted by the prediction unit;
An image forming apparatus comprising:   The image forming apparatus according to claim 1, wherein the correction unit updates the consumption coefficient when the storage unit for the recording material is replaced.   The correcting means sets the value in the first section when the difference between the remaining amount of the recording material acquired by the acquiring means and the remaining amount of the recording material predicted by the predicting means is a predetermined value or more. The image forming apparatus according to claim 1, wherein the consumption coefficient is corrected on the basis of the consumption coefficient.   The correcting means is shorter than the first section when the difference between the remaining amount of the recording material acquired by the acquiring means and the remaining amount of the recording material predicted by the predicting means is not greater than or equal to a predetermined value. 4. The image forming apparatus according to claim 1, wherein the consumption coefficient is corrected based on a value in a section of 2. 5.   The correction unit corresponds to a case where the recording material storage unit should be shipped when the remaining amount of the recording material predicted by the prediction unit is smaller than the remaining amount of the recording material acquired by the acquisition unit. The consumption coefficient is corrected again when the remaining amount of the recording material to be printed is larger than the remaining amount of the corresponding recording material when it is to be notified that the remaining amount of the recording material is low. The image forming apparatus according to any one of 1 to 4.   The correction unit corresponds to a case where the recording material storage unit should be shipped when the remaining amount of the recording material predicted by the prediction unit is larger than the remaining amount of the recording material acquired by the acquisition unit. The consumption coefficient is corrected again when the remaining amount of recording material to be recorded is smaller than the corresponding remaining amount of recording material when it is to be notified that the remaining amount of recording material is low. The image forming apparatus according to any one of 1 to 5.   When the standard deviation of the difference between the remaining amount of the recording material acquired by the acquiring unit and the remaining amount of the recording material predicted by the prediction unit is less than a predetermined value, the correcting unit The image forming apparatus according to claim 1, wherein the consumption coefficient is corrected based on the image quality.   The correction means determines the difference in the entire range when the standard deviation of the difference between the remaining amount of the recording material acquired by the acquiring means and the remaining amount of the recording material predicted by the prediction means is not less than a predetermined value. 8. The image forming apparatus according to claim 1, wherein the consumption coefficient is corrected on the basis of the consumption coefficient. A control method for an image forming apparatus for forming an image using a recording material,
An acquisition step of acquiring the remaining amount of the recording material;
A calculation step of calculating a consumption amount of the recording material based on a dot count value in the raster data and a consumption coefficient indicating a consumption amount of the recording material for each dot;
A predicting step of predicting the remaining amount of the recording material based on the consumption of the recording material calculated by the calculating step;
A correction step of correcting the consumption coefficient based on the remaining amount of the recording material acquired by the acquisition step and the remaining amount of the recording material predicted by the prediction step;
A control method characterized by comprising: In an image forming apparatus that forms an image using a recording material,
An acquisition step of acquiring the remaining amount of the recording material;
A calculation step of calculating a consumption amount of the recording material based on a dot count value in the raster data and a consumption coefficient indicating a consumption amount of the recording material for each dot;
A predicting step of predicting the remaining amount of the recording material based on the consumption of the recording material calculated by the calculating step;
A correction step of correcting the consumption coefficient based on the remaining amount of the recording material acquired by the acquisition step and the remaining amount of the recording material predicted by the prediction step;
A program for running

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