JP7463900B2 - Image data processing device, image forming device, image data processing method and program - Google Patents

Description

This invention relates to an image data processing device, an image forming device, an image data processing method, and a program.

There are image forming devices that form images by applying color materials such as ink to a medium. Not only are each image formed on a different medium as a separate image, but multiple images may also be integrated into a single piece of image data and formed together on a recording medium (imposition), which may then be cut or folded. If a problem occurs with the image quality of the formed image during such an image forming operation, or if a problem such as a media jam occurs, it is pointless to re-output all the images. In response to this, a technology is known that excludes images that have already been output correctly and rearranges the layout of the remaining images to form images (Patent Document 1).

JP 2020-1358 A

When forming an image using a single pass method in which the colorant is output while the forming operation unit that outputs the colorant and the medium are moved relative to each other, image formation abnormalities may occur at specific positions in the width direction perpendicular to the direction of relative movement. Such abnormalities tend to occur continuously, making it necessary to identify the cause and deal with it promptly. However, in such an image forming device, completely interrupting the normal image formation operation to perform an operation to identify the cause may result in increased consumption of media and time, resulting in a problem of reduced work efficiency.

The object of the present invention is to provide an image data processing device, an image forming device, an image data processing method, and a program that can perform image formation operations while dealing with image formation abnormalities more efficiently.

In order to achieve the above object, the present invention provides:
a detection unit for detecting a formation abnormality in an image formed by a forming operation unit that forms an image;
a range specifying means for specifying an abnormal image formation range of the formed image including the detected range of the formation abnormality;
a rearrangement setting means for arranging an inspection image for identifying the cause of the formation abnormality in the abnormal image formation area, and setting image data in which an image that is not normally formed is rearranged outside the abnormal image formation area;
a correction unit that corrects the image forming operation corresponding to the formation abnormality based on the inspection image formed by the forming operation unit in accordance with the image data after the rearrangement;
The image data processing device is characterized by comprising:

The present invention provides an image data processing apparatus according to claim 1,
The two or more predetermined number of images to be formed by the forming operation unit are assigned to a portion of a medium on which the images are to be formed and are imposed;
The area specifying means specifies the abnormal image formation area for each area of the imposed and arranged images.

The present invention provides an image data processing apparatus according to claim 3, comprising:
When the formation abnormality is detected and some of the images to be formed are not yet formed, the rearrangement setting means includes the unformed images as targets for rearrangement.

The invention described in claim 4 provides an image data processing device according to any one of claims 1 to 3,
The rearrangement setting means is characterized in that it arranges the examination images in accordance with the type of the detected malformation.

The present invention provides an image data processing apparatus according to claim 4, comprising:
The type of formation abnormality includes at least one of uneven density of an image and occurrence of streaks.

The present invention provides an image data processing device according to any one of claims 1 to 5,
the forming operation unit has a plurality of ink-jet heads that eject ink,
The range specifying means determines the range of the formation abnormality for each image formation range by each of the inkjet heads.

The present invention provides an image data processing apparatus according to claim 6, comprising:
The rearrangement setting means is characterized in that it arranges the test image formed only by the inkjet head in a position corresponding to the range of the malformation.

The invention described in claim 8 provides an image data processing device according to any one of claims 1 to 7,
When the formation abnormality is detected and there is an intermediate image after the start of formation and before the detection of the formation abnormality, the rearrangement setting means is characterized in that it sets the rearrangement after the abnormal image formation range of the intermediate image is identified.

The present invention provides an image data processing device according to any one of claims 1 to 6,
The present invention is characterized in that, when the malformation is detected from an image that has been reconstructed by the reconstructing means in a position different from the original position, a selection means is provided which selects subsequent processing based on the results of a comparison between the extent of the malformation in this image and the extent of the malformation in the image at the time the malformation was first detected.

The present invention provides an image data processing apparatus according to claim 9,
An operation reception unit is provided,
When the comparison result indicates that the extent of the malformation in the images is the same, the selection means selects the subsequent processing based on the content of the input operation received by the operation receiving unit.

The invention according to claim 11 further comprises:
An image data processing device according to any one of claims 1 to 10;
a forming operation unit for forming an image;
The image forming apparatus is characterized by comprising:

The present invention provides an image forming apparatus according to claim 11,
a reading unit for reading the formed image,
The detection means detects the formation abnormality based on data read from the formed image by the reading section.

The invention according to claim 13 further comprises:
a detection step of detecting a formation abnormality in an image formed by a forming operation unit that forms an image;
a range specifying step of specifying an abnormal image formation range of the formed image including the detected range of the formation abnormality;
a rearrangement setting step of arranging an inspection image for identifying a cause of the formation abnormality in the abnormal image formation area, and setting image data in which an image that is not normally formed is rearranged outside the abnormal image formation area;
a correction step of correcting the image forming operation corresponding to the formation abnormality based on the inspection image formed by the forming operation unit in accordance with the image data after the rearrangement;
The image data processing method includes:

The invention according to claim 14 further comprises:
Computer,
a detection unit for detecting a formation abnormality in an image formed by a forming operation unit that forms an image;
a range specifying means for specifying an abnormal image formation range of the formed image including the detected range of the formation abnormality;
a rearrangement setting means for arranging an inspection image for identifying the cause of the formation abnormality in the abnormal image formation area, and setting image data in which an image that is not normally formed is rearranged outside the abnormal image formation area;
a correction unit that corrects the image forming operation corresponding to the formation abnormality based on the inspection image formed by the forming operation unit in accordance with the image data after the rearrangement;
The program is characterized in that it functions as

According to the present invention, it is possible to perform image formation operations while dealing with image formation abnormalities more efficiently.

1 is a perspective view showing a schematic configuration of an image forming apparatus according to an embodiment of the present invention; 4 is a diagram illustrating a bottom surface of the head unit that faces the medium. FIG. FIG. 2 is a block diagram showing a functional configuration of the image forming apparatus. FIG. 2 is a diagram illustrating an imposed image. 11 is a table illustrating data related to abnormality detection of an imposed image. FIG. 13 is a diagram illustrating a rearranged image. FIG. 13 is a diagram showing an example of a setting screen relating to inspection. 5 is a flowchart showing a control procedure of an image formation control process. 10 is a flowchart showing a control procedure of a rearrangement setting process called in the image formation control process. 13A and 13B are diagrams illustrating an example in which an abnormality that may not be able to be dealt with by 13 is a flowchart showing a control procedure of a reallocation setting process according to a modified example.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is a perspective view showing a schematic configuration of an image forming apparatus 1 according to the present embodiment.

The image forming device 1 forms images using an inkjet method. The image forming device 1 includes a conveying unit 10, a forming operation unit 20, an imaging unit 30 (reading unit), and a control unit 40.

The transport unit 10 supplies the medium M on which an image is to be formed, moves it to the image forming position, and discharges it. The transport unit 10 includes a drive roller 11, a transport belt 12, a driven roller 13, a transport motor 14, and a pressure roller 15.

Here, the conveyor belt 12 is endless, stretched between the driving roller 11 and the driven roller 13, and moves according to the rotation of the driving roller 11. The driving roller 11 rotates at a speed according to the rotation of the conveyor motor 14. The driven roller 13 rotates at a speed according to the movement of the conveyor belt 12. The medium M is placed at a predetermined position on the outer circumferential surface of the conveyor belt 12, an image is formed while moving, and after the image is formed, it is discharged at a predetermined position. The pressure roller 15 removes the lifting of the medium M due to wrinkles, etc. by pressing the medium M placed on the conveyor belt 12 against the conveyor belt 12. The pressure roller 15 may be a roller that presses the medium M against the conveyor belt 12 by its own weight and rotates according to the movement of the medium M and the conveyor belt 12. The medium M is, for example, printing paper. The type of paper may be appropriately selected from various types such as plain paper, fine paper, coated paper, thick paper, embossed paper, etc., and may be replaced as necessary. In addition, the medium M is not limited to paper. For example, it may be a film resin, a plastic plate, or a cardboard material. The operation of each part of the conveying unit 10 may be adjusted according to the type of medium M.

The forming operation unit 20 ejects ink onto the medium M on the conveyor belt 12 to form an image. Although not particularly limited, here, the forming operation unit 20 has four colors: head unit 21C that ejects cyan ink, head unit 21M that ejects magenta ink, head unit 21Y that ejects yellow ink, and head unit 21K that ejects black ink. Hereinafter, some or all of these will also be referred to as head units 21.

Figure 2 is a diagram explaining the bottom surface of the head unit 21 that faces the medium M (the outer surface of the conveyor belt 12).

The head unit 21 has a carriage 210 and multiple inkjet heads 211. The inkjet heads 211 are arranged in pairs across the entire width of the medium M in the width direction perpendicular to the transport direction, over which an image can be formed, and are fixed to the carriage 210 to form a line head. A nozzle 27 is opened on the bottom surface of each inkjet head 211, and ink is ejected from each at a position that is a predetermined distance (distance in the height direction perpendicular to the transport direction and width direction) from the medium M. Here, the opening of the nozzle 27 is clearly shown for the sake of explanation, but in reality, the size and spacing of the opening may be much smaller than this.

The imaging unit 30 is positioned so that it can image the image formation surface of the medium M downstream in the transport direction from the formation position (ink landing position) on the medium M by the formation operation unit 20. The imaging unit 30 is, for example, a line sensor having a CMOS sensor (Complementary Metal Oxide Semiconductor) or a CCD sensor (Charge Coupled Device), and is capable of imaging the maximum width of the medium M on which an image can be formed in the width direction. By sequentially capturing images while transporting the medium M, it is possible to read the surface of the medium M (i.e., the formed image) in two dimensions.

The control unit 40 has a hardware processor that controls the overall operation of the image forming device 1.

FIG. 3 is a block diagram showing the functional configuration of the image forming apparatus 1. As shown in FIG.
In addition to the above-mentioned conveying unit 10, forming operation unit 20, imaging unit 30, and control unit 40, the image forming apparatus 1 includes a drive waveform signal generating unit 29, a memory unit 50, a communication unit 60, an operation receiving unit 70, a display unit 80, a power supply unit 90, etc.

As described above, the transport unit 10 is equipped with a transport motor 14, and outputs an appropriate drive signal to the transport motor 14, causing the transport motor 14 to rotate at a speed corresponding to the drive signal.

The formation operation unit 20 includes a head drive unit 25. The head drive unit 25 outputs a drive signal to a selected piezoelectric element 26 to deform the piezoelectric element 26, and applies pressure fluctuations to the ink in the nozzle 27 to eject the ink, forming an image.

The drive waveform signal generating unit 29 generates a drive waveform signal to be output by the head driving unit 25. Although not particularly limited, the drive waveform signal is generated by converting digital signal data indicating the drive waveform into analog form and outputting the amplified voltage and current drive waveform signal to the head driving unit 25.

The control unit 40 includes a CPU 41 (Central Processing Unit) and a RAM 42 (Random Access Memory). The CPU 41 performs various calculation processes to execute control operations. The control operations include control related to the image forming operation and control related to anomaly response operations related to formation anomalies in the image formed by the forming operation unit 20. The RAM 42 provides a working memory space for the CPU 41 and stores temporary data. In the image forming device 1 of this embodiment, the control unit 40 functions as a detection means, a range identification means, a relocation setting means, a correction means and a selection means, and constitutes an image data processing device.

The storage unit 50 stores job data 51 including image data of the object to be formed, inspection image data 52 for adjusting and inspecting the operation of the forming operation unit 20, and a program 54 for detecting abnormalities in the formed image and inspecting the same. The storage unit 50 also stores position information of the abnormal nozzle where an ejection abnormality occurs and a complementary setting 53 for allocating the ink that the abnormal nozzle should eject to nearby nozzles. The job data 51 may be stored in a volatile memory such as a RAM, and the inspection image data 52, the complementary setting 53, the program 54, and the like may be stored in a non-volatile memory. The non-volatile memory may be, for example, a flash memory, and may have a HDD (Hard Disk Drive) or the like in addition to or instead of this. The contents of the inspection image data 52, the complementary setting 53, and the program 54 may also be read out during operation as necessary and stored in the volatile memory.

The communication unit 60 executes and controls communication with external devices. The communication unit 60 is connected to an external computer based on a communication standard such as TCP/IP, acquires job data including image data to be formed, and outputs the status of the image forming operation based on the job data. The communication unit 60 may also be directly connected to a peripheral device via a USB (Universal Serial Bus) or the like to send and receive data.

The operation reception unit 70 receives input operations by a user or the like, and outputs the received contents to the control unit 40 as an input signal. The operation reception unit 70 includes, for example, a touch panel and a push button switch. The touch panel is positioned so as to overlap with the display screen of the display unit 80, and the operation contents may be specified in synchronization with the display contents on the display screen.

The display unit 80 displays status, selection menus, etc. to the user based on the control of the control unit 40. The display unit 80 has, for example, a display screen and indicators (lamps). The display screen is, for example, a liquid crystal display screen, and can display various characters and figures in a dot matrix. The indicator is, for example, an LED (Light Emitting Diode) lamp, and may be switched on and off or flash when indicating the presence or absence of power supply or the presence or absence of operational abnormalities.

The power supply unit 90 supplies power at a voltage corresponding to each part of the image forming device 1. A voltage corresponding to the peak voltage of each drive waveform is output to the drive board 212 of the forming operation unit 20. Alternatively, only the maximum peak voltage may be output, and multiple voltage signals may be generated on the drive board 212.

Next, an imposition image forming operation in the image forming apparatus 1 of this embodiment will be described.
In the image forming apparatus 1, the image forming area of a predetermined number of images (e.g., four sheets) to be formed is divided and assigned to each part of the supplied medium M, and an imposition arrangement is performed to form the images. When the control unit 40 acquires job data, it assigns and arranges the image data to the image forming area according to the job settings, and further converts it into driving data for operating the forming operation unit 20 according to the arrangement setting. The driving data is output to the forming operation unit 20 at an appropriate timing, and the image forming operation is performed. When the number of sheets to be formed is five or more, the images are imposed and arranged in sequence, a predetermined number at a time, on two or more recording media.

FIG. 4 is a diagram for explaining an imposed image.
4A, when each medium M is divided into four and an image is formed in each divided area, eleven images indicated by numbers 1 to 11 are assigned to three medium M and imposed images are formed. On the third medium, a quarter of the area remains, but when multiple sets of eleven images are formed, the first sheet of the next set may be assigned thereto.

In this imposed image formation, image quality abnormalities (formation abnormalities) may occur in part of the formed image due to operational abnormalities or poor adjustment of the forming operation unit 20. In particular, in the case of an abnormality dependent on a specific nozzle 27 or inkjet head 211, in the line head, streaky or band-like image quality abnormalities (uneven density, streaks, etc.) occur in the width direction only at the position of that nozzle 27 or inkjet head 211. As shown in Figure 4(b), streaky abnormalities N occur at positions 2, 4, 6, and 8 of the imposed image. In this case, images 1, 3, 5, and 7 of the imposed image are formed normally.

If such a partial abnormality results in a portion of the image being formed normally, it is pointless to re-form the entire image, including the normally formed image. On the other hand, if the cause of the abnormality is not quickly identified and dealt with, normal image formation will not be possible in that portion, resulting in reduced efficiency.

In the image forming device 1 of this embodiment, when the above-mentioned partial abnormality occurs, the presence or absence of a formation abnormality is determined for each range of the imposed images, and the image in the area where the abnormality occurred (the image that is not formed normally) is moved to a part where no abnormality occurs (outside the abnormal image formation range) and re-formed, and in parallel with this, an inspection image for identifying the cause of the abnormality is formed in the area where the abnormality occurred (the abnormal image formation range). The control unit 40 generates (re-arranges) and sets image data with such an allocation, and causes the forming operation unit 20 to form it. When the formed inspection image is captured and analyzed by the imaging unit 30 and the cause of the abnormality is identified, a drive setting is performed to complement the specific part as a correction operation of the image forming operation corresponding to the formation abnormality, and the drive setting is registered in the complement setting 53, and then normal image formation is resumed based on the drive setting. The correction operation here may be either one of adjusting the operation of the forming operation unit 20, for example, changing the drive voltage (amplitude) or the waveform (pulse width, etc.) of the drive signal, or adjusting the image data, or a combination of these.

FIG. 5 is a table for explaining data relating to abnormality detection of imposed images.
As shown in Fig. 5A, when forming an imposition image, information on the imposition area to be assigned to each page of the medium M is set and stored. Here, one-sided images are formed on each page (medium M), and the one side (front side) is divided into four equal 2 x 2 parts for imposition. It is set so that images 1 and 2 are formed in the area on the downstream side (leading side) of the conveying direction (Y direction), and images 3 and 4 are formed in the area on the upstream side (trailing side). This data is compared with the detection coordinates of the formation abnormality detected from the image data captured by the imaging unit 30, and the imposition area (abnormal image formation area) including the range of the formation abnormality is specified.

The image forming surface of the medium M on which the image is formed is imaged by the imaging unit 30 downstream in the transport direction, and an analysis process is performed by the control unit 40 to detect the presence or absence of formation abnormalities. The presence or absence and range of formation abnormalities is detected by, but is not limited to, comparing the imaging data with the original image data that was the subject of image formation. For example, a portion in which imaging data with a gradation value that differs from the original image data by more than a predetermined reference value may be determined to be the range of formation abnormalities.

As shown in FIG. 5(b), the presence or absence of an abnormality is determined for each imposition area in near real time for a job in image formation, and is stored. If no abnormality is detected and normal, the image is determined to be normal output, and even if an abnormality occurs (has occurred) in other areas, the image is determined to be one for which reimposition and re-image formation is not required. On the other hand, if an abnormality is detected, an abnormality is detected and re-arrangement is required. Here, images taken between the start of image formation and when an abnormality is detected from the imaging results (intermediate images) are shown as "outputting, not inspected", and images taken before image formation begins (not formed) are shown as "not output".

As shown in FIG. 5(c), normal processing continues from when an abnormality is detected until the inspection of the image being formed or before inspection after the detection is completed. After the presence or absence of abnormalities in all images that have not been inspected during output is determined, all areas in which abnormalities have been detected and images that need to be reformed are determined. For images that have not been formed when an abnormality is detected, whether or not they need to be rearranged is determined depending on the number of images that need to be reformed and the area occupied by the inspection image. In other words, if images are assigned to each imposition area on the medium M without any margins by combining the reformed image and the inspection image, the unformed images may be formed according to the original allocation. If margins are generated, the imposition is reset (rearranged) by inserting an unformed image (included in the image that is not formed normally). In this case, there are four images that "need" to be reformed, and the inspection image occupies two pages, so two of the imposition areas become margins. Therefore, unformed images 9 to 11 are rearranged.

FIG. 6 is a diagram illustrating the rearranged image.
6A, in the rearrangement, the inspection image T is arranged on the right half of the image in which an abnormality was first detected on the leading medium M. Images 2 and 4, which were formed in the area in which an abnormality was detected, are moved to the left half of the image in which a normal image is formed, and images 6 and 8 are arranged on the second medium M. Images 9 and onwards are arranged in order, filling in the area from image 8 onwards. As described above, the next set of images may be arranged again in the blank space after image 11, starting with image 1.

The inspection image T is selected according to the type of abnormality detected. As shown in FIG. 6B, when the abnormality is determined (estimated) to be an abnormality in ejection by the nozzle 27, ink is ejected individually from each possible nozzle 27 to form a straight line, and the landing position and landing amount of the ink from each nozzle 27 are identified. The landing positions of adjacent nozzles 27 overlap each other in the width direction, and considering the deviation width at the time of the abnormality, the landing positions may overlap with the landing positions of nozzles 27 that are two or more away. Therefore, here, a ladder-shaped test pattern (ladder chart) in which the positions are shifted in the transport direction by several nozzles is output. In addition, when an abnormality occurs only in a specific range in the width direction, an inspection image may be formed only by the inkjet head 211 corresponding to the range where the abnormality occurs. As described above, when multiple (two) inkjet heads 211 are arranged in approximately the same range in the width direction, these multiple (two) inkjet heads 211 may correspond to the range where the abnormality occurs. Note that accurate determination (estimation) is not always possible at the anomaly detection stage, and the cause may not always be narrowed down to one, so in some cases multiple different types of test images T may be formed, or a test image for narrowing down the cause may be placed first. Depending on the size and number of test images T, test images may be formed across the same area on the second and subsequent sheets of media.

Regardless of the above, the user can also configure the system so that rearrangement and inspection are not performed on an imposed image basis, as in the past, or so that inspection is not performed in parallel with normal image formation.

FIG. 7 is a diagram showing an example of a setting screen relating to inspection.
This setting screen can be called up, for example, by a user performing a predetermined input operation on the operation reception unit 70. In addition, it may be possible to call up the setting screen of the image forming apparatus 1 from a PC or the like outside the image forming apparatus 1 and open it by performing a predetermined input operation.

Here, it is possible to select whether or not to perform inspection on an imposed image basis, and whether or not to automatically perform image correction in parallel with the formation of a normal image when an abnormality occurs. If the selection is made not to perform inspection on an imposed image basis, the formation of the normal image will be completely stopped if an abnormality is detected anywhere in the normally formed image. The formation of the inspection image and the process of identifying the abnormality itself may be performed automatically, or the system may wait until the user commands the output of the desired inspection image via input to the operation reception unit 70.

If the system is set not to automatically correct anomalies, after an anomaly is identified as described above, the details of the identified anomaly are displayed on the display unit 80 or the like, and the user is requested to take action (may be requested to select from options), and action is taken according to the request input.

Regardless of whether automatic correction is set or not, if the type of abnormality identified cannot be dealt with by automatic adjustment or correction processing, for example, if it requires replacement of a part or consumable, or if it requires a cleaning operation, the subsequent image formation operation may be stopped and a notification operation may be performed to notify the user. Note that the cleaning operation may be started without obtaining user approval, with only a notification operation.

Figure 8 is a flowchart showing the control procedure by the control unit 40 of the image formation control process executed by the image forming device 1 of this embodiment. This image formation control process is included in the program 54, and includes the image data processing method of this embodiment. The image formation control process is started when job data is received or when already received job data is called.

When the image formation control process is started, the control unit 40 (CPU 41) acquires the image data to be formed from the received job data (step S101). The control unit 40 processes the image data, converts it into data for driving the forming operation unit 20, and sets the layout on the medium based on the imposition setting, margin setting, etc. (step S102).

The control unit 40 (CPU 41) outputs drive data to the forming operation unit 20 and performs drive control to start the image forming operation (step S103). The control unit 40 also outputs a control signal to the conveying unit 10 to start supplying and conveying the medium M.

The control unit 40 controls the imaging unit 30 to capture an image on the medium M formed by the operation of the forming operation unit 20 (step S104). The control unit 40 determines whether the captured image includes an inspection image (step S105). If it is determined that an inspection image is included ("YES" in step S105), the control unit 40 analyzes the inspection image and identifies the location of the abnormality (step S111). Depending on the identified content, the control unit 40 adjusts the defective area, prohibits ink ejection, sets complementary ejection by other nozzles, etc. (step S112; correction means, correction step). Then, the processing of the control unit 40 proceeds to step S106.

If it is determined that the captured image does not include an inspection image ("NO" in step S105), the control unit 40 proceeds to step S106.

When the process proceeds to step S106, the control unit 40 detects an abnormality in the normal image to be formed (step S106; detection means, detection step). As described above, the control unit 40 detects an abnormality, for example, by comparing the captured data with the original image data of the image to be formed. The control unit 40 determines whether or not an abnormality has occurred (step S107). If it is determined that an abnormality has occurred ("YES" in step S121), the control unit 40 calls and executes the rearrangement setting process. The process of the control unit 40 then returns to step S103.

If it is determined that there is no abnormality ("NO" in step S107), the control unit 40 determines whether or not formation of all target images has been completed (step S108). If it is determined that formation has not been completed ("NO" in step S108), the control unit 40 returns to step S103. If it is determined that formation has been completed ("YES" in step S108), the control unit 40 ends the image formation control process.

Figure 9 is a flowchart showing the control procedure for the rearrangement setting process called in the image formation control process of Figure 8.

When the rearrangement setting process is called, the control unit 40 determines whether there are any images that have been formed or are being formed but have not been inspected (step S201). If it is determined that there are ("YES" in step S201), the control unit 40 interrupts the subsequent new image formation operation and performs processing related to capturing the remaining images that have not been inspected and detecting abnormalities (step S202). Then, the processing of the control unit 40 proceeds to step S203. If it is determined that there are no images that have not been inspected ("NO" in step S201), the processing of the control unit 40 proceeds to step S203.

When the process proceeds to step S203, the control unit 40 extracts abnormalities from all inspected images (step S203). The control unit 40 identifies the imposition area that contains the abnormalities (step S204; range identification means, range identification step). The control unit 40 determines (estimates) the type of the detected abnormality (step S205).

The control unit 40 places an inspection image in the area where an abnormality is identified according to the type of abnormality determined (step S206). The control unit 40 rearranges the abnormal image in the area where a normal image was formed (step S207). The control unit 40 determines whether there is an unformed image and whether there is a blank space on the medium M after the above rearrangement (step S208). If it is determined that there is a blank space ("YES" in step S208), the control unit 40 rearranges each formed image (step S209). Then, the control unit 40 ends the rearrangement setting process and returns the process to the image formation control process.
The processes of steps S206 and S207 constitute a reallocation setting means (relocation setting step) of this embodiment, and this reallocation setting means (relocation setting step) may include the processes of steps S208 and S209.

If it is determined that no blank space has occurred (step S209: NO), the control unit 40 ends the rearrangement setting process and returns the process to the image formation control process. In this case, following the operation of forming the rearranged image, the image formation operation using the unformed arranged image data continues. The unformed arranged image data may be moved behind the data of the rearranged image and integrated.

If an abnormality is detected multiple times during image formation for a certain job, the relocation setting process may be called each time an abnormality is detected. In other words, the relocation setting process may be executed multiple times.

As described above, depending on the type of abnormality, it may not be possible to identify the type of abnormality from the inspection image, or it may be difficult to form a normal image using automatic responses such as supplementary processing related to the operation of the forming operation unit 20. In such cases, the user of the image forming device 1 must determine the desired response.

Figure 10 shows an example of a case where an abnormality that may not be able to be dealt with by the complementation process is detected. In Figure 10(a), a streak-like abnormality Na occurs in the imposition area of images 2 and 4. In contrast, as shown in Figure 10(b), when an inspection image T is arranged in the imposition area where an abnormality is identified, and images 2 and 4 are rearranged and formed in the area of images 1 and 3 that have been normally output, the same abnormality Na occurs in images 2 and 4 after rearrangement. In this case, no abnormality is identified from the inspection image T, that is, it is presumed that there is no abnormality in the forming operation unit 20 or the conveying unit 10, and a problem in the generation process of the drive image (such as poor compatibility between the data of the original image to be formed and the conversion process) is assumed. However, the possibility that a single abnormality occurs consecutively in different locations and in the same location relative to images 2 and 4 cannot be completely ruled out.

In this case, as shown in FIG. 10(c), a setting selection screen related to the restart policy is displayed on the display unit 80, and awaits any selection input operation by the user. Here, for example, it is possible to select to first restart image formation by rearranging the inspection image T in the imposition area of the rearranged images 2 and 4 in which an abnormality was detected as normal, and then returning the images 2 and 4 to the area of the inspection image T in which no abnormality was identified. It is also possible to select to exclude the images 2 and 4 in which an abnormality not related to the formation location was detected, and to form only the remaining unformed images.

Alternatively, it is possible to select to rearrange images 2 and 4 together with other unformed images, but not to rearrange any more test images T, and to treat images 2 and 4 as normal output, or to simply exclude them if an abnormality is found even after the third image formation. If the abnormality is in an area that is not visible, it may not necessarily be necessary to deal with it. Also, if adjustments or re-creation of the image data itself is required, it may be possible to reduce schedule delays by continuing the formation operation of other images in the meantime. Furthermore, it is also possible to select to cancel the entire job. In this case, a detailed inspection of the image forming device 1 may then be performed.

Figure 11 is a flowchart showing the control procedure of a modified rearrangement setting process that includes the above-mentioned process. In this modified rearrangement setting process, steps S211 to S215 and S221 are added to the above-mentioned rearrangement setting process. The other processes are the same, and detailed explanations of the same process contents will be omitted.

After processing in step S204, the control unit 40 (CPU 41) determines whether or not there is an abnormality in the imposition area of the rearranged and reformed image (step S211). The reformed image here refers to an image that is rearranged in a different position from the original arrangement and formed anew, and does not include an image that is rearranged before being formed. If it is determined that there is no abnormality in the reformed image ("NO" in step S211), the control unit 40 proceeds to processing in step S205.

If it is determined that there is an abnormality in the reformed image ("YES" in step S211), the detected position of the abnormality in the imposition area of the reformed image is compared with the detected position of the abnormality in the imposition area at the time of the previous (first) abnormality detection, and it is determined whether they are the same (step S212). If it is determined that they are not the same ("NO" in step S212), the processing of the control unit 40 proceeds to step S205.

If it is determined that the abnormality detection positions are the same ("YES" in step S212), the control unit 40 causes the display unit 80 to display a restart setting selection screen and waits for the reception of a selection input operation (step S213). The control unit 40 determines whether the selection according to the content of the received input operation is to cancel the job (step S214). If it is determined to be cancel ("YES" in step S214), the control unit 40 stops the rearrangement of the imposed image in response to the input operation and also sets the image formation operation to be stopped (step S221). The control unit 40 then ends the rearrangement setting process and returns the process to the image formation control process.

If it is determined that the selection is not a job cancellation ("NO" in step S214), the control unit 40 determines how to handle the reformed image in which an abnormality was detected according to the selection made by the input operation (step S215). That is, in the example of Fig. 10(c) above, it determines whether to handle the image in the same way as the first abnormality detection, to exclude it from the rearrangement target, or not to form the inspection image T at the position after reformation. Then, the process of the control unit 40 proceeds to step S205.
The processes in steps S214 and S215 constitute a selection means for subsequent processes when the process branches to "YES" in step S212 in this embodiment.

As described above, the image forming apparatus 1 of the present embodiment includes the control unit 40. The control unit 40, as a detection unit, detects formation abnormalities in the formed image from the formed image by the forming operation unit 20 that forms the image, as a range specification unit, specifies an abnormal image formation range of the formed image including the range of the detected formation abnormality, and as a rearrangement setting unit, arranges an inspection image T for specifying the cause of the formation abnormality in the abnormal image formation range, and sets image data in which an image that is not normally formed is rearranged outside the abnormal image formation range. In addition, the control unit 40, as a correction unit, performs correction (complementary setting) corresponding to the formation abnormality based on the inspection image T formed by the forming operation unit 20 according to the image data after rearrangement.
In this way, if an abnormality occurs in the image formation, the image to be formed is reformed avoiding the abnormal image formation area, thereby allowing the image formation operation to proceed, and an inspection image is formed in the portion where the abnormality occurred, allowing the abnormality to be identified and dealt with in parallel, thereby allowing the image formation operation to proceed efficiently while eliminating waste of recording media, ink and time.

Furthermore, a predetermined number of images (four in this example) of two or more to be formed by the forming operation unit 20 are assigned to each part of the medium M on which the images are to be formed and imposed. The control unit 40, as a range identification means, identifies an abnormal image formation range for each range of the imposed images. In this way, particularly when forming imposed images, the presence or absence of an abnormality can be determined for each imposed image, only the necessary images are re-formed, and inspection images are formed only in the necessary range, allowing the image forming operation to proceed easily and efficiently.

In addition, when an image formation abnormality is detected and some of the multiple images to be formed specified in the job data have not been formed, the control unit 40 may, as a rearrangement setting means, include the unformed images in the targets for rearrangement. If a margin is generated on the medium M when the images in the abnormal image formation range and the inspection image are rearranged, the unformed images can also be rearranged to fill the margin, thereby making it possible to more efficiently proceed with image formation.

The control unit 40 also functions as a rearrangement setting means, arranging the test image T according to the type of formation abnormality detected. Since the cause of many formation abnormalities can be estimated, by determining the type of test image to be formed according to the type of formation abnormality, it is possible to quickly identify the cause of the abnormality, deal with it, and return to normal image formation operation.

The types of formation abnormalities include at least one of uneven density and streaks in the image. These are formation abnormalities that frequently occur in image forming devices, and the causes are generally limited and can often be dealt with by using supplementary settings. Therefore, by setting up an inspection image that can identify and deal with these, delays and the effort required for image formation due to formation abnormalities can be significantly reduced.

The forming operation unit 20 also has multiple inkjet heads 211 that eject ink. The control unit 40, as a range identification means, determines the range of formation abnormalities for each image formation range by each inkjet head 211. In the inkjet type image forming device 1, unevenness and abnormalities often occur on an inkjet head 211 basis, so by determining the range of formation abnormalities on an inkjet head 211 basis, abnormalities can be dealt with efficiently.

The control unit 40 may also, as a rearrangement setting means, position the test image formed only by the inkjet head 211 that corresponds to the range of formation abnormality. As described above, since abnormalities tend to occur on an inkjet head 211 basis, it is often sufficient to form the test image only by the corresponding inkjet head 211, so that the test image does not take up more space than necessary and there is no need to eject more ink than necessary.

In addition, if an intermediate image is present after formation has started but before the abnormality is detected when the formation abnormality is detected, the control unit 40, as a rearrangement setting means, sets the rearrangement after the abnormal image formation range of the intermediate image is identified. If an image is already in the middle of formation and the intermediate image can be formed normally, it is pointless to stop midway. On the other hand, if another new abnormality occurs in the image in the middle of formation, even if the abnormality that has occurred earlier is dealt with without taking this into consideration, it will be necessary to form an inspection image to deal with the new abnormality, analyze it, and set supplementary settings, which will take additional time. Therefore, the image formation operation can be made more efficient by completing the image formation of the intermediate image and detecting the abnormality before rearranging it.

In addition, when an abnormality is detected in an image that has been repositioned at a different position from the original position and reformed, the control unit 40 selects the subsequent processing based on the results of comparing the range of the abnormality in this image with the range of the abnormality in the image when the initial abnormality was detected. When an abnormality continues to occur at a position corresponding to the image data, rather than at a position corresponding to the forming operation unit 20, an abnormality in the data processing of the image is assumed, rather than an abnormality in the forming operation unit 20 or the conveying unit 10, and in many cases it is not possible to deal with the problem by supplementary processing without the intervention of a user or administrator. Therefore, when an abnormality is detected in a reformed image, the abnormal area is compared with the original range of the abnormality to determine whether or not it is an abnormality at a position corresponding to the image data, thereby preventing the image forming device 1 from repeating processes that are likely to be meaningless.

The image forming device 1 also includes an operation reception unit 70. If it is determined as a result of the above comparison that the ranges of formation abnormalities in the images are the same, the control unit 40 selects subsequent processing based on the content of the input operation received by the operation reception unit 70 as a selection means. If there is a possibility that intervention by a user or administrator is required, unnecessary time loss can be reduced by promptly entrusting the user or administrator with the handling. Depending on the judgment of the user or administrator, there are also options such as starting over from the beginning or recreating only the necessary images and allowing the other images to be image-formed first, so multiple options for the user's judgment may be provided.

The image forming device 1 of this embodiment also includes the image data processing device (at least the control unit 40) and a forming operation unit 20 that forms an image. Such an image forming device 1 can appropriately determine formation abnormalities and efficiently deal with the abnormalities while proceeding with the image forming operation.

The image forming apparatus 1 also includes an imaging unit 30 that captures and reads the formed image. The control unit 40, as a detection means, detects formation abnormalities based on the data read from the formed image by the imaging unit 30. By providing the imaging unit 30 in-line, the image forming apparatus 1 can quickly read the formed image as it is, detect abnormalities, and deal with them. Therefore, there is no need to attach a separate imaging unit to read and exchange abnormality detection information, and it is less troublesome. In addition, by appropriately arranging the imaging unit 30, it is possible to reduce the time lag from image formation to abnormality detection and reduce the number of intermediate images when an abnormality is detected. This makes it possible to shorten the interruption time of the normal image formation operation during abnormality detection of intermediate images. It is also possible to reduce the number of media M on which images containing the same abnormality are formed.

In addition, the image data processing method of this embodiment includes a detection step of detecting a formation abnormality in an image formed by the forming operation unit 20 which forms an image, a range identification step of identifying an abnormal image formation range of the formed image including the range of the detected formation abnormality, a rearrangement setting step of arranging an inspection image for identifying the cause of the formation abnormality in the abnormal image formation range and setting image data in which the image which is not normally formed is rearranged outside the abnormal image formation range, and a correction step of making a correction corresponding to the formation abnormality based on the inspection image formed by the forming operation unit 20 in accordance with the image data after rearrangement.
Such an image data processing method can reduce waste of media and ink, and identify and address the cause of an abnormality in parallel with the progress of the image forming operation, thereby enabling the image forming operation to proceed more efficiently.

In addition, by installing and starting the program 54 that executes each of the above processes, image formation abnormalities occurring in the image forming device 1 can be detected and dealt with without any special configuration, thereby improving cost-effectiveness and image formation efficiency and enabling proper formed images to be obtained.

The present invention is not limited to the above-described embodiment, but may be modified in various ways.
For example, in the above embodiment, rearrangement and formation of an inspection image are performed after abnormality detection of the intermediate image is completed, but an inspection image may be formed in the corresponding location as soon as a formation abnormality is detected.

In addition, in the above embodiment, a case where an image is formed on one side of the medium M has been described, but when images are formed on both sides, the operation of detecting formation abnormalities may be performed after the image is formed on the front side and before the image is formed on the back side, or the detection operation may be performed together after the images are formed on both sides. When the operation of detecting formation abnormalities is performed before the image is formed on the back side, rearrangement settings may be made so that an inspection image related to formation abnormalities detected on the front side is formed on the back side.

In the above embodiment, an example was given of imposed image formation in which the surface of the medium M was divided into four equal parts, but this does not necessarily have to be the case, and the image may be divided into unequal areas. In this case, there may be restrictions on rearranging the image positions. In particular, in such a case, the order of rearrangement does not have to be the order in which the images were formed, and the images may be rearranged in any order in which they can be rearranged.

In addition, in the above embodiment, the case of forming an imposed image has been described, but a similar rearrangement may be performed even when forming multiple (multiple) images that are partially or completely identical on a medium. Furthermore, in cases where the output size of the formed image is not limited, such as when a specific pattern is repeated, the normal image formation range of the recording target and the formation range of the inspection image may be appropriately divided and processed in parallel, even if the image is not an imposed image.

In addition, in the above embodiment, it has been described that the operation reception unit accepts a selection operation when a formation abnormality occurs in the same position in the formed image even during rearrangement. However, this is not limited to this. When the cause of the abnormality cannot be identified or is difficult to identify, or when it is determined that the problem cannot be dealt with by supplementary settings, etc., an input reception screen may be displayed on the display unit 80 so that a decision can be made promptly by the user or administrator.

In addition, the image forming device 1 may not include the imaging unit 30, and data captured by an external imaging device may be acquired.

In addition, in the above embodiment, the control unit 40 of the image forming device 1 performs processes such as abnormality detection, identification, and correction (complementation), but at least some of these processes may be performed by an external computer, etc.

In the above embodiment, the ink is ejected to form an image by applying a coloring material, but transparent ink may also be used. The image referred to here is not limited to an image drawn using a coloring material. It may include a circuit wiring structure made of a specific conductive material. It may also include a protective film on the base or top surface of the image. It is not limited to a two-dimensional image, but may be an image intended to form unevenness such as an embossment, and may further have a three-dimensional structure.

In addition, in the above embodiment, the image forming device is described as being of an inkjet type, but this is not limited to this. Other types of image forming devices may also be used. Furthermore, even if it is of an inkjet type, it is not limited to a piezo type in which ink is ejected by deformation of a piezoelectric element. Images may be formed by other methods, such as a thermal type.

In the above description, the storage unit 50 consisting of a non-volatile memory such as an HDD, SSD, or flash memory is used as an example of a computer-readable medium for storing the program 54 related to the acquisition control of positioning information of the present invention, but is not limited to these. As other computer-readable media, other non-volatile memories such as MRAM, and portable media such as CD-ROMs and DVD disks can be applied. In addition, a carrier wave is also applied to the present invention as a medium for providing data of the program according to the present invention via a communication line.
In addition, the specific configurations, contents and procedures of the processing operations, etc. shown in the above embodiments can be modified as appropriate without departing from the spirit of the present invention. The scope of the present invention includes the scope of the invention described in the claims and its equivalents.

REFERENCE SIGNS LIST 1 Image forming apparatus 10 Conveying section 11 Driving roller 12 Conveying belt 13 Driven roller 14 Conveying motor 15 Pressing roller 20 Forming operation section 21, 21C, 21M, 21Y, 21K Head unit 210 Carriage 211 Inkjet head 212 Driving board 25 Head driving section 26 Piezoelectric element 27 Nozzle 29 Driving waveform signal generating section 30 Imaging section 40 Control section 41 CPU
42 RAM
50 Storage unit 51 Job data 52 Inspection image data 53 Complement setting 54 Program 60 Communication unit 70 Operation reception unit 80 Display unit 90 Power supply unit M Medium T Inspection image

Claims (14)

a detection unit for detecting a formation abnormality in an image formed by a forming operation unit that forms an image;
a range specifying means for specifying an abnormal image formation range of the formed image including the detected range of the formation abnormality;
a rearrangement setting means for arranging an inspection image for identifying the cause of the formation abnormality in the abnormal image formation area, and setting image data in which an image that is not normally formed is rearranged outside the abnormal image formation area;
a correction unit that corrects the image forming operation corresponding to the formation abnormality based on the inspection image formed by the forming operation unit in accordance with the image data after the rearrangement;
An image data processing device comprising: The two or more predetermined number of images to be formed by the forming operation unit are assigned to a portion of a medium on which the images are to be formed and are imposed;
2. The image data processing apparatus according to claim 1, wherein said area specifying means specifies the abnormal image formation area for each area of the images arranged in the imposition. The image data processing device according to claim 2, characterized in that, when the formation abnormality is detected and some of the images to be formed are not formed, the rearrangement setting means includes the images that are not formed as targets for rearrangement. The image data processing device according to any one of claims 1 to 3, characterized in that the rearrangement setting means arranges the test images according to the type of the detected malformation. The image data processing device according to claim 4, characterized in that the type of formation abnormality includes at least one of uneven density of the image and the occurrence of streaks. the forming operation unit has a plurality of ink-jet heads that eject ink,
6. The image data processing device according to claim 1, wherein the area specifying means determines the area of the formation abnormality for each image formation area by each of the inkjet heads. The image data processing device according to claim 6, characterized in that the rearrangement setting means arranges the test image formed only by the inkjet head corresponding to the range of the malformation. The image data processing device according to any one of claims 1 to 7, characterized in that, when the formation abnormality is detected, if there is an intermediate image after the start of formation and before the formation abnormality is detected, the rearrangement setting means sets the rearrangement after the abnormal image formation range of the intermediate image is identified. The image data processing device according to any one of claims 1 to 6, further comprising a selection means for selecting a subsequent process based on a result of a comparison between the range of the malformation in the image reconstructed by the reconstructing means at a position different from the initial position and the malformation is detected, and the range of the malformation in the image at the time of the initial detection of the malformation. An operation reception unit is provided,
The image data processing device according to claim 9, characterized in that, when the comparison result indicates that the range of the malformation in the images is the same, the selection means selects the subsequent processing based on the content of the input operation accepted by the operation acceptance unit. An image data processing device according to any one of claims 1 to 10;
a forming operation unit for forming an image;
An image forming apparatus comprising: a reading unit for reading the formed image,
12. The image forming apparatus according to claim 11, wherein the detection unit detects the formation abnormality based on data read from the formed image by the reading unit. a detection step of detecting a formation abnormality in an image formed by a forming operation unit that forms an image;
a range specifying step of specifying an abnormal image formation range of the formed image including the detected range of the formation abnormality;
a rearrangement setting step of arranging an inspection image for identifying a cause of the formation abnormality in the abnormal image formation area, and setting image data in which an image that is not normally formed is rearranged outside the abnormal image formation area;
a correction step of correcting the image forming operation corresponding to the formation abnormality based on the inspection image formed by the forming operation unit in accordance with the image data after the rearrangement;
13. An image data processing method comprising: Computer,
a detection unit for detecting a formation abnormality in an image formed by a forming operation unit that forms an image;
a range specifying means for specifying an abnormal image formation range of the formed image including the detected range of the formation abnormality;
a rearrangement setting means for arranging an inspection image for identifying the cause of the formation abnormality in the abnormal image formation area, and setting image data in which an image that is not normally formed is rearranged outside the abnormal image formation area;
a correction unit that corrects the image forming operation corresponding to the formation abnormality based on the inspection image formed by the forming operation unit in accordance with the image data after the rearrangement;
A program characterized by causing the program to function as a

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