Sound diagnostic system

Abstract

To accurately determine the cause of an abnormal sound.SOLUTION: An image formation apparatus 1 includes: one or more operating units (91-93); a sound collector 71 which collects sound waves so as to include a period during which the operating units operate; a sound information storage unit 708 which acquires data including a sound wave level based on the sound wave and an operation status of the one or more operating units in each of a plurality of time sections in which the sound collector 71 collects the sound waves; and a transmission unit which transmits the data to a server SV. The server SV includes: a reception unit which receives the data; a threshold range setting unit 3012 which generates a threshold by adding a predetermined value to a first sound wave level being a sound wave level based on the sound wave collected by the sound collector 71 during a first period; and a determination unit 3013 which determines the cause of the abnormal sound by comparing a second sound wave level being a sound wave level based on the sound wave collected by the sound collector 71 during a second period after the first period with the threshold.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a sound diagnosis system for determining the presence or absence of abnormal sounds.

Background Art

[0002] In image forming apparatuses such as copiers and laser printers, if a component that has reached the end of its life is continuously used without being replaced, abnormal sounds may occur from such a component. In Patent Document 1, a component that generates an abnormal sound in an image forming apparatus is specified. Specifically, by performing frequency analysis on the detected sound, a component that generates an abnormal sound is specified based on the frequency and the peak value of the sound pressure level at that frequency.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, when a plurality of components are operating simultaneously, the frequency bands of each component may overlap, and in the conventional identification method, it may be difficult to identify a component that generates an abnormal sound.

[0005] Therefore, an object of the present invention is to accurately determine the cause of an abnormal sound.

Means for Solving the Problems

[0006] In order to solve the above-described problems, the present invention has the following configuration.

[0007] (1) A sound diagnosis system including an image forming apparatus that forms an image on a recording material and an information processing apparatus that can communicate with the image forming apparatus, wherein the image forming apparatus includes one or more operating units, a sound collecting unit that collects sound waves so as to include a period during which the operating unit is operating, an acquisition unit that acquires data including a sound wave level based on the sound waves in each of a plurality of time intervals during which the sound collecting unit has collected the sound waves and an operating state of one or more of the operating units, and a transmission unit that transmits the data to the information processing apparatus, and the information processing apparatus includes a receiving unit that receives the data, a threshold value generating unit that generates a threshold value by adding a predetermined value to a first sound wave level that is the sound wave level based on the sound waves collected by the sound collecting unit during a first period, and a determination unit that determines a cause of an abnormal sound by comparing the second sound wave level that is the sound wave level based on the sound waves collected by the sound collecting unit during a second period after the first period with the threshold value. A sound diagnosis system characterized by having the above.

Effect of the Invention

[0008] The present invention can accurately determine the cause of an abnormal sound.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6(a)

Figure 6(b)

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Best Mode for Carrying Out the Invention

[0010] Hereinafter, with reference to the drawings, preferred embodiments of the present invention will be illustratively described in detail. However, the dimensions, materials, shapes, relative arrangements, etc. of the components described below should be appropriately changed according to the configuration of the apparatus to which the present invention is applied and various conditions. Therefore, unless otherwise specifically stated, the scope of the present invention is not intended to be limited only to those.

Examples

[0011] [Description of the Image Forming Apparatus] Hereinafter, with reference to the drawings, an image forming apparatus 1 included in the sound diagnosis system 100 and forming an image on a recording material will be described. Here, for example, an electrophotographic color image forming apparatus will be illustrated and described. FIG. 1 is a configuration diagram showing an example of a tandem type color image forming apparatus employing an intermediate transfer belt.

[0012] The configurations of the image forming apparatus 1 in FIG. 1 are as follows. The feed cassette 2 is a storage unit for storing the recording material P. The engine control unit 87 controls the image forming operation of the image forming apparatus 1. The feed roller 4 feeds the recording material P from the feed cassette 2. When the feed roller 4 feeds the recording material P from the feed cassette 2, the separation roller 5 separates and feeds the recording material P one sheet at a time. The transport roller pair 6 as the transport unit transports the fed recording material P. The photosensitive drums 11Y, 11M, 11C, and 11K are image carriers that carry developers of yellow, magenta, cyan, and black colors, respectively. The charging rollers 12Y, 12M, 12C, and 12K are primary charging means for each color to uniformly charge the photosensitive drums 11Y, 11M, 11C, and 11K to a predetermined potential. The optical units 13Y, 13M, 13C, and 13K irradiate laser beams corresponding to the image data of each color onto the photosensitive drums 11Y, 11M, 11C, and 11K charged by the charging rollers 12Y, 12M, 12C, and 12K to form electrostatic latent images. The developing devices 14Y, 14M, 14C, and 14K are developing means for visualizing the electrostatic latent images formed on the photosensitive drums 11Y, 11M, 11C, and 11K. The developing devices 14Y to 14K each have a developer and a developing roller 15Y to 15K. The developing rollers 15Y, 15M, 15C, and 15K are developer carriers for developing the developer in the developing devices 14Y, 14M, 14C, and 14K onto the photosensitive drums 11Y, 11M, 11C, and 11K. The primary transfer rollers 16Y, 16M, 16C, and 16K are primary transfer means for primarily transferring the images formed on the photosensitive drums 11Y, 11M, 11C, and 11K onto the intermediate transfer belt 17. The intermediate transfer belt 17 is an intermediate transfer body that carries the images primarily transferred from each photosensitive drum 11Y to 11K. The driving roller 18 drives the intermediate transfer belt 17. The tension roller 25 applies tension to the intermediate transfer belt 17. The secondary transfer roller 19 transfers the image formed on the intermediate transfer belt 17 to the recording material P. The secondary transfer opposing roller 20 opposes the secondary transfer roller 19 via the intermediate transfer belt 17. The fixing unit 21 is fixing means for melting and fixing the developer image transferred to the recording material P onto the recording material while transporting the recording material P.The discharge roller pair 22 discharges the recording material P on which image fixing has been performed by the fixing unit 21 to the discharge tray 26. Note that a belt cleaning device 36 is installed on the intermediate transfer belt 17, and a cleaning member such as a cleaning blade 35 installed inside scrapes off the developer remaining on the intermediate transfer belt 17 after transfer, in preparation for the next image formation.

[0013] The engine control unit 87 is equipped with a CPU 80 (see FIG. 2) and collectively controls the image forming operations of the image forming apparatus 1. When print data including a print command, image information, etc. is input from a host computer HC or the like (to be described later) to the engine control unit 87, the image forming apparatus 1 starts a printing operation.

[0014] In the image forming apparatus 1 of FIG. 1, a sound collector 71 is disposed near the conveyance path for conveying the recording material P. The sound collector 71 is a sound collecting unit (reception unit) capable of collecting sound waves (sound). The sound collector 71 consists of a MEMS (Micro Electro Mechanical System) microphone that converts the vibration displacement of a diaphragm due to pressure into a voltage change and outputs it, and an electrode terminal. The signal output from the sound collector 71 (sound collecting unit) is sent to the engine control unit 87.

[0015] Also, the image forming apparatus 1 has a recording material detection unit 90. The recording material detection unit 90 is provided near the conveyance path. The recording material detection unit 90 detects the recording material that has passed through the recording material detection unit 90 and transmits the detection result to the engine control unit 87.

[0016] [Explanation of the sound diagnosis system] FIG. 2 is a configuration diagram of a sound diagnosis system 100 (image forming apparatus system) including the image forming apparatus 1 according to the present embodiment. The sound diagnosis system 100 includes the image forming apparatus 1, a server SV, and a management apparatus M. As shown in FIG. 2, the image forming apparatus 1 can communicate with a host computer HC and a server SV (information processing apparatus) via a network. Also, the server SV can communicate with the management apparatus M.

[0017] The control unit 201 of the host computer HC includes a CPU as a processor, and performs various processes by executing a control program stored in a storage device (not shown). The operation display unit 202 includes a display, a keyboard, a mouse, etc., and provides a user interface. For example, according to a user operation on the operation display unit 202, the control unit 201 transmits a print job including image data to a video controller 85 (to be described later) of the image forming apparatus 1, and causes the image forming apparatus 1 to form an image based on the image data. The image forming apparatus 1 includes a video controller 85, an operation display unit 86, a printer engine 84, a feeding motor 91, a fixing motor 92, and a photoreceptor motor 93.

[0018] When the video controller 85 of the image forming apparatus 1 receives a print job from the host computer HC, it causes the printer engine 84 to control image formation based on the print job. The operation display unit 86 includes an operation panel, operation buttons, etc., and provides a user interface. The printer engine 84 has an engine control unit 87 including a CPU 80 as a processor, a ROM 81, and a RAM 82. The ROM 81 is a non-volatile memory that holds and stores a control program and various data. Note that a rewritable non-volatile memory can also be used instead of the ROM 81. The RAM 82 is a volatile memory that stores temporary data. The CPU 80 controls the feeding motor 91, the fixing motor 92, and the photoreceptor motor 93 via the I / O port 83 by executing the control program stored in the ROM 81.

[0019] The image forming apparatus 1 has one or more motors (operating parts). The feeding motor 91 is a drive source for the feeding roller 4 and the pair of conveying rollers 6. The photoreceptor motor 93 is a drive source for the drive roller 18, the photosensitive drum 11, and the developing roller 15. The fixing motor 92 is a drive source for the pressure roller of the fixing unit 21. That is, the feeding roller 4, the pair of conveying rollers 6, the drive roller 18, the photosensitive drum 11, the developing roller 15, and the pressure roller are parts driven by motors. These parts driven by motors (actuators) may generate abnormal sounds due to causes such as deterioration.

[0020] The server SV includes an arithmetic unit 301 and a storage device 302. The arithmetic unit 301 includes one or more processors (CPUs) and performs the process of abnormal sound analysis described below by executing a control program stored in the storage device 302. The storage device 302 includes any volatile and non-volatile storage devices. In addition to the program executed by the arithmetic unit 301, the storage device 302 also stores data used by the arithmetic unit 301 in abnormal sound analysis. Specifically, the storage device 302 receives and stores sound data transmitted from the image forming apparatus 1 described below. In this embodiment, the server SV includes the arithmetic unit 301 and the storage device 302, but the functions of the arithmetic unit 301 and the storage device 302 may be distributed and configured in at least one or more servers. Further, the arithmetic unit 301 and the storage device 302 may be in the image forming apparatus 1, and the abnormal sound analysis described below may be performed by the image forming apparatus 1.

[0021] The server SV transmits (notifies) information regarding the determination result of the arithmetic unit 301 and countermeasure information for the determination result to the management device M capable of communicating with the server SV. The management device M is a display device that receives a notification from the server SV and causes the display unit 401 to display information regarding the determination result of the arithmetic unit 301 and countermeasure information for the determination result.

[0022] [Data Processing of Sound Diagnosis System] Next, the configuration regarding the data processing of the sound diagnosis system 100 will be described with reference to FIG. 3. FIG. 3 is a block diagram showing a part of the sound diagnosis system 100 shown in FIG. 2. The engine control unit 87 includes a received sound processing unit 70, a sound information storage unit 708, and a status notification unit 701.

[0023] The received sound processing unit 70 processes a sound signal output by the microphone 71 receiving a sound wave during a predetermined period described below. That is, the received sound processing unit 70 can be called data generation means for generating data of a sound wave level based on the sound wave collected by the microphone 71 (sound collection unit). The received sound processing unit 70 includes an amplification unit 702, an AD conversion unit 703, a reference value setting unit 704, a filter operation unit 705, a square operation unit 706, and an interval average operation unit 707.

[0024] The amplifier unit 702 amplifies the sound signal generated by the microphone 71. The AD conversion unit 703 converts the sound signal output from the amplifier unit 702 into a digital signal (digital value). Next, the reference value setting unit 704 subtracts the reference value from each value indicated by the digital signal from the AD conversion unit 703, and extracts only the component related to the pressure fluctuation of the sound. This is because the sound signal output from the microphone 71 includes a DC component, and this is to remove the DC component. Note that the reference value is set by the CPU 80.

[0025] The filter operation unit 705 applies a filter to the digital signal from which the DC component has been removed by the reference value setting unit 704 to perform filter processing. Note that the filter operation unit 705 has a plurality of filters, and performs filter processing using the filter set by the CPU 80. The squaring operation unit 706 performs a squaring operation on the digital signal after the filter processing. The interval average operation unit 707 performs an interval average operation on the digital signal after the squaring operation. In the present embodiment, as an example, the time interval for performing the interval average operation is set to 100 ms. Note that the time length for performing the interval average operation is not limited to this, and can be made different for each measurement. By performing the squaring operation and the interval average operation, a sound wave level L indicating the magnitude of the sound pressure fluctuation is obtained for each time interval. The interval average operation unit 707 stores the sound wave level L of each time interval in the sound information storage unit 708.

[0026] The state notification unit 701 acquires the operating states of whether the feeding motor 91, the fixing motor 92, and the photoreceptor motor 93 are operating, respectively. Further, the state notification unit 701 associates the operating states of the feeding motor 91, the fixing motor 92, and the photoreceptor motor 93 in a certain time interval with the sound wave level L in that time interval, and stores them in the sound information storage unit 708. Hereinafter, the motors 91 to 93 may be collectively referred to as an actuator (operating unit) in some cases.

[0027] In the sound information storage unit 708, information indicating the operating state of the actuator and the sound wave level L is stored for each time interval during which the sound collector 71 receives sound. Hereinafter, information including a plurality of consecutive time intervals, the operating state of the actuator in the plurality of consecutive time intervals, and the sound wave level L in the plurality of consecutive time intervals is referred to as sound data.

[0028] One piece of sound data may include information such as the type of filter applied by the filter operation unit 705 and the print setting information such as the type (or basis weight) of the recording material P used for printing. In this way, in the present embodiment, sound data is generated in the image forming apparatus 1. The sound information storage unit 708 transmits data including the sound wave level based on the sound wave and the operating state of one or more operating units in each of the plurality of time intervals during which the sound collector 71 collects the sound wave to the server SV. The server SV receives the sound data acquired from the image forming apparatus 1 and stores it in the storage device 302 (reception unit).

[0029] As will be described later, the statistical value calculation unit 3011 of the calculation unit 301 obtains respective statistical values P based on the sound data of each time interval. The threshold range setting unit 3012 sets the threshold for each time interval based on the statistical value P of each time interval and the operating state of each motor as will be described later. The determination unit 3013 determines whether an abnormal sound is occurring using the threshold for each time interval as will be described later. Further, when the determination unit 3013 determines that an abnormal sound is occurring, the determination unit 3013 determines the replacement unit that is generating the abnormal sound. The notification unit 3014 notifies the determination result by the determination unit 3013. Note that the notification destination can be the user of the image forming apparatus 1 or the management device M used by a dealer or the like who performs maintenance and management of the image forming apparatus 1.

[0030] In this embodiment, sound waves during the period from the timing when the recording material P printed last among the sheets printed in one printing job reaches a predetermined position until all motors of the image forming apparatus 1 stop are collected to generate one sound data. The timing when the recording material P reaches the predetermined position is the timing (timing 1) when the rear end of the recording material P passes through the detection position of the recording material detection unit 90. That is, the sound collector 71 (sound collection unit) collects (gathers) sound waves during the period when the image forming apparatus 1 is operating. Specifically, the sound collector 71 collects sound waves including the period when the operating unit (actuator) is operating and the period when the operating unit is not operating, and the received sound processing unit 70 generates data on the sound wave level based on the signal of the sound collector 71. Note that the period from timing 1 until all motors of the image forming apparatus 1 stop includes the period when the recording material P is not being conveyed in the vicinity of the sound collector 71, so it is a period in which the operating sounds of each motor inside the image forming apparatus 1 are easily received. Therefore, it is possible to accurately determine the occurrence of abnormal sounds by using the sound data during this period.

[0031] Note that the timing, period, and number of times of sound collection by the sound collector 71 are not limited to the above-described example and may be changed as appropriate. For example, the sound data may be collected after the start of feeding of the recording material P. In the following description, the period from the timing when the rear end of the last recording material P passes through the recording material detection unit 90 until all motors of the image forming apparatus 1 stop may be referred to as the "post-rotation period".

[0032] [Explanation of the contact / separation mechanism of the primary transfer roller] The sound waves collected during the above-described post-rotation period may include transfer separation sounds. Therefore, the generation of transfer separation sounds will be described with reference to FIG. 4. FIG. 4 shows the contact / separation mechanism of the primary transfer roller 16 of the image forming apparatus 1.

[0033] The primary transfer roller 16 is in contact with the photosensitive drum 11 during image formation, but is separated from the photosensitive drum 11 during non-image formation to prevent deformation of the primary transfer roller 16. Thus, the mechanism for bringing the primary transfer roller 16 into contact with or separating it from the photosensitive drum 11 is called the contact / separation mechanism.

[0034] The contact-separation mechanism is provided at both longitudinal ends of the primary transfer roller 16. FIG. 4(a) shows the state of the contact-separation mechanism when the primary transfer roller 16 is in contact with a photosensitive drum 11 (not shown). The shaft cores 16JY, 16JM, 16JC, and 16JK of the primary transfer roller 16 are respectively pressed against the slider 101 in the upward direction DIR16 by the compression springs 16BY, 16BM, 16BC, and 16BK of the primary transfer roller 16. The slider 101 is a member attached to the image forming apparatus 1 so as to be movable only in the horizontal direction. The slider is pressed in the horizontal direction DIR102 (first direction) by a compression spring 102 and pressed against a cam 104. The cam 104 is a rotating member that rotates in the direction DIR104 around a rotation shaft 103. The rotation shaft 103 is connected to a motor via a gear and a mechanical clutch (not shown). When the separation operation is started, the driving force of the motor is transmitted to the rotation shaft 103 via a gear and a mechanical clutch (not shown), and the cam 104 rotates. When the cam 104 rotates, due to the action of the compression spring 102 of the slider 101, the slider 101 moves in the horizontal direction (first direction). The slider 101 is provided with inclined surfaces 101Y, 101M, 101C, and 101K. The shaft core 16J of each primary transfer roller moves downward along each inclined surface 101, moves downward in the direction DIR16R with respect to the photosensitive drum 11 (not shown), and separates from the photosensitive drum 11 (FIG. 4(b)). FIG. 4(c) shows the state of the contact-separation mechanism after the separation operation is completed. The transition from the separated state to the contact state again is made by rotating the cam 104 in the direction opposite to that during the separation operation.

[0035] Here, an impact sound may occur during the separation operation shown in FIG. 4(b). As described above, during the separation operation, the compression spring 102 of the slider 101 is gradually released. At this time, the compression spring 102 of the slider 101 acts on the cam 104 via the slider 101 to assist the rotation of the cam 104. Due to this assistance, the torque applied to a gear (not shown) and a mechanical clutch connected to the rotary shaft 103 becomes reverse, and the gear may rotate by the amount of backlash provided in the gear (not shown) and the mechanical clutch, resulting in an impact sound. Hereinafter, this impact sound may be referred to as a transfer separation sound.

[0036] [Threshold Setting for Abnormal Sound Judgment] Next, a method for setting the threshold for abnormal sound judgment will be described with reference to FIG. 5. FIG. 5 is a flowchart showing the procedure up to the threshold setting. In the abnormal sound judgment in this embodiment, when the sound wave level exceeds a predetermined threshold, it is determined that an abnormal sound has occurred.

[0037] FIG. 6(a) shows the signal level [dB] output by the microphone 71 and the time change of the operating state of each actuator (the horizontal axis is time [seconds]) during the backward rotation period. The waveform of the signal level shown in FIG. 6(a) includes the sound at the timing when the feed motor 91, the photoreceptor motor 93, and the fixing motor 92 are sequentially stopped, and the above-described transfer separation sound 110.

[0038] The receiving sound processing unit 70 processes the received signal collected during the backward rotation period shown in Fig. 6(a) through the above-described process, divides it into 16 time intervals as shown in Fig. 6(b), and calculates the sound wave levels [dB] that are respectively averaged in each interval. On the other hand, the state notification unit 701 has detected the operating state of the actuator in each time interval, and in each of the 16 time intervals shown in Fig. 6(b), whether the actuator was in the operating state or the non-operating state is stored in the sound information storage unit 708. When the operating state of the actuator changes during a time interval, for example, the longer state in the time interval is stored as the operating state in that time interval. In this way, the sound wave levels respectively averaged in the 16 time intervals and the operating state of the motor are stored (acquired) in the sound information storage unit 708 (S11 in Fig. 5). That is, the sound information storage unit 708 can be called an acquisition unit that acquires data including the sound wave level based on the sound wave and the operating state of one or more operating parts in each of the plurality of time intervals during which the sound collector 71 collected the sound wave.

[0039] Subsequently, the calculation of the statistical value M1 in S12 of Fig. 5 will be described. When N new sound data are added, the statistical value calculation unit 3011 of the server SV obtains the statistical value P for each of the 16 time intervals based on these N new sound data. The statistical value P can be, for example, the percentile value of the N sound data. As an example, when N = 100, the 95th percentile value can be set as the statistical value P. In this case, if the 16 time intervals of one sound data are defined as interval 1 to interval 16, the value of the 5th highest sound wave level L among the 100 sound wave levels L in interval 1 becomes the statistical value P of interval 1.

[0040] FIG. 7 is a graph showing the transition of the sound wave level L and the statistical value P in section 6 with respect to the number of printed sheets. By calculating the statistical value P in this way, it becomes possible to diagnose abnormal sounds with a smaller amount of data than when directly dealing with the sound wave level L. Note that the method for calculating the statistical value P is not limited to the above method. For example, the statistical value P can be an arbitrary percentile value, or the maximum value of N sound wave levels L. Further, the statistical value P can be the average value of a predetermined number of the top N sound wave levels L.

[0041] When the number of obtained statistical values P reaches M, the statistical value calculation unit 3011 calculates a statistical value M for each of the 16 time intervals based on the M statistical values P. The statistical value M can be, for example, the average value of the M statistical values P. Hereinafter, in the following description, the statistical value M used for setting the threshold range described later is referred to as statistical value M1. The statistical value M1 can be called the first sound wave level based on the sound waves collected by the sound collector 71 during, for example, the first period.

[0042] Next, the setting of the threshold range in S13 will be described. The threshold range setting unit 3012 sets a threshold range for each actuator based on the statistical value M1. That is, the threshold range setting unit 3012 is a threshold generation unit that generates a threshold based on the first sound wave level based on the sound waves collected by the sound collector 71 during the first period. FIG. 8 is a graph in which a threshold range is set for each actuator. In the section where the target actuator is operating, the threshold range is a predetermined range Ra centered on the value obtained by adding a predetermined value H to the initial statistical value M1. In the section where the target actuator is not operating, the threshold range is a predetermined range Rb centered on the statistical value M1. For example, FIG. 8(a) is a graph showing the threshold range of the feeding motor 91. As shown in FIG. 6(b), the feeding motor 91 operates in sections 1 to 4 and does not operate after section 5. In sections 1 to 4 where the feeding motor 91 is operating, a predetermined value H1 is added to the statistical value M1, and a range R1a centered on the added value is set as the threshold range.

[0043] Here, a predetermined value H1 is added to the true number of decibels (dB). For example, if H1 = 20000, when the statistical value M1 = 40 dB, the central value of the threshold range R1a is 10×log10(10^(40 / 10)+20000)=44.8 dB. Also, the range with respect to the central value can be given in decibels (dB). For example, when the range is given as ±1.5 dB, the threshold range R1a = central value (44.8 dB) ±1.5 dB, that is, 43.3 to 46.3 dB. In section 8 where the statistical value M1 is 49 dB, when calculated in the same way with H1 = 20000, the threshold range R1a is 48.5 to 51.5 dB. In this way, a predetermined value is added to the true number of each statistical value M1 (logarithm) in each section. Thereby, compared with the method of adding a predetermined decibel value (logarithm) to each statistical value M1 in each section, a threshold with good accuracy can be generated when performing abnormal sound determination. As shown in FIGS. 8(b) and 8(c), for the photoreceptor motor 93 and the fixing motor 92 as well, the threshold range can be set in the same manner as the feeding motor 91. In this way, for each time interval, the threshold range is set based on the statistical value M1 and the operating state of the target actuator.

[0044] Note that the method of setting the threshold range described here is an example, and it is also possible to set the threshold range individually according to various conditions (such as filters, average time, etc.) for processing the sound wave signal. Furthermore, the addition value H from the initial statistical value P, and the ranges Ra and Rb from the central value can be made different for each actuator. The addition value H uses a preset value, but it can also be set to be different according to the initial statistical value P after obtaining the initial statistical value P. For example, in FIG. 8(b), within the section where the photoreceptor motor 93 is operating, the addition value H can be determined so that the upper limit of the threshold range becomes 45 dB in section 6 where the initial statistical value P is the smallest. In this case, by determining the addition value H in the section where the initial statistical value P is the smallest, that is, the section that contains as little operating noise of other components except the photoreceptor motor 93 as possible, the abnormal sound of the photoreceptor motor 93 can be detected more accurately.

[0045] [Abnormal Sound Judgment] Next, a method for abnormal sound determination by the determination unit 3013 will be described. Note that a statistical value M calculated using a sound wave collected after the sound wave used to calculate the above-described statistical value M1 is referred to as a statistical value M2. The statistical value M2 can also be referred to as a second sound wave level, which is a sound wave level based on a sound wave collected by the sound collector 71 during a second period after the first period. The determination unit 3013 is a determination unit that determines the cause of an abnormal sound by comparing the second sound wave level with the threshold value.

[0046] FIG. 9 is a diagram showing, for each actuator in the graph shown in FIG. 8, the operating state in each time interval and whether the statistical value M2 is within the threshold range. For example, in the feeding motor 91, it is shown that the statistical value M2 is within the threshold range in the time intervals 1 to 4 when the operation is ON. On the other hand, in the time intervals 5 to 16 when the operation is OFF, it is shown that the intervals in which the statistical value M2 is within the threshold range are intervals 8 and 11 to 16.

[0047] In this embodiment, a conformity rate is calculated, which is the number of time intervals within the range in which the statistical value M2 is within the threshold range with respect to the number of time intervals. The conformity rate and the combined conformity rate described later are indicators showing the degree to which the statistical value M2 is included within the threshold range. For example, in this embodiment, let the total number of intervals when the actuator is operating be A, and the number of time intervals within the range in which the statistical value M2 is within the threshold range among A be B. Also, let the total number of intervals when the actuator is not operating be C, and the number of time intervals within the range in which the statistical value M2 is within the threshold range among A be D. Therefore, the conformity rate when the actuator is operating can be expressed as B / A. Also, the conformity rate when the actuator is not operating can be expressed as D / C. Also, the combined conformity rate is defined as (B + D) / (A + C).

[0048] For example, the total number of intervals during the operation (operation ON) of the feeding motor 91 is A = 4, and the number of intervals among A for which the statistical value M2 falls within the threshold range is B = 4. Therefore, the conformity rate is B / A = 100%. Similarly, when calculating for the non-operation state (operation OFF), the conformity rate is D / C = 58.3% (C = 12, D = 7). Also, the combined conformity rate is (B + D) / (A + C) = 11 / 16 = 68.8%. Similarly, when calculating the combined conformity rates for the photoreceptor motor 93 and the fixing motor 92, they are 93.8% and 68.8% respectively.

[0049] The combined conformity rate represents the likelihood of being the cause of abnormal noise. From the conformity rate, units that are likely to be the cause of abnormal noise can be listed as candidates. For example, in the case of FIG. 9, since the combined conformity rate of the photoreceptor motor 93 is the highest, it can be determined that there is a high possibility that the abnormal noise is from the components driven by the photoreceptor motor 93. Note that a threshold value may be set for the conformity rate to determine the presence or absence of the possibility of being the cause of abnormal noise. Furthermore, the combined conformity rate may be calculated by weighting the conformity rate during operation and the conformity rate during non-operation respectively.

[0050] In the above method, a threshold range is set to determine abnormal noise because the conformity rate during non-operation is also calculated. As another method, abnormal noise can also be determined by setting only the lower threshold value. For example, by determining whether the statistical value exceeds the lower threshold value in the intervals when the target actuator is in the operation ON state, the occurrence of abnormal noise can also be detected. When there are few target actuators or few actuators operating simultaneously, it is also possible to narrow down the cause of abnormal noise by this method.

[0051] Next, the flow of abnormal sound determination in this embodiment will be described with reference to FIG. 10. FIG. 10 is a flowchart of abnormal sound determination in this embodiment. Regarding the processes of S21 to S22 and S24, since they are the same processes as S11 to S12 and S13 in FIG. 5, the description will be omitted. In S23, the threshold range setting unit 3012 determines whether the threshold range has been set. If the threshold range has not been set, the threshold range is set based on the actuator information (S24). If the threshold range has been set, in S25, the statistical value M2, the matching rate, and the total matching rate are calculated for each actuator. If there is an actuator with a matching rate equal to or higher than a predetermined value in S26, in S27, the determination unit 3013 determines that the component driven by the actuator with a matching rate equal to or higher than the predetermined value is the cause of the abnormal sound, and proceeds to the process of S28. In addition, the notification unit 3014 notifies the determination result of the determination unit 3013 and the countermeasure information for the determination result. It is possible to notify the user of the presence or absence of abnormal sound and the cause unit of the abnormal sound, and prompt replacement or repair. If the matching rate is less than the predetermined value in S26, the process proceeds to S28. When the diagnosis is repeated in S28, it returns to S21, and the abnormal sound can be continuously diagnosed.

[0052] As described above, according to this embodiment, the sound diagnosis system 100 includes one or more operating parts and a sound collecting part that collects sound waves so as to include the period during which the operating part is operating. Further, the sound diagnosis system 100 has data generation means for generating data on the sound wave level based on the sound waves collected by the sound collecting part, and an acquisition part (sound information storage part 708) for acquiring first data that is data on the sound wave level in the first period and second data that is data on the sound wave level in the second period after the first period. Further, the sound diagnosis system 100 generates a statistical value M1 based on the first data, and further generates a threshold range based on the statistical value M1.

[0053] Note that, in the present embodiment, in order to reduce the data transmitted to the server SV, the sound data was divided into 16 time intervals. However, the present invention is not limited to performing the process of dividing the sound data into finite time intervals. For example, the sound wave level is treated as data of continuous time, and based on this sound wave level, a threshold range is set. The matching rate with the threshold range can also be calculated from the time when the sound wave level is within the threshold range when a new sound wave level is input. Also, in the present embodiment, the system has been described as providing a server SV separately from the image forming apparatus 1, but the present invention is not limited to this. For example, by providing the arithmetic unit 301 inside the image forming apparatus, it is possible to determine abnormal sounds with the image forming apparatus alone.

[0054] As described above, according to the first embodiment, the cause of the abnormal sound can be accurately determined.

Example

[0055] Subsequently, the differences between the second embodiment and the first embodiment will be mainly described. In the present embodiment, by providing a plurality of threshold ranges, the magnitude of the abnormal sound can be determined. FIG. 11 is a graph showing two threshold ranges, a first threshold range and a second threshold range, in the photosensitive drum motor 93. The statistical value M2 is the statistical value when a slight abnormal sound occurs in the photosensitive drum motor 93. Here, the first threshold range and the second threshold range have different central values in each section. By providing a second threshold range whose central value is smaller than the first threshold range, a small abnormal sound can be detected.

[0056] A method for setting the first threshold range and the second threshold range will be described. Each threshold range can be set from the initial statistical value M1, similar to Example 1. For example, given predetermined values H1 and H2 for calculating the central values of the first threshold range and the second threshold range, respectively, in the true number of decibels (dB), H1 = 20000 and H2 = 8000. Then, since the initial statistical value M1 in interval 1 is 40 dB, the central value of the first threshold range is 10×log10(10^(40 / 10)+20000)=44.8 dB, and the central value of the second threshold range is 10×log10(10^(40 / 10)+8000)=42.5 dB. And when setting each threshold range as the range of the central value ±1.5 dB, the first threshold range is 43.3~46.3 dB, and the second threshold range is 41.0~44.0 dB. The first threshold range and the second threshold range may have overlapping regions. The threshold ranges can be set in the same way for other intervals. Also, the feed motor 91 and the fixing motor 92 can also set multiple threshold ranges in the same way.

[0057] Subsequently, with reference to FIG. 12, a method for determining abnormal noise will be described. FIG. 12 is a diagram showing whether the operating state and the statistical value M2 in each time interval are within the threshold range in the photoreceptor motor 93 based on FIG. 11. Similar to Example 1, in each of the first threshold range and the second threshold range, the number of intervals and the number of intervals in which the statistical value M2 is within the threshold range are counted, and the conformity rate is calculated. For example, in FIG. 12, the total conformity rate of the first threshold range is 37.5%, and the total conformity rate of the second threshold range is 93.8%. Since the total conformity rate with the second threshold range having a smaller central value of the threshold range is larger, it can be determined that an abnormal noise smaller than the case of conforming to the first threshold range is generated.

[0058] As described above, in this embodiment, by providing a plurality of threshold ranges, it becomes possible to determine small abnormal noises. As a result, for example, it is possible to prompt the administrator of the management device M to prepare for component replacement at a stage of a more minor abnormal noise, and when a large abnormal noise is detected, it is possible to prompt the administrator to replace or repair the component with a greater sense of urgency. As described above, according to Example 2, the cause of the abnormal noise can be accurately determined.

Example

[0059] Subsequently, Example 3 will be described focusing on the differences from Example 1 and Example 2. In this embodiment, a method for removing the operating noise other than the target actuator will be described. FIG. 13 is a graph showing the statistical values in each time interval in Example 3. FIG. 13 shows the statistical values and threshold ranges when the transfer separation noise 110 is larger than the initial statistical value M1 when obtaining the statistical value M2 when abnormal noise occurs in the photoreceptor motor 93. The above-described transfer separation noise 110 may vary in magnitude due to the sliding state of the cam 104 and the slider 101, and fluctuations in the rotational speed of the cam 104. For example, in section 8 of FIG. 13, the statistical value M2 is out of the threshold range due to the variation in the transfer separation noise 110.

[0060] Next, with reference to FIG. 14, the method for determining abnormal noise in this embodiment will be described. FIG. 14 is a diagram showing whether the operating state and the statistical value M2 in each time interval are within the threshold range in the photoreceptor motor 93 based on FIG. 13. Hereinafter, excluding a specific section from the calculation target will be referred to as masking. First, "without masking" is the result of calculating the conformity rate in all time intervals in the same manner as in Example 1 and Example 2, and the total conformity rate is 87.5%. On the other hand, "with masking" is the result of calculating the conformity rate by excluding section 8 where the transfer separation noise 110 occurs from the calculation target, and the total conformity rate is 93.3%.

[0061] Note that the masking section may be determined in advance as described above, or may be determined after obtaining the initial statistical value M1. For example, when the initial statistical value M1 is a large value, it may be determined that other operating sounds are included and masked. In addition, it is also possible to determine a section in which an operating sound is generated from the operating timing of a motor or a solenoid and mask that section. Further, there may be a plurality of masking sections, or they may be individually set for each target actuator.

[0062] In this way, by masking a section in which the statistical value may vary due to the influence of operating sounds other than the target actuator, the conformity rate when abnormal sounds occur increases, and it is possible to determine abnormal sounds without being affected by operating sounds other than the target actuator. As described above, according to the third embodiment, the cause of the abnormal sound can be accurately determined.

[0063] <Other Embodiments> The present invention can also be realized by supplying a program that realizes one or more functions of the above-described embodiments to a system or device via a network or a storage medium, and having one or more processors in the computer of the system or device read and execute the program. It can also be realized by a circuit (for example, ASIC) that realizes one or more functions.

[0064] The disclosure of this embodiment includes the following configurations. (Configuration 1) A sound diagnosis system including an image forming apparatus that forms an image on a recording material and an information processing apparatus that can communicate with the image forming apparatus, wherein the image forming apparatus has one or more operating parts, a sound collecting part that collects sound waves so as to include a period during which the operating part is operating, an acquisition part that acquires data including a sound wave level based on the sound waves and an operating state of one or more of the operating parts in each of a plurality of time intervals in which the sound collecting part has collected the sound waves, a transmission part that transmits the data to the information processing apparatus, and The information processing apparatus a receiving unit that receives the data; a threshold value generation unit that generates a threshold value by adding a predetermined value to a first sound wave level that is the sound wave level based on the sound wave collected by the sound collection unit during a first period; a determination unit that determines the cause of an abnormal sound by comparing a second sound wave level that is the sound wave level based on the sound wave collected by the sound collection unit during a second period after the first period with the threshold value; A sound diagnosis system characterized by comprising: (Configuration 2) The sound diagnosis system according to Configuration 1, wherein the predetermined value is added to the mantissa of the first sound wave level that is a logarithm. (Configuration 3) The threshold value has a predetermined threshold value range, The determination unit determines the cause of an abnormal sound by calculating the number of time intervals in which the second sound wave level is included in the threshold value range in a plurality of the time intervals. The sound diagnosis system according to Configuration 1 or Configuration 2. (Configuration 4) The sound diagnosis system according to Configuration 3, wherein the acquisition unit generates the sound wave level based on the sound wave collected by the sound collection unit during a period including a period in which the operation unit is operating and a period in which the operation unit is not operating. (Configuration 5) a notification unit that notifies a determination result of the determination unit or countermeasure information based on the determination result of the determination unit when the determination unit determines the cause of the abnormal sound; a display device that receives a notification from the notification unit and displays the determination result of the determination unit or countermeasure information based on the determination result of the determination unit; A sound diagnosis system according to any one of Configurations 1 to 4, characterized by comprising: (Configuration 6) Each of the one or more operation units drives a component included in the image forming apparatus. The sound diagnosis system according to any one of Configurations 1 to 5.

Description of Reference Numerals

[0065] 1 Image forming apparatus 70 Reception sound processing unit 71 Microphone 91 Feeding motor 92 Fixing motor 93 Photoconductor motor 100 Sound diagnosis system 708 Sound information storage unit 3012 Threshold range setting unit 3013 Judgment unit SV server

Claims

1. A sound diagnosis system including an image forming apparatus for forming an image on a recording material and an information processing apparatus capable of communicating with the image forming apparatus, wherein the image forming apparatus has one or more operating parts, a sound collecting part for collecting sound waves so as to include a period during which the operating part is operating, an acquisition part for acquiring data including a sound wave level based on the sound waves in each of a plurality of time intervals during which the sound collecting part has collected the sound waves, and an operating state of one or more of the operating parts, a transmission part for transmitting the data to the information processing apparatus, and the information processing apparatus has a reception part for receiving the data, a threshold value generation part for generating a threshold value by adding a predetermined value to a first sound wave level which is the sound wave level based on the sound waves collected by the sound collecting part during a first period, and a determination part for determining a cause of an abnormal sound by comparing a second sound wave level which is the sound wave level based on the sound waves collected by the sound collecting part during a second period after the first period with the threshold value. A sound diagnosis system characterized by the above.

2. The sound diagnosis system according to claim 1, wherein the predetermined value is added to the mantissa of the first sound wave level which is in logarithm.

3. The threshold value has a predetermined threshold value range, and the determination part determines a cause of an abnormal sound by calculating the number of time intervals in which the second sound wave level is included in the threshold value range in a plurality of the time intervals. The sound diagnosis system according to claim 1.

4. The sound diagnosis system according to claim 2, wherein the acquisition part generates the sound wave level based on the sound waves collected by the sound collecting part during a period including a period during which the operating part is operating and a period during which the operating part is not operating.

5. When the determination unit determines the cause of the abnormal sound, a notification unit that notifies the determination result of the determination unit or countermeasure information based on the determination result of the determination unit; A display device that receives a notification from the notification unit and displays the determination result of the determination unit or countermeasure information based on the determination result of the determination unit; The auscultation diagnosis system according to claim 1, characterized by comprising:

6. The auscultation diagnosis system according to claim 1, characterized in that each of the one or more operation units drives a component of the image forming apparatus.

Images