Diagnostic apparatus, control method for the same, program, and image forming apparatus

Abstract

To provide a mechanism capable of selecting a timing for executing automatic repair in such as an image forming unit.SOLUTION: A diagnostic apparatus: selects and sets, in response to a user operation, a timing for repairing an image forming unit in a case where a sign indicating that the image forming unit is abnormal is detected; performs diagnosis of an abnormality and a sign thereof of the image forming unit based on an image formed by the image forming unit; and executes repair processing of the image forming unit at the set timing when the sign of the abnormality is detected.SELECTED DRAWING: Figure 9

Description

Technical Field

[0001] The present invention relates to a diagnostic apparatus for diagnosing an apparatus from a read image of an image formed by an image forming apparatus, a control method thereof, a program, and an image forming apparatus.

Background Art

[0002] In an image forming apparatus, a printed document is read by a scanner, an image defect (abnormality) of the document is detected from the read image data, and a part causing the defect is specified from the abnormality detection result. Further, there is also known an image forming apparatus that automatically repairs a specified part when an abnormality is detected in an image printed by the image forming apparatus. Patent Document 1 proposes an apparatus that sequentially repairs a plurality of abnormalities when a plurality of abnormalities are detected in an image formed by an image forming apparatus.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the above prior art, when a plurality of abnormalities are detected, it has a function of specifying the repair order of the abnormalities. However, the repair operation is sequentially executed at the timing when the abnormality is detected, and the timing of executing the repair operation has not been studied. Therefore, in the above prior art, when an abnormality is detected, printing of the image forming apparatus is interrupted at that timing and a repair operation is performed. That is, printing cannot be executed during the repair operation, and during that time, the user's printed materials cannot be produced, which reduces the productivity of the user.

[0005] The present invention is made in view of at least one of the above-described problems, and provides a mechanism capable of selecting the timing for executing automatic repair in an image forming unit.

Means for Solving the Problems

[0006] The present invention is, for example, a diagnostic apparatus, comprising: setting means for selecting and setting the timing for repairing the image forming means when a precursor of an abnormality in the image forming means is detected, in response to a user operation; diagnostic means for diagnosing an abnormality and its precursor of the image forming means from an image formed by the image forming means; and repair means for executing a repair process of the image forming means at the set timing when the precursor of the abnormality is detected by the diagnostic means.

Effects of the Invention

[0007] According to the present invention, a mechanism capable of selecting the timing for executing automatic repair in an image forming unit is provided, and a decrease in user productivity can be avoided.

Brief Description of the Drawings

[0008]

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Embodiments for Carrying Out the Invention

[0009] Hereinafter, embodiments will be described in detail with reference to the accompanying drawings. Note that the following embodiments do not limit the invention according to the claims. Although a plurality of features are described in the embodiments, not all of these plurality of features are essential to the invention, and the plurality of features may be arbitrarily combined. Further, in the accompanying drawings, the same or similar configurations are denoted by the same reference numerals, and redundant explanations are omitted.

[0010] <First Embodiment> <System Configuration> Hereinafter, a first embodiment of the present invention will be described. With reference to FIG. 1, a network configuration example including a printing system (image processing system) according to this embodiment will be described. As shown in FIG. 1, the printing system 100 includes an image forming apparatus 101 and an external controller 102. The image forming apparatus 101 and the external controller 102 are communicably connected to each other via an internal LAN 105 and a video cable 106. The external controller 102 is communicably connected to a client PC 103 via an external LAN 104. In this embodiment, a form in which the image forming apparatus 101 and the external controller 102 are provided separately will be described as an example, but it is not intended to limit the present invention. For example, the external controller 102 may be provided integrally with the image forming apparatus 101. In that case, the image forming apparatus 101 and the client PC 103 are communicably connected.

[0011] The client PC 103 can issue a print instruction to the external controller 102 via the external LAN 104. The client PC 103 is installed with a printer driver having a function of converting image data to be printed into a page description language (PDL) that can be processed by the external controller 102. A user who wants to perform printing can issue a print instruction from various applications installed on the client PC 103 via the printer driver by operating the client PC 103. The printer driver transmits PDL data, which is print data, to the external controller 102 based on the print instruction from the user. When the external controller 102 receives the PDL data from the client PC 103, it analyzes and interprets the received PDL data. Based on the result of the interpretation, rasterization processing is performed to generate a bitmap image (print image data) with a resolution suitable for the image forming apparatus 101, and a print instruction is given by submitting a print job to the image forming apparatus 101.

[0012] Next, the image forming apparatus 101 will be described. In the image forming apparatus 101, devices having a plurality of different functions are connected, and it is configured to enable complex printing processes such as bookbinding. The image forming apparatus 101 includes a printing unit 107 (image forming unit), a diagnostic unit 108, a stacker 109, and a finisher 110. Hereinafter, each module will be described.

[0013] The printing unit 107 prints an image according to the content of a print job and discharges the printed recording medium (such as paper or sheets). The printed recording medium discharged from the printing unit 107 is conveyed through the interiors of the respective devices in the order of the diagnostic unit 108, the stacker 109, and the finisher 110. In the present embodiment, the image forming apparatus 101 of the printing system 100 is an example of an image forming apparatus, but in some cases, the printing unit 107 included in the image forming apparatus 101 may be referred to as the image forming apparatus. The printing unit 107 forms (prints) an image on the recording medium fed and conveyed from a paper feeding unit disposed below the printing unit 107 using toner (color material), which is a recording material.

[0014] The diagnostic unit 108 is a diagnostic device, and is an image diagnostic device that diagnoses the presence or absence of abnormal portions of the image forming apparatus 101 using the printed recording medium on which an image is printed by the printing unit 107 and conveyed through the conveyance path. Specifically, the diagnostic unit 108 reads the image printed on the conveyed printed recording medium and performs a diagnosis from the obtained read image. The diagnosis of abnormalities is determined by extracting a diagnostic region from the read image and checking the difference in read signal values within the extracted diagnostic region. The detailed processing of the diagnostic unit will be described later. Note that the diagnostic unit is also used during inspection of products. It is also a device that inspects the presence or absence of defects or abnormalities in the printed recording medium based on the comparison between the data of the printed recording medium on which an image is printed by the printing unit 107 and conveyed through the conveyance path and the print data.

[0015] Stacker 109 is a device capable of stacking a large number of printed recording media. Finisher 110 is a device capable of performing finishing processes such as stapling, punching, and saddle stitching on the conveyed printed recording media. The recording media after being processed by Finisher 110 is discharged onto a predetermined paper discharge tray.

[0016] In the configuration example of FIG. 1, external controller 102 is connected to image forming apparatus 101, but the present embodiment is also applicable to configurations different from this. For example, a configuration may be used in which image forming apparatus 101 is connected to external LAN 104 and print data is transmitted from client PC 103 to image forming apparatus 101 without passing through external controller 102. In this case, data analysis and rasterization for the print data are executed by image forming apparatus 101.

[0017] <Hardware Configuration of Image Forming Apparatus 101> With reference to FIG. 2, a hardware configuration example of image forming apparatus 101 according to the present embodiment will be described. In printing unit 107, a plurality of paper feed decks are provided. In the present embodiment, six types of decks, namely paper feed decks 361, 362, 363, 364, 365, and 366, are provided. Various recording media (papers) are stored in each paper feed deck. At the time of image formation, among the recording media stored in each paper feed deck, the recording media located at the top is separated one by one and fed to conveyance path 303.

[0018] Also, image forming stations 304 to 307 each include a photosensitive drum (photoconductor), and a toner image is formed on the photosensitive drum using toner of a different color. Specifically, image forming stations 304 to 307 form toner images using yellow (Y), magenta (M), cyan (C), and black (K) toners, respectively.

[0019] The toner images of each color formed in the image forming stations 304 to 307 are sequentially superimposed and transferred (primary transfer) onto the intermediate transfer belt 308. The toner image transferred onto the intermediate transfer belt 308 is conveyed to the secondary transfer position 309 as the intermediate transfer belt 308 rotates. At the secondary transfer position 309, the toner image is transferred from the intermediate transfer belt 308 to the recording medium conveyed through the conveyance path 303 (secondary transfer). The recording medium after secondary transfer is conveyed to the fixing unit 311. The fixing unit 311 includes a pressure roller and a heating roller. While the recording medium passes between these rollers, heat and pressure are applied to the recording medium, and a fixing process for fixing the toner image to the recording medium is performed. The recording medium that has passed through the fixing unit 311 is conveyed through the conveyance path 312 to the connection point 315 between the printing unit 107 and the diagnosis unit 108. In this way, a color image is formed (printed) on the recording medium.

[0020] When further fixing processing is required according to the type of the recording medium, the recording medium that has passed through the fixing unit 311 is guided to the conveyance path 314 provided with the fixing unit 313. The fixing unit 313 performs further fixing processing on the recording medium conveyed through the conveyance path 314. The recording medium that has passed through the fixing unit 313 is conveyed to the connection point 315. Also, when the operation mode for duplex printing is set, an image is printed on the first side, and the recording medium conveyed through the conveyance path 312 or the conveyance path 314 is guided to the reverse path 316. The recording medium reversed in the reverse path 316 is guided to the duplex conveyance path 317 and conveyed to the secondary transfer position 309. As a result, the toner image is transferred to the second side opposite to the first side of the recording medium at the secondary transfer position 309. Then, by passing the recording medium through the fixing unit 311 (and the fixing unit 313), the formation of the color image on the second side of the recording medium is completed.

[0021] When the formation (printing) of the image in the printing unit 107 is completed, the printed recording medium conveyed to the connection point 315 is conveyed into the diagnosis unit 108. The diagnosis unit 108 includes image reading units 331 and 332 having CIS (Contact Image Sensor) on the conveyance path 330 through which the printed recording medium from the printing unit 107 is conveyed. The image reading units 331 and 332 are arranged at positions facing each other via the conveyance path 330. The image reading units 331 and 332 are each configured to read the upper surface (first surface) and the lower surface (second surface) of the recording medium. Note that the image reading unit may be configured by, for example, a CCD (Charge Coupled Device) or a line scan camera instead of the CIS.

[0022] The diagnosis unit 108 performs various image diagnosis processes of the image forming apparatus 101 based on the image printed on the printed recording medium conveyed on the conveyance path 330. Specifically, the diagnosis unit 108 performs a reading process of reading the image of the printed recording medium using the image reading units 331 and 332 at the timing when the printed recording medium being conveyed reaches a predetermined position. From the read image, a precursor diagnosis for finding a precursor before the image forming apparatus becomes abnormal, an inspection and inspection diagnosis for inspecting an abnormality in the output during printing, and an image diagnosis for finding an abnormality in the image forming apparatus are performed. Further, based on the diagnosis results of the precursor diagnosis and the image diagnosis, the factors of the precursor and the abnormality are specified, and a process of automatically repairing the parts of the factors is executed. The precursor diagnosis is a diagnosis that finds a precursor that is considered to become abnormal in the future and does not necessarily need to be repaired immediately after the diagnosis. Also, the precursor diagnosis is basically performed by the user on the printed image during printing.

[0023] Image diagnosis is a diagnosis that detects abnormalities and immediately repairs the diagnosis. Basically, it is performed during printing suspension. When performing image diagnosis alone, a chart for image diagnosis is printed, and the diagnosis is made using the printed image. Also, when an abnormality is found on the printed matter during inspection of the product, image diagnosis is also used when analyzing the cause of the abnormality. FIG. 13 shows an example of a chart for image diagnosis. Chart 1300 includes a base portion 1301 and an image forming portion 1302. The diagnosis unit 108 can perform diagnosis of abnormalities (precursors) using the chart 1300 printed by the printing unit 107. Note that various charts may be used for the image diagnosis chart according to the type of abnormality (dots, streaks, etc.), and the present invention is not intended to be limited to the example of the chart shown in FIG. 13. The recording medium that has passed through the diagnosis unit 108 is sequentially conveyed to the stacker 109.

[0024] The stacker 109 includes a stack tray 341 as a tray on which the printed recording medium conveyed from the diagnosis unit 108 arranged on the upstream side in the conveyance direction of the printed recording medium is stacked. The printed recording medium that has passed through the diagnosis unit 108 is conveyed through the conveyance path 344 in the stacker 109. When the printed recording medium conveyed through the conveyance path 344 is guided to the conveyance path 345, the printed recording medium is stacked on the stack tray 341.

[0025] The stacker 109 further includes an escape tray 346 as a paper discharge tray. In the present embodiment, the escape tray 346 is used for discharging the recording medium on which the test chart used for image diagnosis by the diagnosis unit 108 is recorded. When the printed recording medium conveyed through the conveyance path 344 is guided to the conveyance path 347, it is conveyed to the escape tray 346. The printed recording medium that has been conveyed without being stacked or discharged in the stacker 109 is conveyed to the subsequent finisher 110 through the conveyance path 348. Also, the escape tray 346 is also used for discharging the printed recording medium determined to be defective in the inspection of the product by the diagnosis unit 108.

[0026] Stacker 109 further includes an inversion unit 349 for inverting the orientation of the conveyed printed recording medium. The inversion unit 349 is used, for example, to make the orientation of the recording medium input to the stacker 109 the same as the orientation of the printed recording medium when it is stacked on the stack tray 341 and output from the stacker 109. Note that the inversion operation by the inversion unit 349 is not performed on the printed recording medium that is conveyed to the finisher 110 without being stacked in the stacker 109.

[0027] The finisher 110 executes the finishing function designated by the user on the printed recording medium conveyed from the diagnostic unit 108 disposed upstream in the conveyance direction of the printed recording medium. In the present embodiment, the finisher 110 has finishing functions such as a stapling function (stapling at one or two locations), a punching function (two or three holes), and a center-stitching binding function. The finisher 110 includes two paper discharge trays 351 and 352. When the finishing process by the finisher 110 is not performed, the printed recording medium conveyed to the finisher 110 is discharged to the paper discharge tray 351 through the conveyance path 353. When the finishing process such as stapling is performed by the finisher 110, the printed recording medium conveyed to the finisher 110 is guided to the conveyance path 354. The finisher 110 executes the finishing process designated by the user on the printed recording medium conveyed through the conveyance path 354 using the finishing process unit 355, and discharges the printed recording medium on which the finishing process has been executed to the paper discharge tray 352.

[0028] <Functional Configuration> Referring to FIG. 3, the functional configurations of the image forming apparatus 101, the external controller 102, and the client PC 103 according to the present embodiment will be described. The printing unit 107 of the image forming apparatus 101 includes a communication I / F (interface) 201, a network I / F 204, a video I / F 205, a CPU 206, a memory 207, an HDD unit 208, and a UI display unit 225. The printing unit 107 further includes an image processing unit 202 and a print unit 203. These units are respectively connected to be able to transmit and receive data to and from each other via a system bus 209.

[0029] The communication I / F 201 is connected to the diagnostic unit 108, the stacker 109, and the finisher 110 via the communication cable 260. The CPU 206 performs communication for controlling each device via the communication I / F 201. The network I / F 204 is connected to the external controller 102 via the internal LAN 105 and is used for communication such as control data. The video I / F 205 is connected to the external controller 102 via the video cable 106 and is used for communication of data such as image data. Note that the printing unit 107 (image forming apparatus 101) and the external controller 102 may be connected only by the video cable 106 as long as the external controller 102 can control the operation of the image forming apparatus 101. Various programs or data are stored in the HDD unit 208. The CPU 206 controls the operation of the entire printing unit 107 by executing the programs stored in the HDD unit 208. Programs and data required when the CPU 206 performs various processes are stored in the memory 207. The memory 207 operates as a work area for the CPU 206. The UI display unit 225 receives inputs of various settings and operation instructions from the user and is used for displaying print job management. For example, the UI display unit 225 displays the job management screen shown in FIG. 4, and the user can check or change the print job. In the job management screen shown in FIG. 4, lists of saved jobs and completed jobs are displayed. The saved jobs are the input jobs and are a list of jobs that have not been completed yet. The completed jobs are a list of jobs that have been completed. Each of the saved jobs and the completed jobs includes a job identification number, the user name who input the job, the file name used for the job, the number of pages to be printed, the number of copies, the total number of pages, and status information. The status information of the saved jobs includes a hold state waiting to be executed or a state indicating a printing state during execution.

[0030] The diagnostic unit 108 includes a communication I / F 211, a CPU 214, a memory 215, an HDD unit 216, image reading units 331 and 332, and a UI display unit 241. These devices are connected to be able to transmit and receive data to and from each other via a system bus 219. The communication I / F 211 is connected to the printing unit 107 via a communication cable 260. The CPU 214 performs communication necessary for controlling the diagnostic unit 108 via the communication I / F 211. The CPU 214 controls the operation of the diagnostic unit 108 by executing a control program stored in the memory 215. A control program for the diagnostic unit 108 is stored in the memory 215. The image reading units 331 and 332 read images of the conveyed recording medium according to instructions from the CPU 214. In image diagnosis, the CPU 214 diagnoses the presence or absence of abnormal parts of the image forming apparatus 101 based on the read images for diagnosis read by the image reading units 331 and 332. Also, in inspection and product inspection, the CPU 214 inspects defects (abnormalities) of the printed recording medium based on the read images of the printed recording medium read by the image reading units 331 and 332.

[0031] The UI display unit 241 is used for displaying the results of inspection and product diagnosis, precursor diagnosis, abnormality diagnosis, the implementation status of automatic repair based on the diagnosis results, and a setting screen, etc. The operation unit is used in common with the UI display unit 241 and receives various instructions from the user, such as changing the settings of the diagnostic unit 108 and giving execution instructions for inspection and product diagnosis, precursor diagnosis, and abnormality diagnosis, according to user operations.

[0032] FIG. 5 shows an example of a setting screen for various image diagnosis levels. On the setting screen for image diagnosis levels, it is possible to set an inspection sample level 501, an image diagnosis level 502, and a precursor diagnosis level 503. For the inspection sample level 501 and the image diagnosis level 502, the inspection sample level (threshold level) of the inspection can be set in five levels from "strict" to "lenient". At these threshold levels, the closer to "strict", the stricter the level (threshold) is set, and even a slight abnormality will be detected as an abnormal inspection result. On the other hand, the closer to "lenient", the looser the level (threshold) is set, and even if there are some abnormalities, it will be judged as normal. Here, an example of being able to set to five threshold levels is shown, but it may also be divided into two levels, three levels, seven levels, etc. Also, for the precursor diagnosis level 503, the inspection sample level of the inspection can be set in five levels from "early detection" to "late detection". At these levels, the closer to "early detection", the stricter the threshold level is set, and even a slight abnormal level will be detected as a precursor abnormality in the inspection result. On the other hand, the closer to "late detection", the looser the threshold level is set, and even if there is some abnormal level, it will be judged not to be at the precursor level.

[0033] FIG. 6 shows an example of a setting screen for an automatic repair setting of whether to automatically repair precursors and abnormalities detected in inspection sample diagnosis, precursor diagnosis, and image diagnosis. On the screen for automatic repair settings, it is possible to set whether to "automatically repair" 601 or "not automatically repair" 603 when precursors and abnormalities are detected in various diagnoses. Also, on this screen, "detailed timing setting" 602 for when automatic repair is performed can be set. Here, the automatic repair operations when precursors and abnormalities are detected in precursor diagnosis, image diagnosis, etc. are set collectively, but it may also be set for each inspection. The case when "detailed timing setting" 602 is selected will be described later with reference to FIG. 9.

[0034] Return to the description of FIG. 3. In the HDD unit 216, various setting information and image data necessary for inspection, defect diagnosis, precursor diagnosis, and image diagnosis are stored. The various setting information and image data stored in the HDD unit 216 can be reused. The stacker 109 controls whether to discharge the printed recording medium conveyed on the conveyance path to the stack tray, to the escape tray, or to convey it to the finisher 110 connected to the downstream side in the conveyance direction of the printed recording medium. The finisher 110 controls the conveyance and discharge of the printed recording medium, and performs finishing processes such as stapling, punching, or saddle stitching binding.

[0035] The external controller 102 includes a CPU 251, a memory 252, an HDD unit 253, a keyboard 256, a display unit 254, network I / Fs 255, 257, and a video I / F 258. These devices are connected to be able to transmit and receive data to and from each other via a system bus 259. The CPU 251 controls the overall operation of the external controller 102, such as receiving print data from the client PC 103, performing RIP processing, and transmitting the print data to the image forming apparatus 101, by executing the program stored in the HDD unit 253. Programs and data necessary for the CPU 251 to perform various processes are stored in the memory 252. The memory 252 operates as a work area for the CPU 251.

[0036] Various programs and data are stored in the HDD unit 253. The keyboard 256 is used for inputting operation instructions for the external controller 102 from the user. The display unit 254 is, for example, a display and is used for displaying information on the application being executed in the external controller 102 and the operation screen. The network I / F 255 is connected to the client PC 103 via the external LAN 104 and is used for data communication such as print instructions. The network I / F 257 is connected to the image forming apparatus 101 via the internal LAN 105 and is used for data communication such as print instructions. The external controller 102 is configured to be able to communicate with the printing unit 107, the diagnostic unit 108, the stacker 109, and the finisher 110 via the internal LAN 105 and the communication cable 260. The video I / F 258 is connected to the image forming apparatus 101 via the video cable 106 and is used for data communication such as image data (print data).

[0037] The client PC 103 includes a CPU 261, a memory 262, an HDD unit 263, a display unit 264, a keyboard 265, and a network I / F 266. These devices are connected to be able to transmit and receive data to and from each other via the system bus 269. The CPU 261 controls the operation of each device via the system bus 269 by executing the program stored in the HDD unit 263. Thereby, various processes by the client PC 103 are realized. For example, the CPU 261 generates print data and issues a print instruction by executing the document processing program stored in the HDD unit 263. The memory 262 stores programs and data required when the CPU 261 performs various processes. The memory 262 operates as a work area for the CPU 261.

[0038] The HDD unit 263 stores various applications such as a document processing program, programs such as a printer driver, and various data. The display unit 264 is, for example, a display and is used for displaying information on the applications being executed on the client PC 103 and the operation screen. The keyboard 265 is used for inputting operation instructions for the client PC 103 from the user. The network I / F 266 is communicably connected to the external controller 102 via the external LAN 104. The CPU 261 communicates with the external controller 102 via the network I / F 266.

[0039] <Precursor level and abnormal level> Referring to FIG. 8, the precursor diagnosis level and the image diagnosis level will be described. FIG. 8 shows an example of the relationship between the size of a pochi (precursor) and the number of printed sheets, which is not included in the original data. The vertical axis represents the size of the pochi, and the horizontal axis represents the number of printed sheets. The original data corresponds to the image data used for printing. Generally, for abnormal pochi, a pochi (precursor) that becomes the core of the abnormality suddenly appears at a certain number of sheets, and the size increases as the number of sheets increases. When the size becomes equal to or larger than a predetermined size, it can be recognized as abnormal by the user.

[0040] Normally, since it becomes recognizable from 250 μ, generally, for the normal of the image diagnosis level 502 in FIG. 5, the size of the × point at 805 in FIG. 8 becomes the minimum size for abnormal determination of the image diagnosis level. That is, 250 μ or more is determined as abnormal. For the strict of the image diagnosis level 502, the size of the × point at 804 in FIG. 8 becomes the minimum size for abnormal determination of the image diagnosis level. That is, 225 μ or more is determined as abnormal. For the sweet of the image diagnosis level 502, the size of the × point at 806 in FIG. 8 becomes the minimum size for abnormal determination of the image diagnosis level. That is, 275 μ or more is determined as abnormal.

[0041] As a user, since an abnormal output cannot be a product, the core (precursor) of the abnormality grows, and it is desired to remove the core (precursor) of the abnormality before it becomes abnormal. Therefore, among the precursors before becoming abnormal with a small Pochi size, the parts causing the precursor are repaired in advance so as to detect and remove the core (precursor) of the abnormality. The processing procedures of these precursor diagnosis processes and repair processes will be described with reference to FIG. 7.

[0042] Generally, for the precursor diagnosis level 503 in FIG. 5, the size of the △ point at 802 in FIG. 8 is the minimum size for precursor determination at the precursor diagnosis level. That is, 125 μ or more is determined as a precursor. For the early detection of the precursor diagnosis level 503 in FIG. 5, the size of the △ point at 801 in FIG. 8 is the minimum size for precursor determination at the precursor diagnosis level. That is, 100 μ or more is determined as a precursor. Also, for early detection, the number of pieces from the △ of the precursor size to the × of the abnormal size increases, and since it will be automatically repaired early, the frequency of repair increases. For the late detection of the precursor diagnosis level 503 in FIG. 5, the size of the △ point at 803 in FIG. 8 is the minimum size for precursor determination at the precursor diagnosis level. That is, 150 μ or more is determined as a precursor. Also, for late detection, the number of pieces from the △ of the precursor size to the × of the abnormal size decreases, and since it will be automatically repaired late, the frequency of repair decreases. As described above, the precursor diagnosis level and the image diagnosis level are different levels.

[0043] <Precursor Diagnosis Process and Repair Process> With reference to FIG. 7, the processing procedures of the precursor diagnosis process and the repair process according to the present embodiment will be described. The symbol "S" in the description of the flowchart represents a step. The same shall apply in the following description of the flowchart. The processing described below is executed by the CPU 206 of the printing unit 107, the CPU 214 of the diagnosis unit 108, and the CPU 251 of the external controller 102. Here, a form will be described in which various CPUs cooperate to execute the processing described below, but a form in which an integrated single CPU provided in the image forming apparatus executes all the processing may also be possible.

[0044] In S701, the CPU 214 of the diagnosis unit 108 sets the pre-diagnosis level setting in the user mode based on the pre-diagnosis level 503 of the diagnosis level setting in FIG. 5 via the UI display unit 241 that also serves as the operation unit. Here, it is described in terms of the user's UI settings, but it can also be set by the service technician from the service mode. Note that the control related to the setting may be controlled by the CPU 251 of the external controller 102.

[0045] In S702, the CPU 214 sets the automatic repair setting in the user mode based on "Repair Automatically" 601 or "Do Not Repair Automatically" 603 of the automatic repair setting in FIG. 6 via the UI display unit 241 that also serves as the operation unit. When "Do Not Repair Automatically" 603 is selected, repair can be performed by individually operating a repair button (not shown). Here, it is described in terms of the user's UI settings, but it can also be set by the service technician from the service mode.

[0046] In S703, the CPU 214 sets the detailed timing setting in the user mode based on after job printing completion 901 set in the detailed timing setting in FIG. 9 via the UI display unit 241 that also serves as the operation unit. Here, it is described in terms of the user's UI settings, but it can also be set by the service technician from the service mode. Here, when the detailed timing setting is not set, when a precursor is detected, in order to sequentially execute the repair operation, it is necessary to interrupt the printing of the image forming apparatus and perform the repair work. That is, since printing cannot be performed during the repair work, the user's printed materials cannot be printed until the repair work is completed, resulting in a decrease in productivity.

[0047] At S704, the CPU 251 of the external controller 102 receives the print job specified by the print instruction. Subsequently, at S705, the CPU 251 determines whether pre-print processing is necessary. Specifically, if in the detailed timing setting of S703, 902 before the start of job printing is selected and the repair content from the previous execution is stored in S721 (to be described later), the process proceeds to S706. On the other hand, if in the detailed timing setting of S703, before the start of job printing is not selected, the process proceeds to S708.

[0048] At S706, the CPU 206 of the printing unit 107 performs automatic repair based on the repair content stored previously in S721 (to be described later). Details of the automatic repair will be described later. Subsequently, at S707, the CPU 206 displays the content of the automatic repair performed at S706 on the UI display unit 241 and proceeds to S708.

[0049] At S708, the CPU 251 of the external controller 102 generates a bitmap for printing by rasterizing the pages to be printed for the print job received at S704. Subsequently, at S709, the CPU 251 transmits the rasterized bitmap data from the video I / F 258 through the video cable 106 to the video I / F 205 of the printing unit 107. Further, the CPU 206 of the printing unit 107 performs printing based on the image data of the bitmap data received at the video I / F 205.

[0050] At S710, the CPU 214 of the diagnostic unit 108 determines whether it is the pre-symptomatic diagnosis timing. Specifically, the CPU 214 checks the setting information of the pre-symptomatic diagnosis timing. If it determines that it is the timing for pre-symptomatic diagnosis, the process proceeds to S711. If it determines that it is not the timing, the process proceeds to S723. The pre-symptomatic diagnosis timing refers to the timing at which pre-symptoms are determined and is determined based on the setting of the pre-symptomatic diagnosis level 503 described with reference to FIG. 5. The number of sheets from the pre-symptoms before the printer malfunctions until it malfunctions is at least in units of 1000 sheets as shown in FIG. 8. Therefore, it is sufficient to perform the pre-symptomatic diagnosis timing also in units of several hundred sheets, and thus the timing is being checked.

[0051] In S711, the CPU 214 changes the resolution and the like to generate a reference image to be compared for printing so that the rasterized bitmap for printing can be compared for differences with the printed image read in S712 described later. Subsequently, in S712, the CPU 214 executes a process of reading the printed matter by the image reading units 331 and 332. The read image is stored in the HDD unit 216 of the diagnosis unit 108 as a diagnosis image. When the diagnosis image is stored, the process proceeds to S713. In S713, the CPU 214 compares the reference image with the read diagnosis image and generates difference image data for determining an abnormality in the printing unit 107. In S714, the CPU 214 acquires feature information such as the shape and period of the difference from the difference image data generated in S713 and performs a diagnosis of precursors that are precursors of an abnormality. From the diagnosis result of the precursors, if a precursor is found, the process proceeds to S715, and if not, the process proceeds to S723.

[0052] In S715, the CPU 214 identifies the parts that are the causes of the precursors of the abnormality based on the feature information of the difference region. Specifically, the CPU 214 selects combinations with the same color and high similarity in the difference region and identifies which parts are abnormal from the period information of the selected combinations. An example of the factor parts and the cause is shown in FIG. 10. As shown in FIG. 10, the feature information of the difference region includes information on shape, direction, and period. The CPU 214 identifies the factor parts from the period information, and the cause is identified from their shape and direction. When the cause is identified, the repair content is determined. For example, it is desirable that the diagnosis unit 108 previously holds the information in the table shown in FIG. 10 in the HDD unit 216 and identifies the factor parts and the cause according to the detected feature information of the difference region. In S716, the CPU 214 checks the detailed timing setting set in S703. In S717, the CPU 214 determines whether the detailed timing setting set in S703 is an immediate response. If it is an immediate response, the process proceeds to S718, and if it is not an immediate response, the process proceeds to S721.

[0053] In S718, since the automatic repair when a precursor is detected by the CPU 214 is an immediate response, printing is stopped. Subsequently, in S719, the CPU 214 notifies the printing unit 107 of the factor parts shown in FIG. 10 and the repair content corresponding to the cause, and the printing unit 107 performs the corresponding repair content. When automatic repair is performed, it is desirable that the information on the repair content and repair timing held in the HDD unit 216 be deleted from the memory. Thereby, it is possible to avoid duplicate and wasteful automatic repair processes in cases where multiple automatic repair timings are set. The repair content will be described later. In S720, the CPU 214 displays the content of the repair performed in S719 on the UI display unit 241 and proceeds to S723.

[0054] On the other hand, when it is not an immediate response, in S721, the CPU 214 saves the parts and repair content specified in S715 and the timing confirmed in S717 in the HDD unit 216. Further, in S722, the CPU 214 displays the specified parts, repair content, and timing saved in S721 on the UI display unit 241 and proceeds to S723.

[0055] In S723, the CPU 251 of the external controller 102 determines whether printing of all pages of the job to be printed has been completed. If it has been completed, it proceeds to S724, and if it has not been completed, it proceeds to S708. In S724, the CPU 214 of the diagnostic unit 108 determines whether the detailed timing setting set in S703 is 901 after the end of job printing. If it is a response after the end of printing, it proceeds to S725, and if it is not a response after the end of printing, the processing of this flowchart ends. In S725, the CPU 214 notifies the printing unit 107 of the repair content corresponding to the factors in FIG. 10, and the printing unit 107 performs the corresponding repair content. Subsequently, in S726, the CPU 214 displays the content of the repair performed in S725 on the UI display unit 241, and the processing of this flowchart ends.

[0056] <Image Diagnosis Process and Repair Process> The premonitory diagnosis and its repair process were described with reference to FIG. 7 above. Since a premonition is something that finds the state before it becomes abnormal, there is a delay until it is corrected after finding the premonition. However, when an abnormality is detected, there is no delay and immediate response is necessary. Below, with reference to FIG. 11, the image diagnosis process and its repair process will be described in order to explain the difference from the premonitory diagnosis process. The flowchart of FIG. 11 is started by an instruction for the image diagnosis process by the printing unit 107. For the same control as the flowchart of FIG. 7, the same reference numerals are assigned and the description is omitted. The processes described below are executed by the CPU 206 of the printing unit 107, the CPU 214 of the diagnosis unit 108, and the CPU 251 of the external controller 102. Here, a form will be described in which various CPUs cooperate to execute the processes described below, but a form in which an integrated single CPU provided in the image forming apparatus executes all the processes may also be possible.

[0057] In S1101, the CPU 214 of the diagnosis unit 108 sets the image diagnosis level in the user mode based on the image diagnosis level 502 of the diagnosis level in FIG. 5 via the UI display unit 241 that also serves as the operation unit. Here, the description will be based on the user's UI settings, but a service technician can also set it from the service mode. In S1102, the CPU 251 of the external controller 102 receives a print job for diagnosing an abnormality. For example, it is a print job including a chart for image diagnosis shown in FIG. 13. Subsequently, in S708, the CPU 251 generates a bitmap for printing by rasterizing the page to be printed. In S709, the CPU 251 transmits the rasterized bitmap data from the video I / F 258 through the video cable 106 to the video I / F 205 of the printing unit 107. The CPU 206 of the printing unit 107 performs printing based on the image data of the bitmap data received at the video I / F 205. When printing is completed, unlike the flowchart of FIG. 7, the process proceeds to S711. Since S711 to S713 are the same as the control described with reference to the flowchart of FIG. 7, the description is omitted.

[0058] When differential image data is generated by S713, the CPU 214 of the diagnostic unit 108 at S1103 performs a diagnosis of abnormalities from the feature information such as the shape and period of the difference in the differential image data. From the diagnosis result of the abnormality, if an abnormality is found, the process proceeds to S1104, and if no abnormality is found, the process proceeds to S723.

[0059] At S1104, the CPU 214 identifies the parts that are the cause of the abnormality based on the feature information of the differential region. Specifically, the CPU 214 selects combinations with the same color and high similarity within the differential region, and identifies which part is abnormal from the period information of the selected combinations. Since the identification method is the same as the control described in S715 above, a detailed description is omitted. Subsequently, at S1105, the CPU 214 determines whether the cause has been identified. If the cause can be identified, the process proceeds to S1106, and if it cannot be identified, the process proceeds to S723. At S1106, the CPU 214 stores the parts and repair content identified at S1105 in the HDD unit 216 and proceeds to S723.

[0060] At S723, the CPU 251 of the external controller 102 determines whether the printing of all pages of the print job for diagnosing abnormalities has been completed. If it has been completed, the process proceeds to S1107, and if it has not been completed, the process proceeds to S708. At S1107, if there is repair content saved at S1106, the CPU 214 of the diagnostic unit 108 proceeds to S725, and if not, the process of this flowchart ends. At S725, the CPU 214 notifies the printing unit of the repair content corresponding to the cause in FIG. 10, and the printing unit implements the corresponding repair content. If there are multiple repair contents, the repairs are performed sequentially. Further, at S1108, the CPU 214 displays the content of the repair that has been implemented at S725 on the UI display unit 241, and the process of this flowchart ends.

[0061] <Repair process when an abnormality is found in the inspection and product inspection process> Using FIGS. 7 and 11 described above, the preliminary diagnosis and the image diagnosis were explained. Abnormalities can also be detected during inspection. The processing procedure for performing image diagnosis and repair from the abnormalities detected during inspection will be described with reference to FIG. 12. FIG. 12 is started by a print instruction from the printing unit 107 in a state where the inspection diagnosis and the image diagnosis are set in advance. For the control similar to the flowcharts of FIGS. 7 and 11, the same reference numerals are given and the description is omitted. The processing described below is executed by the CPU 206 of the printing unit 107, the CPU 214 of the diagnosis unit 108, and the CPU 251 of the external controller 102. Here, a form in which various CPUs cooperate to execute the processing described below will be described, but a form in which an integrated single CPU provided in the image forming apparatus executes all the processing may also be used.

[0062] In S1201, the CPU 214 of the diagnosis unit 108 sets the inspection diagnosis level in the user mode via the UI display unit 241 also serving as the operation unit, based on the inspection inspection level 501 of the diagnosis level setting in FIG. 5. Here, the description is based on the user's UI setting, but the service technician can also set it from the service mode. Even if the inspection diagnosis fails, there are cases where the abnormality is not a printer abnormality but occurs suddenly. Therefore, in S1202, the CPU 214 initializes the counter NG for counting the number of consecutive occurrences of inspection NG to NG = 0 in order to confirm that the inspection NG is not sudden. Further, in S1203, the CPU 214 initializes the counter N for counting the number of printed pages to N = 0.

[0063] In S708, the CPU 251 of the external controller 102 generates a bitmap for rasterizing and printing the page to be printed. Subsequently, in S709, the CPU 251 transmits the rasterized bitmap data from the video I / F 258 through the video cable 106 to the video I / F 205 of the printing unit 107. The CPU 206 of the printing unit 107 performs halftone processing on the bitmap data received at the video I / F 205, and the printing unit 203 performs printing based on the image data after the halftone processing.

[0064] In S1204, the CPU 214 of the diagnostic unit 108 increments a counter N for counting the number of printed pages by N = N + 1. Subsequently, in S711, the CPU 214 changes the resolution and the like of the rasterized bitmap to be printed so that it can be differentially compared with the printed image read from the printed matter in S712 described later, and generates a reference image to be the object of print comparison. In S712, the CPU 214 executes a process of reading the printed matter by the image reading units 331 and 332. The read image is stored in the HDD unit 216 of the diagnostic unit 108 as a diagnostic image. When the diagnostic image is stored, the process proceeds to S713. In S713, the CPU 214 compares the reference image to be the object of print comparison with the read diagnostic image, and generates differential image data for determining an abnormality in the printing unit 107.

[0065] In S1103, the CPU 214 performs an abnormality diagnosis based on feature information such as the shape and period of the difference from the differential image data in S713. From the abnormality diagnosis result, if an abnormality is found, the process proceeds to S1207, and if no abnormality is found, the process proceeds to S1205. In S1205, the CPU 214 sets NG(N) = 0 because the inspection is not NG for N pages in order to count multiple occurrences of inspection NG. Subsequently, in S1206, since the inspection was not NG, the CPU 214 initializes a counter NG for counting multiple occurrences of inspection NG to check whether multiple consecutive inspection NG have occurred to NG = 0, and proceeds to S723. That is, NG(N) is a variable indicating the presence or absence of detection of inspection NG on the Nth page, and NG is a variable indicating the number of consecutive occurrences of inspection NG.

[0066] On the other hand, in S1207, since the CPU 214 counts the number of occurrences of inspection NG, NG(N) = 1 because inspection NG was detected on the Nth page. Further, in S1208, the CPU 214 displays a message indicating that inspection NG has been detected on the UI display unit 241. Subsequently, in S1209, the CPU 214 determines whether N = 1 or whether the previous page was continuously inspection NG. If it is continuous, the process proceeds to S1210, and if it is not continuous, the process proceeds to S1206.

[0067] At S1210, the CPU 214 stores the inspection NG image in the HDD unit 216. Subsequently, at S1211, the CPU 214 increments the counter NG for counting the number of consecutive occurrences of inspection NG by NG = NG + 1. At S1212, the CPU 214 determines whether the number of consecutive occurrences of inspection NG has reached 5 times (predetermined number of times). If the number of consecutive occurrences has reached 5 times, it proceeds to S718; if not, it proceeds to S723. Here, the case of 5 consecutive times has been described as the threshold for determining non - suddenness. However, the present invention is not intended to be limited, and any number of times can be set.

[0068] At S718, the CPU 214 determines that an abnormality has occurred in the device and stops the printing by the printing unit 107. Subsequently, at S1104, the CPU 214 identifies the parts that are the cause of the abnormality based on the feature information of the difference region. Specifically, the CPU 214 selects combinations with the same color and high similarity within the difference region, and identifies which part is abnormal from the cycle information of the selected combinations. Since the specific method is the same control as S715 described above, detailed description is omitted.

[0069] At S1105, if the cause can be identified at S1104, the CPU 214 proceeds to S725; if not, it proceeds to S1212. At S725, the CPU 214 notifies the printing unit 107 of the repair content corresponding to the cause in FIG. 10, and the printing unit 107 implements the corresponding repair content. If there are multiple repair contents, the repairs are performed sequentially. Subsequently, at S1108, the CPU 214 displays the content of the repair already implemented at S725 on the UI display unit 241 and ends the processing of this flowchart. On the other hand, at S1212, since the cause cannot be identified from the inspection NG image, the CPU 214 implements the processing flow of the image diagnosis process described with reference to FIG. 11 and proceeds to S1213.

[0070] In S1213, the CPU 214 initializes a counter NG for counting the number of consecutive occurrences of inspection NG to NG = 0, and proceeds to S723. In S723, the CPU 251 of the external controller 102 checks whether the printing of all pages of the job to be printed has been completed. If it has been completed, the processing of this flowchart ends. If it has not been completed, the process proceeds to S708.

[0071] <Timing of Repair Processing> With reference to FIG. 9, an example of the timing setting for repairing the difference (precursor) of the diagnostic result according to the present embodiment will be described. Since there is a grace period until an abnormality occurs, the timing of repair when a precursor is detected can be implemented at multiple timings. Therefore, in the printing system according to the present embodiment, the timing can be set via the setting screen 900 shown in FIG. 9. The setting screen 900 may be displayed, for example, on the UI display unit 241 of the diagnostic unit 108, or may be displayed on the display units 264 and 254 of the client PC 103 or the external controller 102. According to the user input via the setting screen 900, the diagnostic unit 108 sets the repair timing when a precursor is detected.

[0072] As shown in FIG. 9, for example, when it is set after power-on, after the power of the image forming apparatus 101 is turned on and it starts up, the unperformed repair content is executed. When it is set before the start of job printing, before printing when a print job is received, the unperformed repair content is executed. When immediate response is set, as described with reference to FIG. 7, printing is stopped as soon as a precursor is found, and the repair content of the found precursor is executed.

[0073] When it is set after the precursor is detected and after printing is stopped, the repair content of the detected precursor is implemented at the timing when printing stops after the precursor is found. When it is set after the job printing is completed, the repair content of the detected precursor is implemented at the timing when the execution of the printing job in progress when the precursor is found is completed. When it is set before the end at the time of power-off, when the power-off button is operated and the image forming apparatus 101 is terminated, the unimplemented repair content is implemented before the actual termination. At the time of individual designation, when the timer designated time is set, the user can set the desired execution timing by operating an individual correction execution button (not shown) individually. The timer designated time is such that after printing is stopped after the execution time is designated with the time designation button, the unimplemented repair content is implemented. Note that the timing shown in FIG. 9 is an example of the present invention and does not limit the present invention. Also, a plurality of these timings may be set simultaneously. In that case, when the set execution timing is reached, if the unimplemented repair content is held, it will be implemented.

[0074] <Repair content> Referring to FIG. 10, the factor parts and their repair content based on the characteristics of the difference (precursor or abnormality) of the diagnosis result according to the present embodiment will be described. The table shown in FIG. 10 is held in the HDD unit 216 of the diagnosis unit 108 and is used when specifying the factor parts and their repair content according to the difference in the diagnosis result.

[0075] Based on the shape (streak or spot), the directionality of the shape, and the period corresponding to the precursor or abnormality of the difference image detected using the table, the factor parts and the cause are specified. For example, when a linear streak shape is occurring horizontally and the factor part is specified as the photosensitive drum from the characteristics (period) of the streak. In that case, as the cause, since it is streaky, it is considered that dust or the like has adhered to the cleaning blade that cleans the photosensitive drum, resulting in streaks, and it is determined that the cleaning of the photosensitive drum is defective. From the factor part and the cause, the repair content is selected as the cleaning of the cleaning blade of the photosensitive drum, and the repair is performed by implementing the cleaning.

[0076] Also, a case will be described where something in the shape of a dot like a pimple occurs, and when the factor part is identified as the photosensitive drum from the characteristics (period) of the pimple. In this case, since it is pimply, it is considered that dust or the like is attached to the photosensitive drum, and it is determined that there is dust attached to the photosensitive drum. From the factor part and the cause, the repair content is selected as cleaning of the photosensitive drum, and the repair is performed by carrying out the cleaning.

[0077] In this way, according to the present embodiment, the cause is identified from the precursors, the shape of the abnormality, the direction, etc., the repair content suitable for the cause is selected and carried out, and thus the repair is performed. It goes without saying that the content shown in FIG. 10 is a part of the repair content and does not limit the present invention.

[0078] <Precursor Image Diagnosis Settings> Referring to FIG. 14, an example of the setting screen for precursor image diagnosis according to the present embodiment will be described. The setting screen 1400 may be displayed, for example, on the UI display unit 241 of the diagnosis unit 108, or may be displayed on the display units 264 and 254 of the client PC 103 or the external controller 102.

[0079] During printing of the precursor image diagnosis, the user can pre-select whether to automatically repair the found precursors by operating buttons 1401 and 1402. If the user has not set it, it is assumed that button 1401 is selected as the default setting. Also, when button 1403 is selected for automatic repair, the timing for automatic repair is set via the setting screen 900 for detailed timing setting shown in FIG. 9. The detailed timing setting can be set at various setting timings such as when a precursor is found, when a job is specified, and when an unexecuted automatic repair log is displayed. Also, it is not intended to limit the present invention to the precursor image diagnosis setting shown in FIG. 14.

[0080] As described above, when a precursor of an abnormality in the image forming unit is detected, the diagnostic apparatus according to the present embodiment selects and sets the timing for repairing the image forming unit according to a user operation. Further, the present diagnostic apparatus diagnoses an abnormality and its precursor in the image forming unit from an image formed by the image forming unit, and when a precursor of an abnormality is detected, causes a repair process of the image forming unit to be executed at the set timing. According to the present embodiment, it is possible for the user to select the timing for repairing the precursor of the abnormality found by diagnosis, and repair can be performed at a timing convenient for the user, thereby preventing a decrease in the user's productivity. Note that, in the present embodiment, a form of setting the repair timing when a precursor of an abnormality is detected has been described, but the present invention is not intended to be limited. For example, in the present invention, instead of immediately performing automatic repair even when an abnormality is detected, the timing for performing automatic repair may be set according to a user setting. In this case, for an abnormality that requires immediate response, when the abnormality is detected, automatic repair may be immediately executed, and for an abnormality that does not, it may be executed at a timing according to the user setting. A form of individually setting the repair timing according to the type of abnormality will be described in detail in the following second embodiment. Although the second embodiment also describes the case when a precursor of an abnormality is detected, the present invention is not intended to be limited and may be applied when an abnormality is detected.

[0081] Further, the above-described diagnostic apparatus can be provided in various device configurations. For example, the above-described diagnostic apparatus may be provided as a device included in an image forming apparatus including an image forming unit and a reading unit, or may be provided as a device separate from the image forming apparatus. Alternatively, the above-described diagnostic apparatus may be integrally provided in the image forming apparatus 101 together with the external controller 102. When the diagnostic apparatus is configured as a device separate from the image forming apparatus, a recording medium printed by the image forming apparatus is read by a scanner inside or outside the image forming apparatus, and the read image is acquired to execute a diagnosis.

[0082] <Second Embodiment> The second embodiment of the present invention will be described below. In the above first embodiment, an example was described in which repair is performed at the timing selected by the user regardless of the repair content for repairing the precursors found by the precursor diagnosis. In this embodiment, an example in which the repair timing can be individually selected for each repair content described with reference to FIGS. 15 and 16 will be described. FIG. 15 shows the situation of individual repair content and repair timing, and the UI screen for individual repair timing setting. FIG. 16 shows the UI screen for individual repair timing setting.

[0083] On the setting screens 1500 and 1510 shown in FIG. 15, the repair timing can be set for each repair content. Also, for each repair content, the individual repair timing can be set individually in the individual repair timing setting (1502). As the default standard setting, as shown in the setting screen 1500, each repair content conforms to the detailed timing setting (1501). Also, as shown in FIG. 16, in the setting screen 1600 for individual correction timing, conformity to the detailed timing setting (1601) is selected. That is, the repair is executed at the timing set in the detailed timing setting screen 900 described with reference to FIG. 9.

[0084] Generally, for repair, as shown in the setting screens 1500 and 1510, paper is often not required during repair. However, for the secondary transfer voltage adjustment, during repair, printing is performed while changing the transfer current to the paper, and an appropriate transfer voltage is detected for repair. Therefore, it is desirable to perform the repair using the paper that will actually be printed. Thus, when the repair content is the secondary transfer voltage adjustment, as shown in the setting screen 1510, it is possible to change and perform the repair before the start of job printing (1503). In practice, by selecting before the start of job printing (1602) in the individual repair timing setting of the setting screen 1610, it becomes possible to make the change. Note that in practice, the transfer voltage is corrected according to the paper, but when starting printing by changing the type of paper to be printed, by setting before the start of job printing (1602), it becomes possible to perform a more accurate repair. On the other hand, when paper is not used, since there is no difference due to paper, it may be executed at any time. Therefore, the same effect can be obtained by making it possible to select the timing depending on whether the repair content uses paper or not.

[0085] As described above, the diagnostic apparatus according to the present embodiment can individually set the timing for performing the repair of the image forming unit for each content of the automatic repair. According to the present embodiment, by making it possible to select the repair timing according to the repair content (or abnormality type), it becomes possible to further improve the repair effect. In addition, since the repair timing can be individually set according to the repair content and the abnormality type, it is possible to provide a more user-friendly operation system.

[0086] <The Third Embodiment> Hereinafter, a third embodiment of the present invention will be described. In the above first and second embodiments, an example was described in which the user selects the timing to repair the precursors found by the precursor diagnosis and performs the repair according to the selected timing. However, if a large number of printed sheets are printed after finding a precursor until the selected repair timing arrives, the possibility that the precursor will become abnormal before repair increases. At that time, if inspection and product inspection are being performed, the abnormality is determined as NG in the inspection, and the printed material is discharged as waste paper to the escape tray 346, resulting in waste of paper. Therefore, in the present embodiment, in order to prevent it from becoming abnormal, an example will be described in which the print count from the detection of the precursor to the time of becoming abnormal is predicted, and before the predetermined number of sheets of the prediction, separately from the selected timing, forced repair is performed before the precursor becomes abnormal.

[0087] <Forced execution setting> With reference to FIG. 17, the processing procedure related to the forced execution setting of automatic repair according to the present embodiment will be described. The symbol "S" in the description of the flowchart represents a step. For the same control as the flowchart of FIG. 7, the same reference numerals will be given and the description will be omitted. The processing described below is executed by the CPU 214 of the diagnosis unit 108.

[0088] First, in S715, the CPU 214 of the diagnosis unit 108 identifies the parts that are the cause of the precursor based on the feature information of the difference region. Among the difference regions, a combination with the same color and high similarity is selected, and it is identified which part is abnormal from the cycle information of the selected combination. In S716, the CPU 214 checks the detailed timing setting set in S703 of FIG. 7. In S721, the CPU 214 stores the parts identified in S715 of FIG. 7, the repair content, and the timing confirmed in S717 of FIG. 7 in the HDD unit 216.

[0089] In S1701, the CPU 214 stores the print output count (number of image formations) of the print unit 107 for which a precursor has been detected in the HDD unit 216. FIG. 18 shows the relationship between the print counter at the time when a precursor is detected and the print counter for anomaly prediction. The vertical axis indicates the size of the dot that is the precursor, and the horizontal axis indicates the number of printed sheets. In the example of FIG. 18, since the print output count when a precursor is detected (1801) is 2000, in S1701, the CPU 214 stores 2000 in the HDD unit 216 as the print output count.

[0090] In S1702, the CPU 214 predicts that the print count (number of image formations) from the precursor size 1801 to the anomaly size 1802 will be 4000 (1803). For example, the CPU 214 can obtain this from a value stored in advance as a predicted value from the precursor size (for example, information corresponding to the graph shown in FIG. 18). From such a graph, when a predetermined number of sheets for performing repair before becoming abnormal is 500 sheets (1804) earlier, the forced execution count is obtained by the following formula (1).

[0091] Forced execution count = Print output count + Print count until becoming abnormal - Predetermined number of sheets ··· Formula (1) The CPU 214 can obtain the forced execution count "5500" using the above formula and stores this value in the HDD unit 216 as the forced execution count. Also, if the repair has not been performed before the automatically set repair timing until the counter reaches 5500, the CPU 214 displays on the UI screen that the repair will be forcibly performed to notify the user. Note that the numerical value of the count is an example and can be determined according to the content of the repair, or can also change depending on the state of the print unit 107, and is not limited to this numerical value.

[0092] <Forced Execution of Automatic Repair> Referring to FIG. 19, the processing procedure for forcibly performing repair during printing according to this embodiment will be described. The processing described below is executed by the CPU 206 of the printing unit 107, the CPU 214 of the diagnosis unit 108, and the CPU 251 of the external controller 102. Here, the description will be given in a form where various CPUs cooperate to execute the processing described below, but it may also be a form where an integrated single CPU provided in the image forming apparatus executes all the processing. The flowchart of FIG. 19 starts together with printing.

[0093] First, in S709, the CPU 206 of the printing unit 107 performs printing based on the image data of the bitmap data received by the video I / F 205. Subsequently, in S1901, the CPU 214 of the diagnosis unit 108 determines whether or not repair has been performed at the automatic repair timing based on the repair content stored previously in S721 of FIG. 7. If repair has been performed at the automatic repair timing, the process proceeds to S723; if not, the process proceeds to S1902.

[0094] In S1902, the CPU 214 checks whether the print count is 5500, which is the forced execution count calculated in S1702 of FIG. 17. If it is 5500, the process proceeds to S718; if it is not the forced execution count, the process proceeds to S723.

[0095] In S718, the CPU 214 determines that it is the timing for forcibly performing automatic repair and stops the printing. Subsequently, in S719, the CPU 214 notifies the printing unit 107 of the factor parts and the repair content corresponding to the cause in FIG. 10, and the printing unit 107 performs the corresponding repair content. In S1903, the CPU 214 displays on the UI display unit 241 the content of the repair performed in S719 and the fact that repair was forcibly performed before the precursor became abnormal, and then proceeds to S723. In S723, the CPU 251 of the external controller 102 confirms that the printing of all pages has ended. If it has ended, the processing of this flowchart ends; if not, the process returns to S709.

[0096] In this embodiment, although the repair is forcibly performed before the precursor becomes abnormal, if the inspection is carried out, the abnormality will ultimately be removed by the inspection. Therefore, if the inspection is not carried out, it is desirable to forcibly execute the repair.

[0097] As described above, when the diagnostic apparatus according to this embodiment detects a precursor of an abnormality, it predicts the number of image formations until the precursor changes abnormally. Further, based on the predicted number of image formations, the diagnostic apparatus determines the timing for forcibly performing the repair of the image forming unit before the precursor changes abnormally and before the set timing. Thus, according to this embodiment, it is possible to forcibly perform the repair before the precursor found by the precursor diagnosis becomes abnormal, in order to prevent the precursor from becoming abnormal before the repair timing. This makes it possible to prevent the printed product from becoming abnormal and being rejected in the inspection, and to prevent the waste of the printed product.

[0098] The disclosure of this specification includes the following diagnostic apparatus, its control method, program, and image forming apparatus. (Item 1) A diagnostic apparatus, a setting means for selecting and setting the timing for repairing the image forming means when a precursor of an abnormality in the image forming means is detected, in response to a user operation; a diagnostic means for diagnosing an abnormality and its precursor of the image forming means from an image formed by the image forming means; a repair means for executing a repair process of the image forming means at the set timing when the precursor of the abnormality is detected by the diagnostic means A diagnostic apparatus characterized by comprising: (Item 2) The diagnostic means includes a specifying means for specifying, from an image used for diagnosis, a part that is the cause and the content of automatic repair when detecting the abnormality or its precursor; a storage means for storing the content of automatic repair of the specified part that is the cause and the set timing when the precursor of the abnormality is detected and comprises The diagnostic apparatus according to item 1, wherein when the content and timing of the automatic repair stored in the storage means are stored, the repair means executes a repair process corresponding to the content of the automatic repair at the timing. (Item 3) The diagnostic apparatus according to item 2, wherein when the repair means executes the repair process, the content and timing of the automatic repair stored in the storage means are deleted. (Item 4) The setting means can select and set at least one of the following timings for performing repair when a precursor of the abnormality is detected: after the image forming means is powered on, before image formation by the image forming means, the timing when the precursor of the abnormality is detected, the timing when the ongoing image formation ends after the precursor of the abnormality is detected, after image formation by the image forming means, before the end when the power of the image forming means is turned off, and an individually specified timing. The diagnostic apparatus according to any one of items 1 to 3. (Item 5) The diagnostic apparatus according to any one of items 1 to 4, wherein the setting means further sets a threshold level for determining an abnormality or its precursor by the diagnostic means according to a user operation. (Item 6) The diagnostic apparatus according to item 5, wherein the setting means can select and set at least two or more levels from the level of detecting earlier to the level of detecting later as the threshold level for determining the precursor of the abnormality. (Item 7) The diagnostic apparatus according to any one of items 1 to 6, wherein the setting means further sets whether to diagnose the precursor of the abnormality when the image forming means performs image formation according to a user operation. (Item 8) The diagnostic apparatus according to item 4, wherein the setting means can individually set the timing for repairing the image forming means for each content of the automatic repair. (Item 9) The diagnostic means, in the diagnosis for each formed image, determines that there is an abnormality in the image forming means when an abnormality is continuously detected a predetermined number of times. The diagnostic apparatus according to any one of Items 1 to 8. (Item 10) When a precursor of the abnormality is detected, prediction means for predicting the number of images to be formed until the precursor changes to an abnormality, Based on the predicted number of images to be formed, determination means for determining a timing for forcibly performing repair of the image forming means before the precursor changes to an abnormality and before the set timing. The diagnostic apparatus according to any one of Items 1 to 9, further comprising the above. (Item 11) A control method for a diagnostic apparatus, A setting step in which setting means selects and sets a timing for repairing the image forming means in response to a user operation when a precursor of an abnormality in the image forming means is detected; A diagnostic step in which diagnostic means diagnoses an abnormality and its precursor of the image forming means from an image formed by the image forming means; A repair step in which repair means executes a repair process of the image forming means at the set timing when the precursor of the abnormality is detected in the diagnostic step. A control method for a diagnostic apparatus, comprising the above. (Item 12) A program for causing a computer to execute each step in a control method for a diagnostic apparatus, the control method comprising: A setting step in which setting means selects and sets a timing for repairing the image forming means in response to a user operation when a precursor of an abnormality in the image forming means is detected; A diagnostic step in which diagnostic means diagnoses an abnormality and its precursor of the image forming means from an image formed by the image forming means; A repair step in which repair means executes a repair process of the image forming means at the set timing when the precursor of the abnormality is detected in the diagnostic step. A program, characterized by including the above. (Item 13) An image forming apparatus, image forming means for forming an image on a recording medium, reading means for reading the recording medium on which an image has been formed by the image forming means, the diagnostic apparatus according to any one of Items 1 to 10, and an image forming apparatus characterized by comprising the same.

[0099] <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 apparatus via a network or a storage medium, and causing one or more processors in a computer of the system or apparatus to read and execute the program. Further, it can also be realized by a circuit (for example, ASIC) that realizes one or more functions.

[0100] The invention is not limited to the above embodiments, and various changes and modifications can be made without departing from the spirit and scope of the invention. Therefore, the claims are attached to disclose the scope of the invention.

Explanation of Reference Numerals

[0101] 100: Printing system, 101: Image forming apparatus, 102: External controller, 103: Client PC, 104: External LAN, 105: Internal LAN, 106: Video cable, 107: Printing unit, 108: Diagnostic unit, 109: Stacker, 110: Finisher

Claims

1. 1. A diagnostic device comprising: a setting means for selecting and setting the timing for repairing the image forming means when a sign of an abnormality in the image forming means is detected in response to a user operation; a diagnostic means for diagnosing abnormalities and signs of abnormalities in the image forming means from the images formed by the image forming means; a repair unit that executes repair processing of the image forming unit at the set timing when the diagnostic unit detects a sign of the abnormality; A diagnostic device comprising:

2. The diagnostic means comprises: an identification means for, when detecting the abnormality or a sign thereof, identifying the part causing the abnormality and the content of automatic repair from the image used for diagnosis; a storage means for storing the details of automatic repair of the identified part causing the abnormality and the set timing when the abnormality precursor is detected; Equipped with The diagnostic device according to claim 1, characterized in that, when the content of the automatic repair and the timing are stored in the memory means, the repair means executes a repair process corresponding to the content of the automatic repair at the timing.

3. 3. The diagnostic device according to claim 2, wherein the restoration means deletes the content of the automatic restoration and the timing stored in the storage means when the restoration process is executed.

4. The diagnostic device according to claim 1, characterized in that the setting means can select and set at least one of the following timings for performing repair when a sign of the abnormality is detected: after power is turned on to the image forming means, before image formation by the image forming means, when the sign of the abnormality is detected, when image formation currently being performed after the sign of the abnormality is detected is completed, after image formation by the image forming means is completed and before completion when power to the image forming means is turned off, and an individually specified time.

5. 2. The diagnostic device according to claim 1, wherein the setting means further sets a threshold level for determining an abnormality or a sign thereof by the diagnostic means in response to a user operation.

6. The diagnostic device according to claim 5, wherein the setting means can select and set the threshold level for determining whether the abnormality is a precursor to the abnormality from at least two or more levels ranging from a level for early detection to a level for late detection.

7. 2. The diagnostic device according to claim 1, wherein the setting unit further sets whether or not to diagnose the abnormality precursor when the image forming unit performs image formation, in response to a user operation.

8. 5. The diagnostic device according to claim 4, wherein the setting means can set the timing for repairing the image forming means individually for each type of automatic repair.

9. 2. The diagnostic device according to claim 1, wherein said diagnostic means determines that an abnormality exists in said image forming means when an abnormality is detected a predetermined number of times consecutively in the diagnosis of each formed image.

10. a prediction means for predicting, when the sign of the abnormality is detected, the number of images to be formed until the sign of the abnormality changes to an abnormal state; a determining means for determining a timing for forcibly performing repair of the image forming means before the symptom changes to an abnormal state and before the set timing, based on the predicted number of sheets of image formation; The diagnostic device according to claim 1, further comprising:

11. A method for controlling a diagnostic device, comprising: a setting step in which a setting unit selects and sets, in response to a user operation, a timing for repairing the image forming unit when a sign of an abnormality in the image forming unit is detected; a diagnostic step in which a diagnostic means diagnoses an abnormality or a sign thereof in the image forming means from an image formed by the image forming means; a repairing step in which a repairing unit executes repair processing of the image forming unit at the set timing when a sign of the abnormality is detected in the diagnosing step; A method for controlling a diagnostic device, comprising:

12. A program for causing a computer to execute each step of a method for controlling a diagnostic device, the control method comprising: a setting step in which a setting unit selects and sets, in response to a user operation, a timing for repairing the image forming unit when a sign of an abnormality in the image forming unit is detected; a diagnostic step in which a diagnostic means diagnoses an abnormality or a sign thereof in the image forming means from an image formed by the image forming means; a repairing step in which a repairing unit executes repair processing of the image forming unit at the set timing when a sign of the abnormality is detected in the diagnosing step; A program comprising:

13. An image forming apparatus, an image forming means for forming an image on a recording medium; a reading means for reading a recording medium on which an image is formed by the image forming means; A diagnostic device according to any one of claims 1 to 10. An image forming apparatus comprising:

Images