Image forming device, replacement part damage determination method, and program

Abstract

To enable appropriate management of the condition of replacement parts of an image forming device.SOLUTION: An image forming device is provided, comprising: a measurement unit equipped with a camera for capturing images of the outside and configured to measure the exposure state of a replacement part 12 on the outside; a determination unit configured to use a machine learning model to compute an exposure rate based on a measurement result of the measurement unit and determine the degree of damage to the replacement part 12; and a recovery control unit configured to provide control to execute a refresh mode based on a determination result of the determination unit to cause damage recovery of the replacement part 12.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to an image forming apparatus for determining the degree of damage to a replacement part, and a method and program for determining the degree of damage to a replacement part. [Background technology]

[0002] Conventional image forming device control technologies primarily rely on information from internal sensors. This approach has the drawback of not fully taking into account various external factors related to the image forming device's external environment and user operation, such as indoor lighting conditions, humidity, the presence of dust, noise and air pressure changes during operation, and vibrations and shocks during installation and preparation. These external factors can damage image forming device consumable parts and cause unexpected degradation of image quality. In particular, photofatigue caused by light exposure is known to change the chemical structure of the photoreceptor's charge generation layer, reducing its charge generation ability and affecting the photoreceptor potential. For this reason, inspections and repairs must be carried out carefully to avoid exposing the photoreceptor to external sources. For example, Reference 1 describes an image forming device that detects when a photoreceptor drum unit has been removed from the image forming device and issues a warning when a predetermined period of time has elapsed. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2018-185351 Summary of the Invention [Problem to be solved by the invention]

[0004] During replacement, deterioration of photoconductor drums due to light fatigue is assumed to occur while the photoconductor drum is protected by a protective sheet. Prolonged exposure to light during replacement is not typically anticipated. However, when the unit is unpacked during replacement, it may be exposed to indoor lighting. In particular, if an inexperienced worker removes the protective sheet and exposes the photoconductor drum to light for extended periods, light fatigue can cause the charge generation layer to degrade in efficiency. This can lead to periodic density variations after the photoconductor drum is inserted into the image forming device. Similarly to light fatigue, humidity, an external influence, can affect the photoconductor drum's charge supply layer, causing similar problems, such as a decrease in charge supply. However, the amount of time the protective sheet is removed alone does not accurately assess the exposure status of the photoconductor drum, which is a replacement part, and therefore makes it difficult to properly assess the degree of damage. The present invention has been made to solve such problems, and aims to provide an image forming device or a method and program for determining the damage level of a replacement part that appropriately determines the damage level of a replacement part of an image forming device. [Means for solving the problem]

[0005] In order to solve the above problems, an image forming apparatus and a method and program for determining the damage level of a replacement part according to the present invention have the following configurations (1) to (13). (1) An image forming apparatus including: a measuring unit that measures an exposure state of a replacement part outside; and a determining unit that determines a degree of damage to the replacement part based on the measurement result of the measuring unit. (2) The image forming apparatus according to (1), wherein the measuring unit has a camera that captures an image of the replacement part outside. (3) An image forming apparatus as described in (2) that includes an exposure detection unit that detects an exposure rate, which is an indicator of the exposure state of the replacement part, and the exposure detection unit calculates the exposure rate for an image of the replacement part using a machine learning model. (4) The image forming apparatus according to (1), wherein the measuring unit has an illuminance meter that measures external illuminance. (5) The image forming apparatus according to (1), wherein the measuring unit has a hygrometer that measures the external humidity. (6) The image forming apparatus according to (3), wherein the determining unit determines the degree of damage using the exposure rate and illuminance and / or humidity. (7) The image forming apparatus according to (1), further comprising a determination correction unit that corrects the degree of damage in accordance with the elapsed time from when the degree of damage is determined to when the replacement part is installed. (8) The image forming apparatus according to any one of (1) to (7), further comprising a recovery control unit that recovers damage to the replacement part based on the determination result of the determination unit. (9) The image forming apparatus according to (8), wherein the recovery control unit repeatedly executes the operation of recovering the replacement part a number of times according to the degree of damage. (10) The image forming apparatus according to any one of (1) to (7), further comprising a replacement time notification unit that corrects the replacement time of the replacement part according to the degree of damage and notifies the corrected replacement time. (11) The image forming apparatus according to any one of (1) to (7), further comprising a countermeasure notification unit that notifies a user of a countermeasure according to the degree of damage. (12) A method for determining the degree of damage to a replacement part, comprising the steps of measuring the exposure state of the replacement part outside, and determining the degree of damage to the replacement part based on the exposure state of the replacement part. (13) A program for causing a computer to execute a procedure for measuring the exposure state of a replacement part outside, and a procedure for determining the degree of damage to the replacement part based on the exposure state of the replacement part. [Effects of the Invention]

[0006] According to the present invention, the degree of damage to a replacement part of an image forming apparatus can be appropriately determined. [Brief explanation of the drawings]

[0007] [Figure 1A] 1 is a side view illustrating an outline of an image forming apparatus according to an embodiment of the present invention; [Figure 1B] 1 is a plan view illustrating an outline of an image forming apparatus according to an embodiment of the present invention; [Figure 1C]1 is a diagram illustrating an internal configuration of an image forming apparatus according to an embodiment of the present invention. [Figure 2A] 1 is a block diagram illustrating a hardware configuration of an image forming apparatus according to a first embodiment. [Figure 2B] 3 is a block diagram illustrating the functional configuration of a control unit according to the first embodiment. FIG. [Figure 3A] FIG. 10 is a diagram showing image information of a replacement part corresponding to an exposure rate of 100%. [Figure 3B] FIG. 10 is a diagram showing image information of a replacement part corresponding to an exposure rate of 0%. [Figure 3C] FIG. 10 is a diagram showing image information of replacement parts corresponding to an exposure rate of 50%. [Figure 3D] FIG. 10 is a diagram showing image information of replacement parts corresponding to an exposure rate of 50%. [Figure 4] FIG. 10 is a diagram showing image information of a replacement part acquired by a camera of the measurement unit. [Figure 5A] 10 is a flowchart of a process for learning training data in which image information is labeled with an exposure rate. [Figure 5B] 10 is a flowchart of a process for outputting an exposure rate. [Figure 6] FIG. 10 is a diagram illustrating an example of criteria for determining the degree of damage. [Figure 7] 3 is a flowchart of a damage recovery method for a replacement part according to the first embodiment. [Figure 8] FIG. 10 is a block diagram illustrating the functional configuration of a control unit according to a second embodiment. [Figure 9] 10 is a flowchart of a control method for an image forming apparatus according to a second embodiment. [Figure 10] FIG. 10 is a diagram showing a replacement time notification screen. [Figure 11] FIG. 10 is a block diagram illustrating the functional configuration of a control unit according to a third embodiment. [Figure 12] 10 is a flowchart of a control method for an image forming apparatus according to a third embodiment. [Figure 13] FIG. 10 is a diagram showing a screen that notifies the user of measures to be taken against damage to a replacement part. DETAILED DESCRIPTION OF THE INVENTION

[0008] Embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited to these embodiments. [Present embodiment] An image forming apparatus 1 according to this embodiment will be described with reference to Figures 1A, 1B, and 1C. The image forming apparatus 1 is an apparatus that forms images using electrophotography, such as a copier or multifunction peripheral. Figures 1A, 1B, and 1C show parts common to image forming apparatuses 1 of first to third embodiments, which will be described later.

[0009] 1A and 1B, the image forming apparatus 1 includes a measurement unit 20, a determination unit 33, a determination correction unit 34, an auxiliary storage device 53, a communication interface 54, the image forming unit 10, and paper feed trays 191 and 192. The determination unit 33 and the determination correction unit 34 are part of a control unit 30 that controls the image forming apparatus 1. The control unit 30, together with the auxiliary storage device 53 such as a hard disk and the communication interface 54, is disposed inside the image forming apparatus 1, which is covered by an openable and closable access door 18. The camera 22, illuminance meter 24, and hygrometer 26 of the measurement unit 20 are disposed on the outer surface of the image forming apparatus 1. When the access door 18 is opened, part of the image forming unit 10 is exposed, allowing replacement of a replacement part 12.

[0010] 1C, image forming apparatus 1 includes therein a paper feed unit 19, a conveyance unit 17, an image forming unit 10, and a fixing unit 15. Each component of image forming apparatus 1 will be described below.

[0011] (Paper feed section) The paper feed unit 19 includes a plurality of paper feed trays 191 and 192 that store paper sheets. Paper sheets of different sizes are stored in the paper feed trays 191 and 192. The paper sheets stored in the paper feed trays 191 and 192 are transported by the transport unit 17 through a transport path to the image forming unit 10.

[0012] (Image forming section) The image forming unit 10 is a device that forms toner images of yellow (Y), magenta (M), cyan (C), and black (K) on the photosensitive drum 14 based on an image forming job sent from an external device, and transfers the toner images to a recording medium. The image forming unit 10 includes image forming units 130Y, 130M, 130C, and 130K, an intermediate transfer body 11, and a primary transfer unit 137.

[0013] (Image forming unit) 1C, image forming units 130Y, 130M, 130C, and 130K have the same configuration. Below, the configuration of image forming unit 130Y will be described, and descriptions of the other image forming units 130M, 130C, and 130K will be omitted.

[0014] The image forming unit 130Y includes a photosensitive drum 14, a charging unit 134, an exposure unit 135, a developing unit 136, a primary transfer unit 137, and a cleaning unit 133. The replacement part 12 includes the photosensitive drum 14, the charging unit 134, and the cleaning unit 133 from the above configuration.

[0015] (intermediate transfer body) Intermediate transfer body 11 is made up of an endless belt and travels at a constant speed in the direction of the arrow. The intermediate toner images formed by the primary transfer of the respective color toner images onto intermediate transfer body 11 are secondarily transferred onto the paper by pressing intermediate transfer body 11 against the paper by secondary transfer roller 111. The paper is then transported to fixing unit 15 where it is pressurized and heated, thereby fixing the toner image to the paper.

[0016] (Primary transfer section) The primary transfer unit 137 is a roller that transfers the toner image formed on the photosensitive drum 14 of each color onto the intermediate transfer body 11 in the transfer area.

[0017] (Secondary transfer roller) The secondary transfer roller 111 is disposed outside the intermediate transfer body 11 and is positioned so that paper can pass between it and the intermediate transfer body 11. The toner images formed in each of the image forming units 130Y to 130K are transferred onto the intermediate transfer body 11 by the primary transfer section 137, forming a color toner image in which yellow, magenta, cyan, and black layers are superimposed. The toner image formed on the secondary transfer roller 111 is transferred by the secondary transfer roller 111 onto the paper that has been transported thereto.

[0018] (Photosensitive drum) The photosensitive drum 14 is a drum-shaped member that is an image carrier that is driven to rotate. An electrostatic latent image of each color component is formed on the surface of the photosensitive drum 14 due to a potential difference with the surroundings.

[0019] (Charging part) The charging unit 134 is a member for uniformly charging the surface of the photosensitive drum 14. The charging unit 134 uses a charger to charge the surface of the photosensitive drum 14 to a constant potential.

[0020] (exposed area) The exposure unit 135 is a part for forming an electrostatic latent image by exposing the surface of the photosensitive drum 14 charged by the charging unit 134. The exposure unit 135 is configured with, for example, a semiconductor laser, and irradiates the photosensitive drum 14 with laser light corresponding to an image of each color component.

[0021] (development section) The developing unit 136 is a part that visualizes the electrostatic latent image formed on the photosensitive drum 14 by the exposure unit 135 using a developer containing toner. The developing unit 136 contains developers of each color component, and by attaching the toner of each color component to the surface of the photosensitive drum 14, the electrostatic latent image is visualized to form a toner image.

[0022] Specifically, the developing unit 136 includes a developing sleeve 136a disposed to face the photosensitive drum 14 across a developing region. A developing bias is applied to the developing sleeve 136a, for example, a DC developing voltage having the same polarity as the charging polarity of the charging unit 134, or a developing bias in which an AC voltage is superimposed with a DC voltage having the same polarity as the charging polarity of the charging unit 134. This causes reversal development, in which toner adheres to the electrostatic latent image formed by the exposure unit 135.

[0023] The developer used here contains a toner and a carrier for charging the toner. The toner is not particularly limited, and any commonly used known toner can be used. For example, the toner can be a binder resin containing a colorant and, if necessary, a charge control agent, a release agent, etc., and treated with an external additive.

[0024] The toner image formed on the photosensitive drum 14 by the developing unit 136 is carried to a transfer area formed between the photosensitive drum 14 and the primary transfer unit 137. In the transfer area, a voltage of the opposite polarity to that of the toner is applied to the primary transfer unit 137. The toner image on the photosensitive drum 14 is transferred onto the intermediate transfer member 11.

[0025] The toner remaining on the photosensitive drum 14 without being transferred onto the intermediate transfer body 11 in the transfer area is collected by a cleaning unit 133 . Furthermore, the photosensitive drum 14 from which the toner on the surface has been collected by the cleaning unit 133 is again charged by the charging section 134, and the next electrostatic latent image is formed, and the process of forming a toner image is repeated.

[0026] During image formation in the image forming unit 10, the charging unit 134 uniformly charges the photosensitive material formed as a film on the cylindrical surface of the photosensitive drum 14. Next, the exposure unit 135 exposes the photosensitive drum 14 to light to form an electrostatic latent image. The developing unit 136 uses electrostatic force to attach toner to the photosensitive drum 14 on which the electrostatic latent image has been formed, forming a toner image. The primary transfer unit 137 transfers the toner images formed on the photosensitive drum 14 for each color to the intermediate transfer body 11 in the transfer region. After the toner images formed on the photosensitive drum 14 are transferred to the intermediate transfer body 11, the cleaning unit 133 removes any toner remaining on the surface of the photosensitive drum 14. The charging unit 134 then uniformly charges the photosensitive drum 14 again. In this way, the image forming unit 10 can repeatedly form toner images while rotating the photosensitive drum 14.

[0027] Repeated formation of toner images causes the photosensitive material on the surface of the photosensitive drum 14 to wear out, resulting in a deterioration in image quality. Therefore, by replacing the photosensitive drum 14 with a new one, the image quality can be maintained. The photosensitive drum 14 can be replaced in units of a replacement part 12 that is configured to include the photosensitive drum 14. The replacement part 12 may differ depending on the type of image forming apparatus 1. For example, the replacement part 12 may be the photosensitive drum 14 alone, or may include the photosensitive drum 14 and its peripheral components, or may further include other devices in the image forming unit 10. The replacement part 12 may also be the entire image forming unit 10. On the other hand, there may be a period of time when replacement part 12 is left outside image forming apparatus 1 before being installed as a new replacement or when it is temporarily removed for inspection, etc. At this time, the external environment to which photosensitive drum 14 is exposed may cause an unexpected deterioration in image quality. For this reason, it is preferable to manage replacement part 12 while taking the external environment into consideration.

[0028] (Measurement section) The measurement unit 20 is a device that measures the exposure state of the replacement part 12 outside the image forming apparatus 1. The measurement unit 20 has a camera 22, an illuminance meter 24, and a hygrometer 26. Camera 22 is a device that captures images of the outside of image forming apparatus 1. Camera 22 can capture images of replacement parts 12 outside. In this example, camera 22 is installed on the side of image forming apparatus 1 on the side of work door 18, which is the front side of image forming apparatus 1. Camera 22 can monitor replacement parts 12 and their surroundings in real time during replacement work, etc., and can capture images of replacement parts 12 during work. Note that multiple cameras 22 may be installed in different positions to monitor and capture images from multiple directions. The resolution of the camera 22 is preferably 1920 x 1080 pixels or more. Furthermore, the camera 22 preferably has a lens and an image sensor that can retain high-quality images even under low lighting conditions. The measurement unit 20 may have a near-infrared camera or a three-dimensional camera in addition to the camera 22. The near-infrared camera or the three-dimensional camera can acquire images that supplement the camera 22, enabling more accurate image processing.

[0029] The illuminance meter 24 is a device that measures the illuminance outside the image forming apparatus 1. The illuminance meter 24 enables management of the replacement parts 12 by more appropriately considering the effects of light irradiation. Light irradiation refers to irradiation from direct sunlight or indoor lighting. Here, the illuminance meter 24 measures the intensity of light irradiation in lux (lx). The illuminance meter 24 can be placed on, for example, the top panel of the image forming apparatus 1.

[0030] The hygrometer 26 is a device that measures the humidity outside the image forming apparatus 1. The hygrometer 26 allows the management of the replacement parts 12 to take into account the influence of the humidity outside. Here, the hygrometer 26 measures the amount of moisture in the air in terms of absolute humidity (g / m 3 The hygrometer 26 can be placed on the side of the front side of the image forming apparatus 1, for example. The measurement unit 20 may be configured to include either a luminance meter 24 or a hygrometer 26 in addition to the camera 22, and is not limited thereto.

[0031] [First embodiment] An image forming apparatus 1 according to the first embodiment will be described with reference to FIGS. 2A to 6. FIG. 2A is a block diagram illustrating the hardware configuration of the image forming apparatus 1 according to the first embodiment. The image forming apparatus 1 includes a measurement unit 20, an image forming unit 10, a control unit 30, an auxiliary storage device 53, a communication interface 54, and an operation panel 60, all of which are interconnected via a bus 55.

[0032] (Control unit) The control unit 30 is a device that controls the image forming apparatus 1. As illustrated in Fig. 2A, the control unit 30 has a central processing unit (CPU) 51 and a main memory device 52, and performs information processing related to the control of the image forming apparatus 1. The main memory device 52 is a ROM or RAM. The control unit 30 is mutually connected to each device of the image forming apparatus 1, such as an auxiliary memory device 53, a communication interface 54, an operation panel 60, and the like, via a bus 55.

[0033] FIG. 2B is a block diagram illustrating the functional configuration of the control unit 30 according to the first embodiment. 2B, the control unit 30 has a measurement control unit 31, an exposure detection unit 32, a machine learning model 321, a determination unit 33, a recovery control unit 36, and a determination correction unit 34. Although not described here, the control unit 30 can also have an image reading control unit 391 that controls the image reading unit, and an image formation control unit 392 that controls image formation by the image forming unit 10.

[0034] (Measurement control unit) The measurement control unit 31 is a means for controlling the measurement unit 20. The measurement control unit 31 instructs the camera 22, illuminance meter 24, and hygrometer 26 of the measurement unit 20 to take images and perform measurements. The measurement control unit 31 can, for example, detect that the access door 18 has been opened and start taking images and performing measurements. The measurement control unit 31 can continue taking images and performing measurements while the replaceable part 12 is detected in the captured image, and can stop taking images and performing measurements by detecting that the access door 18 has been closed after the replaceable part 12 is no longer detected. Note that the image taking and measurement may be performed continuously or at predetermined time intervals regardless of whether the replaceable part 12 is outside or not.

[0035] The camera 22 may capture multiple images with different brightness levels to create a high dynamic range (HDR) image, as in high dynamic range (HDR) compositing, or it may capture images while changing the orientation and position of the camera 22 and combine multiple images to create a single image with a wide range, as in panoramic compositing. Additionally, multiple images captured at different focal lengths may be combined to create an image in which everything is in focus, from the foreground to the background, as in depth stacking. Here, high dynamic range compositing is performed using a single lens and a charge-coupled device (CCD) image sensor, which provides excellent performance under low-light conditions, prioritizing cost. Image compositing and the like can be performed by the exposure detection unit 32.

[0036] (Exposure detection unit) The exposure detection unit 32 is a means for detecting the exposure rate of the replacement part 12. The exposure detection unit 32 can also perform processing such as combining images acquired by the camera 22. The exposure rate is an index of the exposure state of the replacement part 12, and is a numerical value that indicates the degree of exposure to the external environment of the replacement part 12. Even when the replacement part 12 is placed outside the image forming apparatus 1, if the replacement part 12 is covered with a light-blocking protective sheet 71 or the like to prevent exposure, the effects of exposure to the external environment can be reduced.

[0037] The exposure rate is calculated for an image of the replacement part 12 using a machine learning model 321 that has been trained in advance. The machine learning model 321 has trained in advance on training data in which image information for each exposure state of the photoconductor and the exposure rate of the photoconductor are pre-labeled. In the training data, the exposure rate is labeled on image information for the exposure state (covered state) of the photoconductor drum 14 as exemplified in FIGS. 3A to 3D.

[0038] 3A is a diagram showing image information 81 of replacement part 12 corresponding to an exposure rate of 100%. In image information 81 of replacement part 12 in FIG. 3A, photosensitive drum 14 is not covered with protective sheet 71 at all. 3B is a diagram showing image information 82 of replacement part 12 corresponding to an exposure rate of 0%. In image information 82 of FIG. Fig. 3C is a diagram showing image information 83 of the replacement part 12 corresponding to an exposure rate of 50%. Fig. 3D is a diagram showing image information 84 of the replacement part 12 corresponding to an exposure rate of 50%. 3C and 3D differ in the covered area of ​​the photosensitive drum 14 and the position of the protective sheet 71, but the protective sheet 71 covers half of the photosensitive drum 14. The machine learning model 321 has previously learned training data in which such image information is labeled with exposure rates.

[0039] The machine learning model 321 can use deep learning techniques such as convolutional neural networks (CNN) and recurrent neural networks (RNN), which are strong in image recognition. In addition to these machine learning models, any learning model that can be used for image recognition, such as a multimodal large-scale language model (LMM), a support vector machine (SVM), a random forest, or a reinforcement learner, may also be used. Here, a CNN deep learning model, which is widely applied to image recognition, image classification, object detection, etc., is used.

[0040] 4, for example, current image information 80 captured by camera 22 during replacement work is input to machine learning model 321, which outputs the exposure rate of the photosensitive member. When image information 80 in FIG. 4 is input to machine learning model 321, an exposure rate of 50% for replacement part 12 is output.

[0041] FIG. 5A is a flowchart of a process for learning training data in which image information is labeled with exposure rates. The control unit 30 causes the machine learning model 321 to learn training data in which image information is labeled with an exposure rate (step S32). The training data is configured by labeling each exposure rate on image information such as that shown in Figures 3A to 3D. By learning the training data, the machine learning model 321 learns the relationship between image information and exposure rates.

[0042] 5B is a flowchart of a process for outputting an exposure rate in exposure detection unit 32. Exposure detection unit 32 inputs an image captured by camera 22 to machine learning model 321 (step S34). Then, machine learning model 321 outputs an exposure rate (step S36), and the process in FIG. 5B ends.

[0043] The machine learning model 321 can be implemented by being incorporated into the software of the image forming apparatus 1. By using a machine learning algorithm, the exposure detection unit 32 can accurately determine the exposure rate of the photosensitive member from 0% (fully protected) to 100% (fully exposed). In addition, in order to accurately identify the photosensitive drum 14 of the replacement part 12, a separate machine learning model for image recognition may be prepared to distinguish between people (workers, passersby, etc.) and other objects (other replacement parts, tools, work desks, etc.) and the photosensitive drum 14.

[0044] (Judgment Department) The determination unit 33 is a means for determining the degree of damage to the replacement part 12. The degree of damage is the degree of damage to the photosensitive drum 14 predicted based on information about exposure to the external environment. The determination unit 33 can appropriately determine the degree of damage to the photosensitive drum 14 based on the measurement results of the measurement unit 20. Here, the damage level is expressed in four stages from damage level (I) to damage level (IV) in order of increasing damage level of the photosensitive drum 14.

[0045] Damage level (I) is when the exposure of the photosensitive drum 14 is kept low, and the illuminance and humidity are unlikely to damage the photosensitive drum 14. When damage level (I) is reached, no special measures are required for the replacement part 12. Damage level (II) is when the photosensitive drum 14 is slightly exposed or when the illuminance or humidity can damage the photosensitive drum 14. Damage level (II) requires appropriate action, such as refreshing the replacement part 12 or displaying a warning, as described below.

[0046] Damage level (III) is when the photosensitive drum 14 is clearly exposed and the effects of light and humidity must also be considered. Damage level (III) requires immediate action to protect the photosensitive drum 14 of the replacement part 12 and restore its performance. Damage level (IV) is when the photosensitive drum 14 is significantly exposed and the illuminance and humidity are high. Damage level (IV) requires replacement of the photosensitive drum 14 of the replacement part 12 or special treatment.

[0047] 6 is a diagram showing an example of criteria for determining the degree of damage. Here, the measurement results of the measurement unit 20 are three items: exposure rate, illuminance, and humidity, and the determination unit 33 determines the degree of damage using the exposure rate, illuminance, and humidity. The determination unit 33 classifies the measurement results of each item according to their numerical values. The exposure rate is divided into four categories: low (0% to less than 10%), medium (10% to less than 30%), slightly high (30% to less than 70%), and high (70% to 100%). The illuminance is divided into three categories: low (50 lx or less), medium (more than 50 lx but less than 1000 lx), and high (1000 lx or more). The humidity is low (7 g / m 3 below), moderate (7g / m 3 Larger than 15g / m 3 (less than 15g / m 3 There are three categories: The determining unit 33 then determines the damage level based on the combination of the categories of each item. For example, in the case of a combination of high exposure rate, medium illuminance, and low humidity, the determining unit 33 determines the damage level as (II).

[0048] (Judgment correction section) The judgment correction unit 34 is a means for correcting the degree of damage of the replacement part 12 judged by the judgment unit 33. The judgment correction unit 34 corrects the degree of damage of the replacement part 12 in accordance with the elapsed time from the time when the degree of damage of the replacement part 12 is judged to the time when the replacement part 12 is installed.

[0049] The judgment correction unit 34 corrects and outputs the initially evaluated damage level of the replacement part 12 based on the elapsed time from the time exposure of the photosensitive drum 14 was detected until it was attached to the image forming device 1. The determination correction unit 34 increases the damage level of the replacement part 12 by one level each time the elapsed time exceeds a predetermined threshold. The predetermined threshold is, for example, 30 minutes. That is, the determination correction unit 34 increases the damage level by one level each time the state in which exposure is detected continues for 30 minutes. If the damage level is already at damage level (IV), the damage level (IV) is maintained. The recovery control unit 36 ​​executes the refresh mode a number of times corresponding to the corrected damage level.

[0050] The determination correction unit 34 corrects the damage level determination so that the accumulated load due to exposure to the external environment is reflected, thereby enabling a more accurate evaluation of the effects of exposure. The image forming device 1 can take into account the time lapse of the exposure state of the replacement part 12 by correcting the damage degree using the judgment correction unit 34, enabling more accurate management. This can also contribute to maintaining the performance of the image forming device and improving its reliability.

[0051] (Recovery control unit) The recovery control unit 36 ​​performs control to recover the damage of the replacement part 12 based on the determination result of the determination unit 33. The recovery control unit 36 ​​can execute a refresh mode in which charging and exposure using the replacement part 12 are alternately repeated depending on the degree of damage to the replacement part 12. In this way, the recovery control unit 36 ​​recovers damage to the replacement part 12. The refresh mode is an operation in which charging and exposure are repeatedly performed on the photosensitive drum 14 that has suffered from light fatigue, thereby removing the charge accumulated in the photosensitive drum 14 and restoring performance. The recovery control unit 36 ​​changes the number of times the refresh mode is repeated depending on the degree of damage to the replacement part 12.

[0052] In the refresh mode, one rotation is counted as one cycle of charging the cylindrical surface of the photosensitive drum 14 around its cylindrical axis and then exposing it to light. Here, the recovery control unit 36 ​​repeatedly executes the refresh mode 100 times for replacement part 12 damage level (IV), 50 times for replacement part 12 damage level (III), and 10 times for replacement part 12 damage level (II). Note that the recovery control unit 36 ​​does not execute the refresh mode for replacement part 12 damage level (I). The recovery control unit 36 ​​executes the refresh mode when the replacement of the replacement part 12 is completed and the control unit 30 is able to control the replacement part 12. The refresh mode is preferably executed after the replacement part 12 is installed and before the user starts normal use such as printing. When the recovery control unit 36 ​​has executed the refresh mode a number of times according to the degree of damage, the image forming apparatus 1 returns to a state ready for normal printing, etc.

[0053] The image forming apparatus 1 configured as described above includes a measurement unit 20 that measures the external exposure state of the replacement part 12, and based on the measurement results, detects the exposure state of the photosensitive drum 14 during replacement work, etc., and determines the degree of damage. Then, a refresh mode is executed as a control for managing the replacement part 12, and damage to the replacement part 12 can be repaired. The image forming apparatus 1 performs appropriate management based on the degree of damage to the replacement part 12, suppressing deterioration in the quality of the images formed and maintaining performance.

[0054] When replacing the replacement part 12, it is removed from its packaging and installed. Even if replacement is not required, it may be temporarily removed for inspection, repair, or other purposes. When the replacement part 12 is outside the image forming apparatus 1 or its packaging, the external environment may damage the replacement part 12, potentially resulting in an unexpected decline in image quality. In particular, photofatigue caused by light exposure is known to change the chemical structure of the charge generation layer of the photoreceptor drum 14, reducing its charge generation capacity and affecting the photoreceptor potential.

[0055] The replacement work of replacement part 12 is premised on the photoreceptor drum 14 being covered and protected with a light-shielding protective sheet or the like to prevent deterioration of the photoreceptor due to light fatigue, and is not intended to be exposed to light for long periods of time. However, for example, if an operator exposes the photoreceptor to indoor lighting without covering it with a protective sheet or the like after unpacking replacement part 12, the generation efficiency of the charge generation layer may deteriorate due to light fatigue depending on the illuminance of the lighting, which may cause periodic density unevenness after installation in image forming apparatus 1. Similar to light fatigue, humidity is also one of the external environmental factors that can cause deterioration of photoreceptors. Moisture in the air can affect the charge supply layer of the photoreceptor, causing similar problems such as a decrease in the amount of charge supplied.

[0056] The image forming apparatus 1 can accurately detect the exposure state from the image captured by the camera 22 using a machine learning algorithm, and can also accurately determine the predicted degree of damage by combining information from the illuminance meter and the hygrometer.Then, the image forming apparatus 1 can appropriately adjust and control the determined exposure state, and manage the image formation quality to maintain the quality.

[0057] The determination unit 33 can determine the degree of damage using the exposure rate and illuminance and / or humidity. That is, the degree of damage may be determined using the exposure rate and illuminance, or the degree of damage may be determined using the exposure rate and humidity. When the exposure rate and illuminance are used, the humidity can be determined to be medium in FIG. 6. When the exposure rate and humidity are used, the illuminance can be determined to be medium. In these cases, the measurement unit 20 only needs to have the camera 22 and one of the illuminometer 24 and the hygrometer 26. Furthermore, the camera 22, the illuminance meter 24, and the hygrometer 26 may be separate from the image forming apparatus 1. The machine learning model 321 may be incorporated into an external server connected to the image forming apparatus 1 via the Internet or a local area network (LAN).

[0058] [Replacement part damage recovery method according to the first embodiment] Next, a replacement part damage recovery method according to the first embodiment will be described with reference to Fig. 7. Fig. 7 is a flowchart of step S1 of the replacement part damage recovery method. This step S1 can be performed by the image forming apparatus 1 according to the first embodiment.

[0059] 7, the replacement part damage recovery method for image forming apparatus 1 includes step S20 of measuring the exposure state of replacement part 12 outside, step S40 of determining the degree of damage to replacement part 12 based on the exposure state of replacement part 12, and step S61 of executing control to recover from damage to replacement part 12 based on the degree of damage to replacement part 12, and here further includes step S50 of correcting the degree of damage. Each step will be described with reference to FIG. 2B, taking as an example a case where replacement work of replacement part 12 is performed.

[0060] When the replacement work is started, the measurement control unit 31 detects the start of the replacement work (step S10), causes the measurement unit 20 to start measurement, and the measurement unit 20 and the exposure detection unit 32 measure the exposure state of the replacement part 12 (step S20). The start of the replacement work can be detected based on the detection of the replacement part 12 in an image captured by the camera 22. The image capture by the camera 22 may be performed continuously, or may be started when the work door is opened, for example. The measurement of the exposure state includes the steps of the camera 22 of the measurement unit 20 capturing an image of the replacement part 12 outside (step S21), the exposure detection unit 32 detecting the exposure rate from the image (step S30), and, in parallel with this, the measurement unit 20 measuring the illuminance and humidity as external environmental information (step S22). Then, the determination unit 33 determines the degree of damage based on these results (step S40).

[0061] When the judgment correction unit 34 detects that the replacement part 12 has been attached to the image forming device 1, i.e., when it detects that the replacement part 12 has been attached (step S45), it corrects the degree of damage based on the elapsed time since the exposure was detected (step S50). The recovery control unit 36 ​​executes control to recover from the damage based on the corrected damage level (step S61). Here, the control to recover from the damage is to execute the refresh mode a predetermined number of times. When the refresh mode ends, the image forming apparatus 1 enters a normal print preparation state (step S70), and the process S1 ends.

[0062] Note that step S1 of the replacement part damage recovery method according to the first embodiment includes steps of a replacement part damage degree determination method, which includes step S20 of measuring the exposure state of the replacement part 12 outside, and step S40 of determining the damage degree of the replacement part 12 based on the exposure state of the replacement part 12.

[0063] [Second embodiment] Next, an image forming apparatus 1 according to a second embodiment will be described. The second embodiment differs from the first embodiment in the functional configuration of the control unit 30, but the rest is the same. 8 is a block diagram illustrating the functional configuration of the control unit 30 according to the second embodiment. The control unit 30 of the image forming apparatus 1 according to the second embodiment has a replacement time notification unit 37. As other points are common to the control unit 30 of the image forming apparatus 1 according to the first embodiment shown in FIG. 2B, their description will be omitted and only the replacement time notification unit 37 will be described. The image forming apparatus 1 is equipped with an operation panel 60. The operation panel 60 is a device that functions as an interface that notifies the operator of the status of the image forming apparatus 1 and information regarding necessary measures.

[0064] (Replacement time notification section) The replacement time notification unit 37 is a means for predicting and notifying the replacement time of the replacement part 12, and corrects the replacement time depending on the degree of damage. In this way, the replacement time notification unit 37 manages the replacement part 12. The replacement time for the replacement part 12 is predicted based on an index of the lifespan of the photosensitive drum 14. When the index value exceeds a preset threshold, the usable life is set to, for example, 20% of that of a new product, and the replacement time is predicted. Examples of the index include the travel distance corresponding to the number of rotations of the photosensitive drum 14 and the film thickness of the photosensitive drum, and here the travel distance is used. The replacement time notification unit 37 applies a correction coefficient to the index threshold value depending on the damage level. This makes it possible to derive the replacement time in line with the environmental conditions and usage state. As an example, for damage level (IV), the replacement time notification unit 37 multiplies the threshold value by a correction coefficient of 0.7 to make the prediction of the usable period more strict. Similarly, for damage level (III), the correction coefficient is 0.8, and for damage level (II), the correction coefficient is 0.9. For damage level (I), the correction coefficient is 1.0, and it is determined that there is no effect of exposure.

[0065] The replacement time notification unit 37 then notifies the maintenance worker or the user of the recommended replacement based on the corrected replacement time. This notification can be provided in multiple forms, such as a warning displayed on the operation panel 60 or by email. Furthermore, the replacement time notification unit 37 can request a response from the worker or user indicating that they have acknowledged the notification recommending replacement. For example, the replacement time notification unit 37 can display a confirmation button or the like on the operation panel 60, and the worker or the like can respond by pressing the button. After receiving a response from the worker or the like, the image forming apparatus 1 may return to a normal preparation state for printing, etc.

[0066] The image forming device 1 of the second embodiment makes corrections according to the determined degree of damage and more accurately predicts and notifies the user when it is time to replace the image forming device 1, thereby improving user convenience and managing the device to maintain its performance.

[0067] [Method of notifying replacement time according to the second embodiment] Next, a method for notifying the replacement time according to the second embodiment will be described with reference to Figures 9 and 10. The method for notifying the replacement time is a method for correcting the replacement time of replacement part 12 according to the degree of damage and notifying the user.

[0068] 9 is a flowchart of the process S2 of the replacement time notification method, which can be performed by the image forming apparatus 1 according to the second embodiment. As illustrated in Figure 9, the method for notifying the replacement time includes step S20 of measuring the exposure state of replacement part 12 outside, step S40 of determining the degree of damage to replacement part 12 based on the exposure state of replacement part 12, and step S62 of correcting the replacement time according to the degree of damage to replacement part 12 and notifying the replacement time, and here further includes step S50 of correcting the degree of damage. Note that the processing up to step S50 of correcting the degree of damage is common to the replacement part damage recovery method shown in Figure 7, and therefore description thereof will be omitted. The flowchart of Figure 9 will be described below with reference to Figure 8.

[0069] The replacement time notification unit 37 corrects the replacement time of the replacement part 12 in accordance with the damage level corrected in step S50 and notifies the user (step S62). The replacement time notification unit 37 predicts the replacement time of the replacement part 12 in advance, for example, based on the travel distance of the photosensitive drum 14. The replacement time notification unit 37 corrects the predicted replacement time in accordance with the damage level. The correction is performed by multiplying a threshold value, such as the travel distance of the photosensitive drum 14, by a correction coefficient. The replacement time notification unit 37 then notifies the maintenance worker or user of the corrected replacement time by displaying it on the operation panel 60, etc.

[0070] FIG. 10 is a diagram showing a replacement time notification screen 41. This notification screen 41 displays "The replacement date for this photosensitive drum is December 2024," and also displays a "Back" button 411. By tapping the "Back" button 411, the user can transition to the normal print preparation screen.

[0071] 9, the explanation will be continued. When the user taps the "Back" button 411 (step S65), the normal print preparation state is restored (step S70), and the process S2 ends. Note that the process of step S65 can be omitted.

[0072] [Third embodiment] Next, an image forming apparatus 1 according to a third embodiment will be described. The third embodiment differs from the first embodiment in the functional configuration of the control unit 30, but the rest is the same. The control unit 30 of the image forming apparatus 1 according to the third embodiment shown in Fig. 11 has a countermeasure notification unit 38. As other points are common to the control unit 30 of the image forming apparatus 1 according to the first embodiment shown in Fig. 2B, a description thereof will be omitted and only the countermeasure notification unit 38 will be described. The image forming apparatus 1 is provided with an operation panel 60.

[0073] (Countermeasures and Notification Department) Countermeasure notification unit 38 is a means for notifying the user of recommended countermeasures for replacement part 12. Countermeasure notification unit 38 notifies the user of countermeasures according to the degree of damage to replacement part 12. The notification of countermeasures can be made via operation panel 60, email, etc., but it is preferable to display the notification on operation panel 60, as this allows for immediate action on the spot. The countermeasure notification unit 38 issues instructions to notify the worker or user of the following countermeasures via the operation panel 60 depending on the degree of damage to the replacement part 12.

[0074] If the damage level of the replacement part 12 is (IV), the countermeasure notification unit 38 warns that the damage level of the photosensitive drum is at the highest level. Also, depending on the level of image quality required by the user, the countermeasure notification unit 38 may recommend replacing the photosensitive drum 14. If the damage level is (III), the countermeasure notification unit 38 warns that the photosensitive drum is highly damaged and recommends that the photosensitive drum be placed in a black bag or dark room to recover and then reused. If the damage level is (II), the countermeasure notification unit 38 warns that the photosensitive drum is damaged and recommends that the refresh mode be manually executed from the operation panel. If the damage level is (I), the countermeasure notification unit 38 does not display a warning or recommends a countermeasure. Furthermore, the countermeasure notification unit 38 can request a response from the worker or user indicating that they have acknowledged the notification of the recommended operation. For example, the countermeasure notification unit 38 can display a confirmation button or the like on the operation panel 60, and the worker or the user can respond by pressing the button. After receiving a response from the worker or the user, the image forming apparatus 1 may return to a normal preparation state for printing or the like.

[0075] The image forming device 1 according to the third embodiment notifies the worker or user of recommended measures depending on the degree of damage to the replacement part 12, thereby enabling more appropriate management of the replacement part 12 and maintaining the performance of the image forming device.

[0076] [Measure notification method according to the third embodiment] Next, a method for notifying measures according to the third embodiment will be described with reference to Figs. 12 and 13. The method for notifying measures is a method for notifying measures such as recommended operations depending on the degree of damage to the replacement part 12. Fig. 12 is a flowchart of process S3 of the method for notifying measures. This process S3 can be performed by the image forming apparatus 1 according to the third embodiment.

[0077] As illustrated in Fig. 12, the method for notifying measures includes step S20 of measuring the exposure state of replacement part 12 outside, step S40 of determining the degree of damage to replacement part 12 based on the exposure state of replacement part 12, and step S63 of notifying measures such as recommended operations according to the degree of damage to replacement part 12, and here further includes step S50 of correcting the degree of damage. Note that the processing up to step S50 of correcting the degree of damage is common to the replacement part damage recovery method shown in Fig. 7, and therefore description thereof will be omitted. The flowchart of Fig. 12 will be described below with reference to Fig. 11.

[0078] The countermeasure notification unit 38 notifies the user of a countermeasure such as an operation recommended in accordance with the damage level corrected in step S50 (step S63). 13 is a diagram showing a screen 42 that notifies users of recommended measures depending on the damage to the replacement part 12. As an example, in the case of damage level (II), this screen 42 displays a message such as "Damage to the photosensitive drum has been detected. Please manually execute refresh mode 10 times from the operation panel.", and also displays a "Back" button 422. The user can transition to the normal print preparation screen by tapping the "Back" button 422.

[0079] Returning to FIG. 12, the explanation will continue. The countermeasure notification unit 38 notifies the user of the countermeasure corresponding to the damage level. The countermeasure notification unit 38 displays the countermeasure corresponding to the damage level on the operation panel 60 or the like to notify the maintenance worker or the user. When the user taps the "Back" button 422 (step S65), the printer enters the normal print preparation state (step S70), and the process S3 in FIG. 12 ends. Note that the process of step S65 can be omitted.

[0080] It should be noted that two or more of the first to third embodiments can be combined.

[0081] [program] Next, a program according to an embodiment will be described. The program according to an embodiment is a program that, when loaded into a computer, causes the computer to execute processes for a method for recovering from damage to a replacement part, a method for notifying the replacement timing, and a method for informing the user of a countermeasure. For example, a program for the replacement part damage recovery method causes a computer to execute the steps of measuring the external exposure state of the replacement part 12, determining the degree of damage to the replacement part 12 based on the exposure state of the replacement part 12, and executing control to recover from damage to the replacement part 12 based on the degree of damage to the replacement part 12. Furthermore, a computer that has been loaded with the program for the replacement part damage recovery method can control the hardware of the image forming apparatus 1 to function as the image forming apparatus 1 according to the first embodiment. Note that the programs for the replacement part damage recovery method, the replacement time notification method, and the countermeasure notification method include a program for a replacement part damage degree determination method. The program for the replacement part damage degree determination method causes a computer to execute the steps of measuring the external exposure state of the replacement part 12 and determining the degree of damage to the replacement part 12 based on the exposure state of the replacement part 12.

[0082] Furthermore, the control unit 30 executes the program according to the embodiment, thereby allowing the image forming apparatus to function as the image forming apparatus 1 according to the first to third embodiments. The program according to the embodiment can be obtained through an electric communication line and can be recorded on a computer-readable recording medium. [Explanation of symbols]

[0083] 1. Image forming device 10 Image forming unit 12 Replacement Parts 14 Photosensitive drum 18 Working door 20 Measurement section 22 Camera 24 Light meter 26 Hygrometer 30 Control Unit 31 Measurement control section 32 Exposure detection unit 321 Machine Learning Models 33 Judgment section 34 Judgment correction section 36 Recovery control section 37 Replacement time notification section 38 Countermeasures and Notification Department 60 Operation Panel 71 Protective Sheet

Claims

1. a measuring unit that measures the exposure state of the replacement part outside; a determination unit that determines a degree of damage to the replacement part based on the measurement result of the measurement unit; An image forming apparatus comprising:

2. The image forming apparatus according to claim 1 , wherein the measuring unit has a camera for capturing an image of the outside and acquires an image of the replacement part outside.

3. an exposure detection unit that detects an exposure rate that is an index of an exposure state of the replacement part; The image forming apparatus according to claim 2 , wherein the exposure detection unit calculates the exposure rate for the image of the replacement part using a machine learning model.

4. 2. The image forming apparatus according to claim 1, wherein the measuring unit includes an illuminance meter that measures external illuminance.

5. 2. The image forming apparatus according to claim 1, wherein the measuring unit includes a hygrometer for measuring external humidity.

6. The image forming apparatus according to claim 3 , wherein the determining unit determines the degree of damage using the exposure rate and illuminance and / or humidity.

7. 2. The image forming apparatus according to claim 1, further comprising a determination correction unit that corrects the degree of damage in accordance with the elapsed time from when the degree of damage is determined to when the replacement part is installed.

8. a recovery control unit that recovers damage to the replacement part based on the determination result of the determination unit; The image forming apparatus according to claim 1 , further comprising:

9. The image forming apparatus according to claim 8 , wherein the recovery control unit repeatedly executes the operation of recovering the replacement part a number of times corresponding to the degree of damage.

10. The image forming apparatus according to claim 1 , further comprising a replacement time notification unit that corrects the replacement time of the replacement part according to the degree of damage and notifies the corrected replacement time.

11. The image forming apparatus according to claim 1 , further comprising a countermeasure notification unit that notifies a user of a countermeasure according to the degree of damage.

12. measuring the exposure state of the replacement part outside; determining a degree of damage to the replacement part based on an exposure state of the replacement part; A method for determining the degree of damage to a replacement part, comprising:

13. On the computer, Procedures for measuring the external exposure of replacement parts; determining a degree of damage to the replacement part based on an exposure state of the replacement part; A program to execute.

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