Image forming system and information processing device, their control method, and program

Abstract

By predicting whether a job will fail inspections during execution before it is executed, the system aims to reduce the occurrence of job interruptions during execution. [Solution] An image forming system comprising a printing device, an inspection device for inspecting printed materials printed by the printing device, and an information processing device for controlling the printing device and the inspection device, wherein the information processing device sets the print settings for a job to be printed by the printing device and sets the inspection settings for that job for inspection by the inspection device. The inspection device reads the printed material printed by the printing device according to the job and generates a read image, and detects signs of potential defects in the printed material contained in the read image. Based on the print settings, inspection settings and the detected signs, the information processing device predicts whether the defect will occur when printing according to the print settings and inspection settings, and notifies if the defect is predicted to occur.

Description

Technical Field

[0001] The present invention relates to an image forming system, an information processing apparatus and a control method thereof, and a program.

Background Art

[0002] In order to guarantee the quality of printed matter output from a printing apparatus, inspection of the printed matter is performed. In recent years, in an inspection system that automatically performs inspection, there is known an inspection apparatus that inspects by comparing an inspection target image obtained by reading the printed matter with a scanner and a reference image (reference image). Such an inspection apparatus can detect defects in the printed matter such as dots, streak-like stains, white spots, or misalignment of the printing position.

[0003] These defects may occur due to the gradual deterioration of the process parts inside the apparatus, such as when the printing apparatus or inspection apparatus is used over a long period of time. When such deterioration of the parts progresses to a certain extent and the resulting defects reach an unacceptable level for the user, it becomes necessary to replace the process parts that are the cause of the defects. In that case, for example, a serviceman is called to repair the defective part. However, in the case of repair that requires a serviceman, downtime occurs because printing cannot be performed while waiting for the serviceman to arrive.

[0004] Patent Document 1 describes a technique for continuing printing by avoiding the abnormal portion by adjusting the image forming area or the position of the paper so that abnormalities such as dirt or defects on the paper are moved to the paper cutting planned area.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] Ideally, printing should continue even if there are image defects such as smudges on the paper, as long as the degree of the defect is acceptable to the user. In such cases, for example, jobs with a low sensitivity setting for detecting defects (hereinafter referred to as the inspection level) should be prioritized. However, with current printing equipment, it is difficult for users to determine what inspection level is acceptable for a job to run without problems. As a result, jobs are sometimes executed at an unnecessarily high inspection level, leading to frequent failures in inspection due to the number of defects detected exceeding the threshold, and resulting in the need to interrupt the job.

[0007] The object of the present invention is to solve at least one of the problems of the prior art described above.

[0008] The object of the present invention is to provide a technology that can suppress situations such as interrupting a job in progress by predicting whether or not the job will fail inspections during execution before the job is executed. [Means for solving the problem]

[0009] To achieve the above objective, an image forming system according to one aspect of the present invention has the following configuration. That is, An image forming system comprising a printing device, an inspection device for inspecting printed materials printed by the printing device, and an information processing device for controlling the printing device and the inspection device, The aforementioned information processing device is A print setting means for setting the print settings for a job to be printed by the aforementioned printing device, The system includes an inspection setting means for performing inspection settings for the inspection in the inspection device for the job, The inspection device, A reading means that reads the printed material printed by the printing device according to the job and generates a read image, The system includes a precursor detection means for detecting precursors to defects in the printed material that are included in the read image, The aforementioned information processing device further, A prediction means predicts whether the defect will occur when printing according to the print settings and inspection settings, based on the print settings set by the print setting means, the inspection settings set by the inspection setting means, and the precursors detected by the precursor detection means. The system includes a notification means that notifies when the prediction means predicts that the defect will occur, The inspection setting is characterized by including an inspection threshold for determining whether the precursor is a defect in the printed material. [Effects of the Invention]

[0010] According to the present invention, by predicting and notifying whether a job will fail inspections during execution before the job is executed, it is possible to suppress situations such as interrupting a job in progress.

[0011] Other features and advantages of the present invention will become apparent from the following description with reference to the accompanying drawings. In the accompanying drawings, the same or similar components are given the same reference numeral. [Brief explanation of the drawing]

[0012] The attached drawings are included in the specification and constitute part thereof, illustrating embodiments of the present invention and are used together with the description to explain the principles of the present invention. [Figure 1] A diagram illustrating the schematic configuration of an image forming system according to Embodiment 1 of the present invention. [Figure 2] Hardware configuration diagram of the image forming system according to Embodiment 1. [Figure 3] A functional block diagram illustrating the configuration of the software module of the image forming system according to Embodiment 1. [Figure 4] This figure shows an example of a print settings screen displayed on the display unit of an external PC according to Embodiment 1. [Figure 5] This figure shows an example of the inspection setting screen displayed on the display unit of an external PC according to Embodiment 1. [Figure 6] A diagram for explaining an example of a precursor that appears in an inspection target image. [Figure 7] A diagram for explaining the operation of the precursor diagnosis module during precursor tracking in Embodiment 1. [Figure 8] A graph showing an example of the variation of the precursor tracked by the precursor diagnosis module from after precursor detection until automatic recovery is performed. [Figure 9] A diagram for explaining the operation of the inspection result prediction module according to Embodiment 1. [Figure 10] A diagram showing an example of a warning screen displayed on the display unit when the external PC according to Embodiment 1 determines that printed materials with NG inspection results are continuously generated. [Figure 11] A sequence diagram for explaining from the job setting to the print completion executed by the image forming system according to Embodiment 1. [Figure 12] A flowchart for explaining the processes of the print setting and inspection setting in FIG. 10 executed by the external PC in the image forming system according to Embodiment 1. [Figure 13] A flowchart for explaining the details of the precursor diagnosis process (S1109) executed by the inspection device of the image forming system according to Embodiment 1. [Figure 14] A diagram for explaining the operation of the inspection result prediction module of the external PC according to Embodiment 2. [Figure 15] A flowchart for explaining the processes of the print setting and inspection setting (S1101) executed by the external PC in the image forming system according to Embodiment 2. [Figure 16] A diagram showing an example of a job management screen for displaying the jobs held in the print job queue in Embodiment 3. [Figure 17] A sequence diagram for explaining from the job setting to the print completion executed by the image forming system according to Embodiment 3. [Figure 18] A diagram for explaining the operation of the inspection result prediction module according to Embodiment 3. [Figure 19]A flowchart illustrating the details of the status change process (S1702) for a pending job, which is performed by an external PC of the image forming system according to Embodiment 3. [Modes for carrying out the invention]

[0013] Embodiments of the present invention will be described in detail below with reference to the attached drawings. Note that the following embodiments do not limit the invention to the claims. While multiple features are described in the embodiments, not all of these features are essential to the invention, and the features may be combined in any way. Furthermore, in the attached drawings, the same or similar configurations are given the same reference numerals, and redundant descriptions are omitted.

[0014] [Embodiment 1] Figure 1 is a diagram illustrating the schematic configuration of an image forming system 100 according to Embodiment 1 of the present invention.

[0015] Server 102 generates job data and transmits the generated job data to the printer 103 and inspection device 104 to perform printing and inspection. An external PC 101 is connected to Server 102 via the network 110 for communication. The external PC 101 functions as an information processing device that receives original image data, print settings, and inspection settings from the user and transmits them to Server 102. From the received original image data, Server 102 generates print image data necessary for printing and reference image data necessary for inspection. Alternatively, the server 102 may receive pre-created reference image data from the external PC 101. Server 102 generates job data based on the original image data, various setting information, and reference image data. The external PC 101 instructs Server 102 to execute the job according to the user's instructions. When server 102 receives a job execution instruction, it sends the print image data and print setting information (hereinafter referred to as print job data) from the job data to the printing device 103, and the reference image data and inspection setting information (hereinafter referred to as inspection job data) to the inspection device 104. Alternatively, server 102 may be configured to accept job execution requests from users.

[0016] The printing device 103 forms (prints) an image on a recording material such as paper or a sheet, based on the print job data received from the server 102. The printing medium may be long paper. In Embodiment 1, a configuration in which the printing device 103 uses an electrophotographic method is described, but the device is not limited to this configuration, and for example, the printing device 103 may use other printing methods such as offset printing or inkjet printing.

[0017] The printing device 103 is equipped with multiple paper feed decks. In this embodiment, it is equipped with six types of paper feed decks: 61, 62, 63, 64, 65, and 66. Various types of recording material (paper) are stored in each paper feed deck. Of the recording material stored in each paper feed deck, the topmost sheet is separated one by one and fed to the transport path 03.

[0018] Furthermore, each of the image forming stations 04 to 07 contains a photosensitive drum (photoreceptor) and uses a different colored toner to form a toner image on the photosensitive drum. Specifically, each of the image forming stations 04 to 07 uses yellow (Y), magenta (M), cyan (C), and black (K) toners to form a toner image.

[0019] The toner images of each color formed in the image forming stations 04-07 are sequentially transferred onto the intermediate transfer belt 08 (primary transfer). The toner images transferred to the intermediate transfer belt 08 are then transported to the secondary transfer position 09 as the intermediate transfer belt 08 rotates. At the secondary transfer position 09, the toner images are transferred from the intermediate transfer belt 08 to the recording material that has been transported along the transport path 03 (secondary transfer). After the secondary transfer, the recording material is transported to the fixing unit 11. The fixing unit 11 is equipped with pressure rollers and heating rollers. Heat and pressure are applied to the recording material as it passes between these rollers, fixing the toner images onto the recording material. The recording material that has passed through the fixing unit 11 is transported through the transport path 12 to the connection point 15 between the printing device 103 and the inspection device 104. In this way, a color image is formed (printed) on the recording material.

[0020] If further fixing is required depending on the type of recording material, the recording material that has passed through the fixing unit 11 is guided to the transport path 14 where the fixing unit 13 is located. The fixing unit 13 performs further fixing on the recording material being transported along the transport path 14. The recording material that has passed through the fixing unit 13 is transported to the connection point 15. If the operation mode for double-sided printing is set, an image is printed on the first side, and the recording material that has been transported along the transport path 12 or transport path 14 is guided to the inversion path 16. The recording material that has been inverted in the inversion path 16 is guided to the double-sided transport path 17 and transported to the secondary transfer position 09. As a result, at the secondary transfer position 09, the toner image is transferred to the second side of the recording material, which is opposite to the first side. After that, the recording material passes through the fixing unit 11 (and fixing unit 13), completing the formation of the color image on the second side of the recording material.

[0021] Once the image formation (printing) in the printing device 103 is complete, the printed recording material that has been transported to the connection point 15 is transported into the inspection device 104.

[0022] The inspection device 104 includes image reading units 31 and 32, each equipped with a Contact Image Sensor (CIS), located above and below the transport path 30 through which the printed recording material from the printing device 103 is transported. The image reading units 31 and 32 are positioned opposite each other across the transport path 30. As shown in Figure 1, the image reading units 31 and 32 are arranged to read the upper surface (first surface) and lower surface (second surface) of the recording material, respectively. Note that the image reading units may be composed of, for example, a Charge Coupled Device (CCD) or a line scan camera instead of a CIS.

[0023] The inspection device 104 performs an inspection to determine whether printed materials (printed materials) contain defects and a predictive diagnostic, as described later, based on the image printed on the printed material being transported along the transport path 30. Specifically, when the transported printed material reaches a predetermined position, the inspection device 104 uses image reading units 31 and 32 to read the image of the printed material. Based on a comparison of the obtained read image with a reference image, the device performs a predictive diagnostic to detect signs of defects occurring before they occur due to the printing device 103, and inspects the printed material for defects during printing. Furthermore, the image forming system 100 may also be configured to perform image diagnostics to detect defects that have already occurred. Based on the diagnostic results of these predictive diagnostics and image diagnostics, the device identifies signs of defects and the causes of defects, and automatically performs processes such as repairing or replacing the parts (components) that are causing the defects.

[0024] Furthermore, predictive diagnostics are a diagnostic process that identifies signs (abnormal areas) that are likely to cause future malfunctions, and even if a sign is found through predictive diagnostics, immediate repair is not required. Also, predictive diagnostics are basically performed on the printed image that the user is printing. Abnormal areas refer to pixels where the difference in pixel values ​​between the image being inspected and the reference image exceeds a predetermined value.

[0025] The stacker 105 is a device for stacking printed recording materials (printed materials). It distinguishes between printed materials that the inspection device 104 has determined to contain defects and those that have been determined to be normal, and discharges them separately. The stacker 105 may also be configured to include a post-processing device 106 that performs finishing processes such as stapling, punching, and saddle stitching on the stacked printed materials to produce finished products.

[0026] The post-processing device 106 performs post-processing on the transported printed materials. Specifically, the post-processing device 106 has post-processing functions such as stapling (single-point or double-point binding), punching (two-hole or three-hole binding), and saddle-stitch binding. However, it is not necessary for the device to have all functions of stapling, punching, and saddle-stitch binding. The post-processing device 106 has two output trays 51 and 52. If no post-processing such as stapling is performed, the sheet bundle is output to the output tray 51 via the sheet transport path 53. On the other hand, if post-processing such as stapling is performed, the sheet bundle is output to the output tray 52 after the specified post-processing is performed in the processing unit 55 via the sheet transport path 54. The output trays 51 and 52 can be raised and lowered, and it is also possible to lower the output tray 51 and load the printed materials that have been post-processed in the processing unit 55 onto the output tray 51. If saddle stitching is specified, the saddle stitching processing unit 56 staples the center of the printed material, then folds the printed material in half and outputs it to the saddle stitching tray 58 via the sheet transport path 57. The saddle stitching tray 58 is configured as a belt conveyor, and the bundles of saddle-stitched books stacked on the tray 58 are transported to the left and discharged.

[0027] Figure 2 is a hardware configuration diagram of the image forming system 100 according to Embodiment 1.

[0028] First, let me explain the configuration of external PC101.

[0029] The external PC 101 includes a CPU 211, memory 212, auxiliary storage 213, operation unit 214, display unit 215, and I / F (interface) 216. The auxiliary storage 213 stores application programs and data necessary to operate the system. The CPU 211 loads the programs and data stored in the auxiliary storage 213 into memory 212 and executes them. The operation unit 214 includes a keyboard and pointing device and accepts input from the user, such as print settings and inspection settings. The display unit 215 includes, for example, an LCD display and displays the application screen. The display unit 215 may be a touch panel type integrated with the operation unit 214. The I / F 216 is connected to the server 102's I / F 226 via wired LAN, wireless LAN, or USB. The CPU 211 transmits document image data, various setting information, etc., to the server 102 via the I / F 216. It also receives information such as the printing status of the printing device 103 and the inspection results of the inspection device 104.

[0030] Next, we will explain the configuration of server 102.

[0031] Server 102 comprises a CPU 221, memory 222, auxiliary storage 223, operation unit 224, display unit 225, and interface 226. The auxiliary storage 223 stores application programs and data necessary for operating the system. The CPU 221 loads the programs and data stored in the auxiliary storage 223 into memory 222 and executes them. The interface 226 connects to the interfaces of other devices via wired LAN, wireless LAN, USB, etc. The CPU 221 receives original image data, various setting information, etc., from the external PC 101 via the interface 226. It also transmits job data to the printer 103 and inspection device 104 via the interface 226. Furthermore, it receives information such as the printing status of the printer 103 and the inspection results of the inspection device 104 via the interface 226. The CPU 221 stores the data received via the interface 226 in memory 222 and auxiliary storage 223. The operation unit 224 includes a keyboard and pointing device and accepts input from the user, such as print settings and inspection settings. The display unit 225 includes, for example, a liquid crystal display and displays the application screen. The display unit 225 may be a touch panel type integrated with the operation unit 224.

[0032] Next, the configuration of the printing device 103 will be described.

[0033] The printing device 103 includes a CPU 231, memory 232, auxiliary storage 233, operation unit 234, display unit 235, interface 236, and image forming unit 240. The auxiliary storage 233 stores programs and data for controlling the printing device 103. The CPU 231 loads the programs and data stored in the auxiliary storage 233 into the memory 232 and executes them. The interface 236 is connected to the interface 226 of the server 102 via wired LAN, wireless LAN, USB, etc. The CPU 231 stores print job data received from the server 102 via the interface 236 into the memory 232 and auxiliary storage 233. The operation unit 234 includes a keyboard and pointing device, and accepts input for, for example, maintenance of the printing device 103. The display unit 235 includes, for example, a liquid crystal display, and displays the status of the printing device 103. The display unit 235 may be a touch panel type integrated with the operation unit 234.

[0034] The image forming unit 240 further comprises a paper feeding unit 241, an exposure unit 242, an image formation unit 243, a fixing unit 244, and a transport unit 245. Paper is pre-loaded in the paper feeding unit 241 by the user. Based on the print job data received from the server 102, the image forming unit 240 transports the paper loaded in the paper feeding unit 241 along the transport unit 245, forms an image on one or both sides of the paper, and outputs the printed material with the image formed to the inspection device 104. The exposure unit 242 first charges the surface of the photosensitive drum to a negative potential. Next, it irradiates the photosensitive drum with laser light to form an electrostatic latent image. The image formation unit 243 includes a developing unit, a transfer unit, a toner supply unit, etc., and transfers the toner on the photosensitive drum to the paper. In the developing unit, negatively charged toner from the developing cylinder adheres to the electrostatic latent image on the surface of the photosensitive drum. In the transfer unit, the primary transfer roller is first charged to a positive potential, transferring the toner from the surface of the photosensitive drum to the transfer belt. Next, the secondary transfer roller transfers the toner on the transfer belt to the paper. The fixing unit 244 consists of a heating heater, fixing belt, pressure belt, etc., and melts and fixes the toner on the paper to the paper using heat and pressure. The paper feeding unit 241 corresponds to the paper decks 61, 62, 63, 64, 65, 66, etc. in Figure 1. The transport unit 245 corresponds to the transport paths 03, 12, 14, 17, etc., and the motors that drive them. Furthermore, the exposure unit 242, image formation unit 243, and fixing unit 244 correspond to the image forming stations 04-07, intermediate transfer belt 08, fixing units 11, 13, etc. shown in Figure 1.

[0035] Next, the configuration of the inspection device 104 will be described.

[0036] The inspection device 104 includes a CPU 251, memory 252, auxiliary storage 253, transport unit 256, reading unit 255, and interface 254. The auxiliary storage 253 stores programs and data for controlling the inspection device 104. The CPU 251 loads the programs and data stored in the auxiliary storage 253 into the memory 252 and executes them. In addition to the CPU 251, a GPU (not shown) may also be included. The GPU is used to perform image comparison processing at high speed. The interface 254 is connected to the interface of the server 102 or the printer 103 via a wired LAN, wireless LAN, USB, or a bus 110 connecting the printer 103 and the inspection device 104.

[0037] The CPU 251 stores the inspection job data received from the server 102 via the I / F 254 into the memory 252 and auxiliary storage 253. It is also connected to the operation unit 234 and display unit 235 of the printing device 103, allowing the user to perform maintenance and check the status of the inspection device 104 from the operation unit 234 and display unit 235 of the printing device 103.

[0038] The reading unit 255 uses one or more reading sensors (corresponding to image reading units 31 and 32) located near the transport unit 256 to read one or both sides of the transported printed material and generate an inspection target image. These reading sensors may be provided only on one side of the printed material, or they may be provided on both the front and back sides of the transported printed material to read both sides simultaneously. In a configuration where the reading sensors are provided only on one side of the printed material, the transport unit 256 can flip the printed material over after reading one side, and the reading sensors can then read the other side. The inspected printed material is transported to the stacker 105 by the transport unit 256. The inspection device 104 compares the inspection target image with a reference image to check for defects in the printed material. The result of the inspection, whether a defect was detected or not, is transmitted to the stacker 105 via the I / F 254.

[0039] Next, I will explain the configuration of the Stacker 105.

[0040] The stacker 105 comprises a CPU 261, memory 262, auxiliary storage 263, transport unit 266, loading unit 265, and interface 264. The auxiliary storage 263 stores programs and data for controlling the stacker 105. The CPU 261 loads the programs and data stored in the auxiliary storage 263 into the memory 262 and executes them. The interface 264 is connected to the interface of the server 102 or the inspection device 104 via a wired LAN, wireless LAN, USB, or a bus 110 connecting the inspection device 104 and the stacker 105. The loading unit 265 consists of a normal stacker for loading printed materials judged to be normal by the inspection device 104 and a defective stacker for loading printed materials judged to be defective. Printed materials transported from the inspection device 104 by the transport unit 266 are loaded into either the normal stacker or the defective stacker according to the inspection results of the inspection device 104.

[0041] Figure 3 is a functional block diagram illustrating the configuration of the software module of the image forming system 100 according to Embodiment 1.

[0042] First, I will explain the function modules of the external PC101.

[0043] The external PC 101 includes a print setting module 311, an inspection setting module 312, and an inspection result prediction module 313 as software modules. The functions of these modules are realized by the CPU 211 of the external PC 101 executing programs loaded into memory 212.

[0044] The print settings module 311 performs print settings for the executed job, such as the original image data, number of copies, paper size, single-sided / double-sided printing specification, color profile, and whether or not finishing processing is performed, based on user input.

[0045] Figure 4 shows an example of a print settings screen displayed on the display unit 215 of the external PC 101 according to Embodiment 1.

[0046] The print settings screen 400 is displayed, for example, when the user presses the "Create New Job" button on the menu screen (not shown) in an application running on an external PC 101. The print settings screen 400 has a document image reference button 401, a print copy specification field 402, and a print settings completion button 403. In addition, it may have setting fields for specifying paper size, single-sided / double-sided printing, and image processing such as color conversion, sharpening, and fine line enhancement, allowing users to configure settings necessary for printing.

[0047] When the document image reference button 401 is pressed, a file reference screen is displayed on the external PC 101, external storage (not shown), or network server, where the document image data (e.g., PDF file, TIFF file, etc.) can be selected. The number of copies to print is set by the user entering a number in the print quantity specification field 402. Other setting fields are also set according to the user's input. When the print settings complete button 403 is pressed, the above settings are confirmed and the user returns to the previous screen. Instead of returning to the previous screen, the user may proceed to the inspection settings screen 500 described later.

[0048] The inspection setting module 312 performs inspection settings such as the contamination inspection level, misalignment inspection threshold, and inspection area for the job being executed, based on user input.

[0049] Figure 5 shows an example of the inspection setting screen displayed on the display unit 215 of the external PC 101 according to Embodiment 1.

[0050] This inspection settings screen 500 is displayed when, for example, the job inspection settings start button (not shown) for an application running on an external PC 101 is pressed, or when the print settings complete button 403 is pressed on the aforementioned print settings screen 400.

[0051] The inspection settings screen 500 includes a field for setting the inspection level for dot-like stains 501, a field for setting the inspection level for streaky stains 502, a field for setting the threshold for misalignment inspection 503, an inspection area setting area 504, an inspection setting completion button 505, and an inspection setting cancellation button 506. In addition, it may have a barcode inspection setting field, a button for reading pre-created reference image data, and setting fields for making settings necessary for inspection. The inspection level setting fields for dot-like stains 501 and 502 for streaky stains select the sensitivity for detecting dot-like and streaky stains, respectively. For example, the levels can be divided into 9 stages from 1 to 9, and the smaller the level number, the larger the minimum size of the detectable stain, i.e., the lower the detection sensitivity. In Figure 5, both the inspection level for dot-like stains and the inspection level for streaky stains are set to "7".

[0052] The threshold setting field 503 for positional misalignment inspection is where the allowable amount of misalignment when the printed position of the image deviates from the expected position is entered, for example, in millimeters. In Figure 5, it is set to 4 mm. Other setting fields also have set values ​​specified according to user input. The inspection area setting area 504 specifies the area to which the above settings apply. For example, by dragging the cursor 507 on the image using a pointing device, the user can select a rectangular area 508 to perform inspection for spot stains. However, it is also possible to set an area that is not inspected (non-inspection area) instead of an area to be inspected. When the inspection setting cancellation button 506 is pressed, the inspection settings on this screen are discarded and the user returns to the previous screen. When the inspection setting completion button 505 is pressed, the settings on this screen are confirmed and the user returns to the previous screen. Alternatively, instead of returning to the previous screen, the user may transition to a settings confirmation screen (not shown). The settings confirmation screen has fields that display the setting values ​​for the print settings and inspection settings described above, and a job start button. When the job start button is pressed, the CPU 211 of the external PC 101 sends the original image data, print settings, and inspection settings to the server 102 and instructs the server 102 to start the job execution.

[0053] The inspection result prediction module 313 determines, based on the predictive information generated by the predictive diagnostic module 322 of the inspection device 104, whether the print settings and inspection settings set on the external PC 101 are settings that could cause consecutive NG (Not Good) results in the inspection device 104. Details of the processing performed by the inspection result prediction module 313 will be described later.

[0054] Next, we will describe the functional modules of the inspection device 104.

[0055] The inspection device 104 includes an inspection module 321 and a predictive diagnostic module 322 as software modules. The functions of these modules are realized by the CPU 251 of the inspection device 104 executing programs loaded into memory 252.

[0056] The inspection module 321 reads the printed material with a reading sensor (corresponding to image reading units 31 and 32) and compares the resulting inspection target image with a reference image to detect defects in the printed material. The inspection module 321 acquires the inspection settings set in the inspection setting module 312 and the reference image generated by the server 102. An example of spot stain inspection is described below. First, the inspection target image and the reference image are aligned so that the printed patterns match. Next, a difference image is generated by performing a difference process on each image. Next, the difference image is binarized to generate a binarized difference image. Next, if the size of the pixel group appearing as a difference in the binarized difference image is larger than the size that can be detected by the spot stain inspection level set in the inspection setting module 312, it is determined that a spot stain defect has been detected. When a defect is detected, the inspection module 321 notifies the stacker 105 that a defect has been detected so that the defective printed material is ejected to the defective stacker.

[0057] The predictive diagnostic module 322 detects and tracks signs of impending defects based on the inspection target image generated by the inspection device 104. These signs include small stains (abnormal areas) that appear on the printed material due to the gradual damage or soiling of process parts inside the device, such as from prolonged use of the printing device 103 or the inspection device 104.

[0058] Figure 6 is a diagram illustrating examples of warning signs that may appear in the images being examined.

[0059] Process parts of the printing apparatus that can be the cause of a precursor include the charging roller, developer unit, and transfer belt. Scratches or dirt on these parts cause dot-like stains or white spots on the printed material, which are characterized by appearing periodically at regular intervals on the image. From these characteristics, the type of process part causing the precursor can be identified. Image 600 in Figure 6(A) is the image to be inspected, and the dot-like stains 601 appear periodically at the same position 604 in the main scanning direction and at intervals L602 in the print material transport direction. Brightness changes that occur in the image to be inspected due to contamination of the image reading units 31 and 32 of the inspection device 104 by dust from the printed material or toner can also be considered a precursor. Such precursors are characterized by appearing as streaky shadows on the image to be inspected. The streaks 603 in Figure 6(A) appear continuously at the same position in the main scanning direction and in the print material transport direction.

[0060] The sizes of the various precursors described above are smaller than the size detectable by the inspection level set in the inspection settings. Therefore, as a method for detecting precursors, the precursor diagnosis module 322 first detects abnormal areas in the image under inspection with a sensitivity stricter than the inspection level that can be set in the inspection settings. Furthermore, it determines whether the detected abnormal areas have the characteristics specific to the precursors described above. As a method for this determination, pattern matching is first performed on abnormal areas that appear at the same position in the main scanning direction to extract multiple abnormal areas with similar shapes. Furthermore, if the extracted multiple abnormal areas are located periodically in the transport direction, it is determined that they have the characteristics specific to the precursors.

[0061] Furthermore, in the print settings screen 400 or inspection settings screen 500 mentioned above, when tracking precursors, it is also possible to display the inspection level at which an inspection is predicted to fail.

[0062] Images 610 and 611 in Figure 6(B) are both images to be inspected, with image 611 showing the image to be inspected read immediately after image 610. If the length of the side parallel to the transport direction of the printed material is shorter than twice the period of the precursor, it may not be possible to determine whether the precursor is periodic based on a single image. For example, the stain 612 on image 610 is a stain that indicates a precursor, but it is not possible to determine whether it is periodic based on image 610 alone. Therefore, the precursor diagnosis module 322 makes a determination using image 610 and the subsequent image 611. In order to determine the interval between the defects detected in this way, the interval 615 between the two images when consecutive images 610 and 611 are read is determined from the transport speed of the transport section 256 of the inspection device 104, and is used when determining the interval L613 between stains 612 and 616. Then, the interval L614 between stain 616 and the next stain is determined, and if interval L613 and interval L614 are approximately the same, it is determined that stains are occurring at this cycle. Alternatively, without determining the cycle, it may be determined that a precursor is occurring if the frequency of abnormal locations appearing at the same position in the main scanning direction is high. In the example in Figure 6(B), precursors are detected from two images, but three or more images may also be used. The number of inspection target images acquired consecutively may be changed based on the cycle of the process part with the longest operating cycle and the length in the transport direction of the printed material.

[0063] Furthermore, the timing for detecting the precursor may be determined each time an image to be inspected is generated, or it may be determined by inspecting several consecutive images acquired at predetermined intervals (e.g., 100 images). In addition, the printed material targeted for precursor diagnosis may be an image that could become an actual output, or a diagnostic chart may be used.

[0064] The precursor diagnosis module 322 further tracks the detected precursors.

[0065] Figure 7 is a diagram illustrating the operation of the precursor diagnosis module 322 during precursor tracking.

[0066] Image 700 in Figure 7(A) shows an example of an image to be inspected read by the precursor diagnostic module 322 during precursor tracking. Images 710 and 711 in Figure 7(B) are both examples of images to be inspected read by the precursor diagnostic module 322 during precursor tracking, with image 711 being the image to be inspected read immediately after image 710. Images 710 and 711 show streaky precursors 715 and 716. If the precursor is a dot-like stain or white spot, as shown in Figure 7(A), precursor 701 appears at intervals corresponding to the operating cycle L702 of the process part that is the cause of the precursor. During precursor tracking, precursor detection is performed in the same way as during precursor detection, and the size 704 of the detected precursor 701 is recorded. The size of the precursor is, for example, the diameter 704 for a dot-like precursor 701, and the thickness 705 of the streak for a streaky precursor 703. If multiple precursors are detected, the size is the average of their respective sizes. Furthermore, as shown in images 710 and 711 in Figure 7(B), if precursors 712, 713, and 714 are detected across multiple images, the average of their sizes is recorded as the size of the precursor during that tracking period. The process part causing the occurrence and the inspection type, such as whether it is dot-like or streaky, are also recorded.

[0067] Furthermore, the timing for tracking the precursors can be the same as the timing for detecting the precursors; it can be done each time an image to be inspected is generated, or it can be done on several consecutive images to be inspected at predetermined intervals (e.g., 100 images).

[0068] The predictive diagnostic module 322 further instructs the printer 103 to perform an automatic recovery to resolve the predictive error. This instruction may also be sent to an external PC 101, which then instructs the printer 103.

[0069] Figure 8 is a graph showing an example of fluctuations in precursors tracked by the precursor diagnostic module 322 from the time of precursor detection until automatic recovery is performed.

[0070] Figure 8 shows fluctuations in precursors caused by a single process part, for example, an example of fluctuations in precursors of spot stains caused by the intermediate transfer belt 08. In Figure 8, tracking point 801 indicates the recorded magnitude of the precursor when it was tracked at its cumulative number of printed sheets. The magnitude of the precursor occurring in the image to be inspected increases according to the cumulative number of printed sheets in the image forming system 100. The precursor diagnosis module 322 calculates a prediction curve 802 of the future magnitude of precursors based on the magnitude 801 of the precursor recorded when the precursor was tracked. This prediction curve 802 shows the change in the magnitude of the precursor with respect to the future cumulative number of printed sheets, and can be calculated using known approximation methods such as linear regression and polynomial approximation. The precursor diagnosis module 322 then determines whether the magnitude of the precursor shown in the prediction curve 802 will exceed the magnitude 804 of the precursor that can be detected at the inspection level of the previous job when a predetermined number of sheets 806 are printed after the current job has finished. Here, the predetermined number of sheets refers to the number of sheets printed by the previous job, or a predetermined number of sheets. When the prediction curve 802 is determined to exceed the magnitude of the precursor 804, the precursor diagnostic module 322 activates automatic recovery. This automatic recovery is a process that automatically eliminates the cause of the precursor. At this time, the precursor diagnostic module 322 causes the process part that is causing the precursor, such as the printing device 103, to perform cleaning of the intermediate transfer belt. For example, toner stains accumulated on the intermediate transfer belt 08 are removed by running the transfer belt cleaner for a while.

[0071] The predictive diagnostic module 322 performs a process equivalent to tracking the predictive error during the first job after the automatic recovery operation is activated on the printer 103, and checks whether the predictive error has been resolved. In Figure 8, point 805 shows an example of the magnitude of the predictive error measured during the first job after the automatic recovery operation. Point 805 indicates that the predictive error has been resolved by the automatic recovery because the magnitude of the predictive error has decreased. When the predictive error is resolved, the tracking points that have been recorded up to that point are discarded.

[0072] On the other hand, point 803 shows an example of the magnitude of a precursor when the magnitude of the precursor is not resolved by automatic recovery. Examples of precursors that do not improve include the deterioration of process parts that are difficult to clean, such as charging rollers and pre-exposure parts. Also, if damage to a part worsens, it cannot be improved even with automatic recovery. In such cases where the precursor is not resolved, the precursor diagnostic module 322 cancels the job that was about to be executed. At the same time as canceling the job, a message recommending that a service technician be contacted to request repair or replacement of the part may be displayed on the display unit 215 of the external PC 101. Alternatively, the image forming system 100 may notify a service technician via the internet to repair or replace the problematic part. The precursor diagnostic module 322 also checks whether the precursor has been resolved after the repair or replacement of the part by the service technician. If the precursor has been resolved in this way, the tracking points that have been recorded up to that point are discarded.

[0073] The inspection result prediction module 313 runs on the application necessary to operate the system on the external PC 101. When setting up the print settings or inspection settings for a job, the inspection result prediction module 313 determines whether the magnitude of any of the precursors reaches a size detectable by the inspection level of the inspection settings while the job is running. One method of making this determination is to base the determination on the print settings or inspection settings of the job and the precursor tracking record generated by the precursor diagnosis module 322.

[0074] The inspection result prediction module 313 acquires the print settings and inspection settings set in the print settings module 311 and the inspection settings module 312, respectively. Furthermore, it acquires the tracking record of the precursors generated in the precursor diagnosis module 322.

[0075] Figure 9 is a diagram illustrating the operation of the inspection result prediction module 313 according to Embodiment 1.

[0076] In Figure 9, tracking point 901 shows an example of a precursor variation caused by a single process part, specifically an example of a precursor variation of spot-like contamination caused by the intermediate transfer belt 08. In Figure 9, the magnitude of the precursors indicated by reference numbers 910 and 911 represent the minimum size detectable at inspection level M and inspection level N, respectively. This shows that inspection level N can detect smaller defects than inspection level M.

[0077] Tracking point 901 indicates the magnitude of the anomaly when tracking was performed by the predictive diagnostic module 322. The dashed line 802 is the prediction curve calculated from tracking point 901 by the predictive diagnostic module 322. The post-automatic recovery confirmation point 903 indicates the magnitude of the anomaly after automatic recovery was performed, and here it indicates that the anomaly was not resolved by automatic recovery. Post-printing points 904 for Job A and 905 for Job B show the predicted magnitude of the anomaly assuming that only the number of copies set for Job A and Job B were printed, respectively. Job A has a larger number of printed pages than Job B, and the predicted size of the anomaly is also larger. Furthermore, post-printing point 906 for Job C shows the predicted size of the anomaly assuming that Job C, which has the same number of copies set as Job A, was printed, and the same size as Job A is predicted. Note that here it is assumed that Job C has different inspection settings than Job A.

[0078] The inspection result prediction module 313 calculates the number of copies to be printed until printing is complete, based on the number of copies and the number of pages in the original image data set in the print settings. It then predicts the size of the abnormal area when that number of copies are printed, based on the prediction curve 802. Furthermore, the inspection result prediction module 313 determines whether the predicted size of the abnormal area exceeds the detection size of the inspection level set in the inspection settings. In Figure 9, the print point 904 from job A exceeds the detectable size 911 of inspection level N. Therefore, the inspection result prediction module 313 determines that when inspection level N is set for job A, the size of the abnormal area will exceed the detectable size 911 of inspection level N during the execution of the job, resulting in a series of printed materials with an inspection result of NG.

[0079] Furthermore, in Figure 9, the print point 905 from job B is smaller than the detectable size 911 of inspection level N. Therefore, the inspection result prediction module 313 determines that when inspection level N is set for job B, the size of the defect will not exceed the detectable size 911 of inspection level N while the job is running. As a result, when inspection level N is set for job B, it determines that no consecutive printed materials will result in an inspection failure.

[0080] Furthermore, in Figure 9, the printout point 906 from job C is smaller than the detectable size 910 of inspection level M. Therefore, the inspection result prediction module 313 determines that when inspection level M is set for job C, the size of the abnormal area will not exceed the detectable size 910 of inspection level M while the job is running. As a result, when inspection level M is set for job C, it is determined that no consecutive printed materials with an inspection result of NG will be produced while job C is running.

[0081] Thus, the inspection result prediction module 313 warns the user if it determines that a series of printouts will fail the inspection while the job is running.

[0082] Figure 10 shows an example of a warning screen displayed on the display unit 215 when the external PC 102 according to Embodiment 1 determines that a series of printed materials will result in a "NG" (Not Good) inspection result. Figure 10 shows the state in which a warning pops up on the inspection setting screen 500 of Figure 5.

[0083] This warning is displayed via pop-up 1001 when the user has configured print or inspection settings, and the inspection result prediction module 313 determines that a series of printouts will result in an inspection failure. On the inspection settings screen, inspection settings are made for each inspection type, such as the inspection level for spot stains and the inspection level for streaks. Therefore, the inspection result prediction module 313 determines whether to display a pop-up for each inspection type. In the example in Figure 10, both the inspection level for spot stains and the inspection level for streaks are set to 7, and the user is notified that there is a possibility of inspection failures with an inspection level of 7.

[0084] Specifically, for job A in Figure 9, the warning is displayed when inspection level N is selected in the dot stain inspection level setting field 501 of the inspection setting screen 500. This timing may also be when the inspection setting completion button 505 is pressed. In the case of a setting method where the setting value options are displayed in a pull-down menu or similar and the setting value is obtained by clicking with a pointing device, the options that should trigger a warning may be displayed visually, such as by graying them out. In this case, a warning may be displayed as a pop-up when a grayed-out option is clicked. This warning displays a message informing the user that there is a possibility of an inspection failure. This message has a close button 1002, and when the close button 1002 is pressed, the user returns to the inspection setting screen 500.

[0085] This allows users to know if a test failure is likely to occur and to stop the job execution or modify the test settings before running it. Furthermore, if a warning is displayed before performing automatic recovery for a tracked precursor, the user may be prompted to perform automatic recovery. For example, a message prompting automatic recovery may be displayed in popup 1001, or a button to perform automatic recovery may be provided. This warning is not limited to a popup; it may also be expressed through light, sound, or voice.

[0086] Furthermore, the message displayed in Pop-up 1001 in Figure 10 is "Inspection failure may occur with inspection level 7 settings," but the message can be changed according to the inspection level. For example, it could be displayed as "Cannot print" when the inspection level is high, or as "Inspection failure is more likely when printing a large number of pages" when the inspection level is low.

[0087] Furthermore, the inspection result prediction module 313 does not display the pop-up 1001 if it is not determined that a series of print jobs will result in a "NG" (fail) inspection result. Specifically, in the example in Figure 9, no warning is displayed when inspection level M is set for job C.

[0088] This prevents situations where a series of "NG" (Not Good) errors interrupt the job and cause rework. Furthermore, by prioritizing jobs with fewer print runs or less stringent inspection requirements, printing can continue even while waiting for a service technician to arrive.

[0089] Figure 11 is a sequence diagram illustrating the process from job setup to print completion executed by the image forming system 100 according to Embodiment 1. This sequence begins when the application program necessary to operate the system is launched on the external PC 101.

[0090] First, in S1101, the CPU 211 of the external PC 101 performs print settings and inspection settings. Details of this will be described later with reference to Figure 12. Next, in S1102, the CPU 211 sends the original image data, print settings, and inspection settings to the server 102 and instructs the server 102 to start the job execution, then proceeds to S1103, which is processed by the server 102.

[0091] In S1103, the CPU 221 of server 102 generates print image data and reference image data. Here, the reference image data includes a RIP image obtained by converting the original image data into a raster image, and an attribute image containing inspection area information set in the inspection area setting area of ​​the inspection settings. Note that the reference image data may also be received from an external PC 101 that has been created in advance. Alternatively, instead of the RIP image, the scanned image obtained by printing the original image data and scanning it may be used as the reference image data. For example, a scanned image created by printing multiple copies of the original image data and combining the scanned images read by the reading unit can be used as the reference image data. The print image data is image data to which the RIP image has been further processed by the user as specified in the print settings, such as color conversion, sharpening, and fine line enhancement. Once the generation of the print image data and reference image data is complete, the process proceeds to S1104.

[0092] In S1104, the CPU 221 of server 102 starts executing the job. Once job execution begins, it sends the print image data and print setting information from the job data to the printer 103. Next, in S1105, the CPU 221 of server 102 sends the reference image data and inspection setting information to the inspection device 104. Once this transmission is complete, the process proceeds to S1106, where the printer 103 is processed.

[0093] In S1106, the CPU 231 of the printing device 103 forms an image on the paper. Next, in S1107, the CPU 231 transports the printed material to the inspection device 104.

[0094] Next, proceeding to S1108, the CPU 251 of the inspection device 104 reads the printed material transported from the printing device 103 with the reading unit 255 and generates an inspection target image (scanned image). Next, proceeding to S1109, the CPU 251 of the inspection device 104 performs a predictive diagnosis based on the inspection target image. Details of this will be described later with reference to Figure 13.

[0095] Next, the process proceeds to S1110, where the CPU 251 of the inspection device 104 performs an inspection of the image to be inspected. Then, the process proceeds to S1111, where the CPU 251 determines whether the pre-announcement status is in a state requiring action. The pre-announcement status is initialized in the initial stages of using this image forming system 100, when no pre-announcement has been detected yet. In the detailed flow of pre-announcement described later, if the pre-announcement is not resolved by automatic recovery, the pre-announcement status switches to a state requiring action. If the CPU 251 determines in S1111 that the pre-announcement status is in a state requiring action, the process proceeds to S1112 to cancel the job or notify a service technician. In S1112, the CPU 231 of the printing device 103 stops image formation and notifies the external PC 101 that the job has been canceled.

[0096] As a result, in S1113, the CPU 211 of the external PC 101 displays on the display unit 215 of the external PC 101 that the job has been canceled. At this time, a message advising the user to request repair or parts replacement from a service technician may also be displayed, or the image forming system 100 may notify the service technician via the internet. The process then proceeds to S1114, where the CPU 211 of the external PC 101 changes from a predictive diagnostic state to a predictive tracking state, and the job submission process is completed.

[0097] On the other hand, if the CPU 251 of the inspection device 104 determines in S1111 that the pre-diagnosis state is not in a state requiring action, it determines that printing can continue and proceeds to S1115. In S1115, the CPU 231 of the printing device 103 determines whether printing of all copies specified for that job has been completed. If it determines that it has not been completed, it proceeds to S1106 and starts image formation for the next page or the first page of the next number of copies. Also, if the CPU 231 determines in S1115 that printing of all copies has been completed, it proceeds to S1116.

[0098] In S1116, the CPU 251 of the inspection device 104 determines whether to perform automatic recovery. In S1116, it is determined whether the predicted curve for printing the number of pages printed by the completed job, from the current state, exceeds the detectable size of the inspection level of the previous job. If it is determined in S1116 that it exceeds the size and the precursor diagnosis state is the precursor tracking state, the process proceeds to S1117, and the CPU 251 performs automatic recovery and proceeds to S1118. Otherwise, the submission process for this job ends. In S1118, after performing automatic recovery, the CPU 251 of the inspection device 104 changes the precursor diagnosis state to the automatic recovery confirmation state and ends this process. When the state is changed to the automatic recovery confirmation state, when the next job is submitted, a process is performed to check whether the magnitude of the precursor has improved in the detailed precursor diagnosis flow described later.

[0099] Through the process described above, if the inspection image obtained by scanning the printed material contains a precursor (abnormal area), it is possible to detect a precursor to a future defect caused by the printing device based on the characteristics of the cause of that precursor. In this way, the precursor to a defect caused by the printing device and the cause of that defect can be identified, and processes such as repairing or replacing the part causing the defect can be automatically executed.

[0100] Figure 12 is a flowchart illustrating the print setting and inspection setting (S1101) processes executed on the external PC 101 in the image forming system 100 according to Embodiment 1. The processes shown in this flowchart are realized by the CPU 211 of the external PC 101 executing a program loaded into memory 212. Furthermore, the processes shown in this flowchart are started, for example, when a new job creation button (not shown) is pressed in an application executed on the external PC 101.

[0101] First, in S1201, the CPU 211 displays, for example, the print settings screen 400 shown in Figure 4 above on the display unit 215 of the external PC 101. Next, in S1202, the CPU 211 obtains the print settings information specified by the user through operation of the print settings screen 400. Next, in S1203, the CPU 211 detects that the print settings have been completed when the user presses the print settings complete button 403.

[0102] Next, proceeding to S1204, the CPU 211 displays, for example, the inspection setting screen 500 shown in Figure 5 above, on the display unit 215 of the external PC 101. Next, proceeding to S1205, the CPU 211 obtains the inspection setting information specified by the user through operation of the inspection setting screen 500. For example, if a level is specified in the spot stain inspection level setting field, that level is obtained. Then, proceeding to S1290, the CPU 211 determines whether the precursor diagnosis state is the tracking state. If it is determined to be the tracking state, proceeding to S1206, the CPU 211 functions as the inspection result prediction module 313 and starts predicting the inspection result. If it is not the tracking state, i.e., the detection state or the automatic recovery confirmation state, proceeding to S1210. The reason why inspection result prediction is not performed when the automatic recovery confirmation state is that a job needs to be executed to confirm whether the precursor has been resolved by automatic recovery. In S1210, the CPU 211 waits for the user to press the inspection setting completion button 505. When the system detects that the "Inspection Settings Complete" button 505 has been pressed, it confirms the inspection settings and terminates this print settings and inspection settings process.

[0103] In S1206, the CPU 211 acquires a record of the precursor. Next, in S1207, the CPU 211 calculates a prediction curve for the magnitude of the precursor from the acquired record of the precursor. Then, in S1208, the CPU 211 calculates the number of copies to be printed by the time printing is complete, based on the number of copies set in the print settings and the number of pages in the original image data. Then, in S1209, the CPU 211 uses the calculated number of copies and the prediction curve to determine whether the predicted size of the precursor at the time printing is complete exceeds the detection size of the inspection level set in the inspection settings. If it is determined that it exceeds the detection size, the CPU 211 proceeds to S1211 and displays a warning pop-up 1001 on the display unit 215. When the CPU 211 detects that the close button 1002 of this warning pop-up 1001 has been pressed by the user, it proceeds to S1204 and displays the inspection settings screen 500 again. If it is determined that the value is not exceeded, the process proceeds to S1210, and CPU211 waits for the user to press the "Complete Inspection Settings" button 505. Upon detecting that the "Complete Inspection Settings" button 505 has been pressed, the inspection settings are confirmed, and the process of setting the print settings and inspection settings is terminated.

[0104] In the flowchart in Figure 12, the inspection result prediction is performed when the settings values ​​in the various settings fields are entered, but the timing of the inspection result prediction is not limited to this. It is sufficient if the inspection result prediction is performed after both the job print settings and inspection settings have been set, and before the job is executed, and a warning pop-up 1001 is displayed according to the prediction result. For example, it could be at the time the inspection settings complete button 505 is pressed.

[0105] As explained above, this process allows for the creation of a prediction curve of the magnitude of a printing device-related defect from tracking records of precursors to defects. Based on this prediction curve and the planned number of prints, it is possible to determine whether a printing device-related defect will occur during printing. If a defect is predicted, a warning, such as instructing a change in the inspection level, can be issued before executing the job.

[0106] Figure 13 is a flowchart illustrating the details of the predictive diagnostic process (S1109) performed by the inspection device 104 of the image forming system 100 according to Embodiment 1. The process shown in this flowchart is realized by the CPU 251 of the inspection device 104 executing a program loaded into memory 252.

[0107] First, in S1301, the CPU 251 determines whether the premonitory diagnosis state is a premonitory detection state, a premonitory tracking state, or neither. If it is neither, proceed to S1313. If it is a premonitory detection state or a premonitory tracking state, proceed to S1302. In S1302, the CPU 251 determines whether it is time to detect or track a premonitory sign in the acquired image to be inspected. This timing may be, for example, each time an image to be inspected is generated, or it may be at intervals of a predetermined number of images (e.g., 100 images). However, if the timing is at intervals of a predetermined number of images, the inspection device 104 counts which image to inspect has been acquired, and determines that it is the right timing when the count value exceeds the predetermined number. If it is not the right timing, the CPU 251 terminates the premonitory diagnosis for the image to be inspected. If it is the right timing, proceed to S1303.

[0108] In S1303, CPU251 determines whether it has acquired a predetermined number of images (e.g., 5 images) for feature extraction since it was determined that it was time to detect or track an anomaly. If it has not acquired any images, it terminates the anomaly diagnosis for these images. On the other hand, if it has acquired the predetermined number of images, it proceeds to S1304.

[0109] In S1304, CPU251 determines whether the current premonitory diagnosis state is the detection state. If it determines that it is the detection state, it proceeds to S1305; if it determines that it is not the detection state, i.e., the tracking state, it proceeds to S1309.

[0110] In S1305, the CPU 251 extracts features specific to the process parts that are the cause of the anomaly from the image under inspection for feature extraction. Then, proceeding to S1306, the CPU 251 determines whether the image under inspection for feature extraction possesses the specific features for each type of process part that is the cause of the anomaly. If it is determined that the specific features are present, that is, that the features of that part have been extracted from the image under inspection, the process proceeds to S1307, where the CPU 251 identifies the type of process part that is the cause of the anomaly. Then, proceeding to S1308, the CPU 251 changes the anomaly diagnosis state to the tracking state and terminates this process. On the other hand, if it is determined in S1306 that no features were extracted, the anomaly diagnosis for this image under inspection for feature extraction is terminated.

[0111] If tracking is determined in S1304, the process proceeds to S1309, where the CPU 251 extracts features specific to the process part that is the cause of the precursor identified in S1307 from the inspection image used for feature extraction. Then, in S1310, the CPU 251 measures the magnitude of the precursor based on the extracted features. Then, in S1311, the CPU 251 records the measured magnitude of the precursor as a precursor tracking record, associating it with the type of process part that is the cause of the precursor and the cumulative number of printed pages. Then, in S1312, the CPU 251 calculates a prediction curve based on the precursor tracking record and proceeds to S1305, where it performs detection on precursors that have not yet been tracked.

[0112] Furthermore, if in S1301 the CPU 251 determines that the precursor diagnosis state is neither the precursor detection state nor the precursor tracking state, that is, if it determines that it is in the automatic recovery confirmation state, it proceeds to S1313. In S1313, the CPU 251 determines whether it has acquired a predetermined number of images to be inspected for feature extraction, which is necessary for automatic recovery confirmation, since the start of printing of the first job after automatic recovery was activated. If it has not acquired any images, the CPU 251 terminates the precursor diagnosis for the images to be inspected.

[0113] On the other hand, if the CPU 251 determines in S1313 that it has acquired a predetermined number of sheets, the process proceeds to S1314, where the CPU 251 extracts features specific to the process part that is the cause of the precursor identified in S1307 from the inspection target image for feature extraction. Next, the process proceeds to S1315, where the CPU 251 measures the location and size of the precursor based on the extracted features. Then, the process proceeds to S1316, where the CPU 251 records the size of the precursor measured in S1315 as a precursor tracking record, associating it with the type of process part that is the cause of the precursor identified and the cumulative number of printed sheets.

[0114] Next, the process proceeds to S1317, where the CPU 251 determines whether the warning sign has been resolved based on the recorded magnitude of the warning sign. If it determines that the warning sign has been resolved, the process proceeds to S1318. If it determines that the warning sign has not been resolved, the process proceeds to S1319, where the CPU 251 changes the warning sign diagnosis state to a state requiring action, and terminates this warning sign diagnosis process.

[0115] In S1318, CPU251 determines whether there are any other signs being tracked besides those confirmed in S1317. If it determines that there are signs being tracked, it proceeds to S1321, changes the sign diagnosis state to the tracking state, and terminates this process in order to continue tracking those signs. If CPU251 determines in S1318 that there are no other signs being tracked, it proceeds to S1320, changes the sign diagnosis state to the detection state, and terminates this sign diagnosis process.

[0116] As described above, according to Embodiment 1, when one or more warning signs are detected, a prediction curve of the future warning sign size is calculated based on the recorded warning sign size. Then, when the user sets the print settings or inspection settings, the size of the warning sign (abnormal area) when printing the set number of pages is predicted from the prediction curve. Furthermore, it is determined whether the predicted warning sign size exceeds the detection size of the inspection level set in the inspection settings. If it is determined that the set inspection level is such that consecutive print jobs with inspection results of NG will occur during job execution, a warning is displayed as a pop-up on the external PC display. This prevents the user from executing jobs that would be interrupted and require rework due to consecutive NGs. Furthermore, depending on the determination result, the user can prioritize jobs with fewer print jobs or jobs with less stringent inspection levels. In this way, printing can continue while waiting for the arrival of a service technician who has been requested to resolve warning signs that may cause future inspection NGs, while suppressing the occurrence of inspection NGs.

[0117] Although Embodiment 1 has been described above, the present invention is not limited to Embodiment 1 described above. For example, although the inspection device 104 was equipped with an inspection module 321 and a precursor diagnosis module 322, these modules may be equipped in the server 102. That is, the inspection process, which includes the process of comparing the image to be inspected with a reference image, and the precursor diagnosis process may be performed by the server 102. Furthermore, the server 102 may be equipped with a GPU as hardware to perform image comparison processing at high speed.

[0118] Specifically, the reading unit 255 of the inspection device 104 reads and generates an image to be inspected, which is then sent to the server 102. The inspection module 321 of the server 102 then compares the reference image generated by the server 102 with the image to be inspected acquired from the inspection device 104 to determine whether or not there are defects in the printed material. In addition, the predictive diagnostic module 322 of the server 102 may perform predictive detection, predictive tracking, and automatic recovery to resolve the predictive issue based on the image to be inspected generated by the inspection device 104.

[0119] [Embodiment 2] Embodiment 2 describes a case where the amount of change in the size of the precursor varies depending on the image to be printed. Note that the configuration and hardware configuration of the image forming system in Embodiment 2 are the same as in Embodiment 1, so their description will be omitted.

[0120] One factor that can change the magnitude of a warning sign is the amount of toner used. For example, in the case of a warning sign that grows larger due to toner adhering to scratches or foreign objects on the drum, the increase in the magnitude of the warning sign will increase as the amount of toner used increases. Therefore, by changing the amount of increase in the prediction curve according to the amount of toner used when printing print image data, a more accurate prediction curve can be obtained.

[0121] Figure 14 is a diagram illustrating the operation of the inspection result prediction module 313 of the external PC 101 according to Embodiment 2. Since Figure 12 is a variation of Figure 9 of Embodiment 1, the parts common to both Figure 9 and Figure 12 are given the same reference numerals, and their explanations are omitted.

[0122] The post-print point 1401 for Job D shows the predicted magnitude of the warning sign, assuming that Job D, which has different print settings than Job A, printed the set number of copies. Here, the number of pages printed for Job D is assumed to be less than that of Job A. Furthermore, the print image data for Job D is assumed to use more toner than that of Job A. Print image data that uses a lot of toner is, for example, original image data that contains many pages with high density, or print image data generated when the toner density is set high in the print settings. The prediction curve 1402 is the prediction curve calculated to determine the post-print point 1401 for Job D. It is also assumed that the toner usage of the print image data of the job that was running at the time the tracking point 901 used to calculate the prediction curve 802 was recorded is the same as that of Job A. The slope of the prediction curve 1402 is steeper than that of the prediction curve 802 calculated using the tracking point 901. Therefore, as shown in Figure 14, even though the number of pages printed for Job D is less than that of Job A, the predicted magnitude of the warning sign may be greater than that of Job A.

[0123] To determine the predicted curve 1402, first, the predicted curve 802 is calculated using the tracking point 901. Here, it is obtained as a linear straight line using linear regression. Next, the slope of the linear straight line is adjusted according to the toner usage of job D. This adjustment is determined based on the ratio of the average toner usage of job D to the average toner usage of each page of the print image data of the immediately preceding job. For example, if the toner usage doubles, the slope of the linear straight line is adjusted to double. The toner usage of the immediately preceding job is obtained, for example, from the job history recorded in the application on the external PC 101.

[0124] Figure 15 is a flowchart illustrating the print setting and inspection setting (S1101) processes executed on the external PC 101 in the image forming system 100 according to Embodiment 2. This flowchart is a variation of the flowchart in Figure 12 according to Embodiment 1, and processes common to both Figure 12 and Figure 12 are indicated by the same reference numerals, and their explanations are omitted. The processes shown in this flowchart are realized by the CPU 211 of the external PC 101 executing a program loaded into memory 212. Furthermore, the processes shown in this flowchart are started, for example, when a new job creation button (not shown) is pressed in an application executed on the external PC 101.

[0125] When the print settings are completed in S1203, the process proceeds to S1501, where the CPU 211 calculates the toner usage for the current job and the previous job based on the print settings set by the user on the print settings screen 400. The toner usage for the previous job can be obtained, for example, from the job history recorded in an application on an external PC 101. S1501 is executed when it is detected that the print settings complete button 403 was pressed in S1203. After S1501 is performed, the process proceeds to S1204.

[0126] Then, in S1206, the CPU 211 acquires a record of the precursor and proceeds to S1502. From the record of the precursor, the toner usage of the previous job, and the toner usage obtained in S1501, the CPU 211 calculates a prediction curve 1402 of the magnitude of the precursor. The subsequent processing is the same as in Embodiment 1 described above.

[0127] According to Embodiment 2, a more accurate prediction curve can be obtained by changing the amount of increase in the prediction curve according to the amount of toner used when printing print image data. This makes it possible to prevent the job from being interrupted by consecutive NGs even if no warning is issued when printing print image data with high toner usage.

[0128] Furthermore, the prediction curve derived from the number of printed pages and the size of the warnings suggests that even for jobs with low toner usage that are predicted to be interrupted midway due to consecutive NGs during job execution, it may be possible to execute them without warning by using a prediction curve that corresponds to the amount of toner used.

[0129] [Embodiment 3] Embodiment 3 describes the operation when multiple pre-configured jobs are accumulated in the print job queue and the warning signs are not resolved by automatic recovery. Note that the configuration of the image forming system and hardware configuration in Embodiment 3 are the same as in Embodiment 1, so their description will be omitted.

[0130] The print job queue holds jobs for which print and inspection settings have been configured until printing is complete. The print job queue can be implemented, for example, by holding the job data in the memory 212 or auxiliary storage 213 of the external PC 101 after the print and inspection settings of the job have been completed on the external PC 101 until it is sent to the server 102. Alternatively, the job data sent to the server 102 may be held in the memory 222 or auxiliary storage 223 of the server 102 until all pages have been printed and inspected.

[0131] Figure 16 shows an example of a job management screen in Embodiment 3 that displays jobs held in the print job queue.

[0132] The job management screen 1600 has a list of jobs held in the queue 1601, a new job creation button 1602, and a print start button 1603. When the new job creation button 1602 is pressed, the user is sequentially redirected to the print settings screen 400 and the inspection settings screen 500, where print settings and inspection settings are performed. When these settings are completed and the user returns to the job management screen 1600, the job created is added to the end of the job list 1601. Even if the user returns to the job management screen 1600 before the settings are completely completed, the incomplete job may still be added to the job list 1601. The job list 1601 includes an ID that identifies the job, the name of the original image data, the number of pages in the original image data, the number of copies specified in the print settings, the inspection level for spot stains specified in the inspection settings, and the job status, but the information displayed is not limited to these. For example, the number of pages does not have to be displayed, and the inspection level for streak stains may also be displayed. When the print start button 1603 is pressed while a job is selected, such as job 1604, it sends the data of the selected job to the server 102 and instructs the server 102 to start executing that job.

[0133] In the job list 1601, the status of a job is displayed as follows: for example, a job that is currently being printed by the printer is displayed as "Printing," and a job that has had the print start button 1603 pressed and is waiting for the above job to finish printing is displayed as "Waiting to print." Jobs for which the print start button 1603 has not been pressed are displayed as "Not sent." Once the above job that is currently printing is completed, jobs in the "Waiting to print" state will sequentially switch to "Printing," and printing and inspection will begin.

[0134] Furthermore, in the job management screen 1600 shown in Figure 16, the inspection level for the defects that are expected to result in a "NG" (Not Good) inspection, such as spot stains or streaks, may be displayed in the job list 1601.

[0135] Alternatively, in the job list 1601, jobs with a low inspection level, i.e., jobs that are less likely to fail inspection, can be displayed at the top of the job list 1601 to encourage users to prioritize the execution of jobs that are less likely to fail inspection.

[0136] Embodiment 3 describes the processing of jobs waiting to be printed when multiple pre-configured jobs are accumulated in the print job queue and the warning signs are not resolved by automatic recovery. According to Embodiment 3, the status of jobs waiting to be printed is changed according to the prediction of the inspection result prediction module 313. This prevents jobs from being interrupted midway due to consecutive NGs and resulting in rework.

[0137] Figure 17 is a sequence diagram illustrating the process from job setup to print completion executed by the image forming system 100 according to Embodiment 3. This sequence begins when the application program necessary to operate the system is launched on the external PC 101. Figure 17 shows a modified example of Figure 11 and begins when one printing job is completed and there are subsequent jobs waiting to be printed. Processes common to Figure 11 are indicated by the same reference numerals, and their explanations are omitted.

[0138] In S1701, CPU211 of external PC101 changes the status of a job that is waiting to print to "printing" and starts printing.

[0139] Furthermore, if image formation by the printing device 103 is stopped in S1112, the process proceeds to S1702, where the CPU 211 of the external PC 101 changes the status of subsequent jobs waiting to be printed according to the prediction of the inspection result prediction module 313. This process in S1702 is executed after the inspection device 104 determines in S1111 that the precursor diagnosis state is in a state requiring action, and after the printing device 103 stops image formation in S1112.

[0140] Figure 18 is a diagram illustrating the operation of the inspection result prediction module 313 according to Embodiment 3. Here, the process of changing the status of a job that is waiting to print, as shown in S1702 in Figure 17, according to the prediction of the inspection result prediction module 313, will be explained with reference to Figures 16 and 18.

[0141] In Figure 18, tracking point 1801 shows the recorded size of the precursor tracked at the cumulative number of printed pages. Automatic recovery confirmation point 1802 shows the size of the precursor after automatic recovery was performed after the completion of job ID "1611" in the job list 1601 in Figure 16, indicating that the precursor was not resolved by automatic recovery. The dashed line 1803 is the prediction curve calculated from tracking point 1801. Jobs ID "1612" and "1614" both have the same number of printed pages. After confirming the automatic recovery of job ID "1611", if either job ID "1612" or job ID "1614" is executed, the precursor expands to the size indicated by point 1804 in either case. Job ID "1612" has an inspection level of 7, and since the size of the precursor after expansion is larger than the minimum size 1806 detected by inspection level 7, there is a high possibility of consecutive NGs occurring. Therefore, after confirming automatic recovery, it is desirable to prioritize job ID "1614" (inspection level 3). Accordingly, the status of job ID "1612" will be changed to recovery waiting state, preventing it from running until repairs are carried out by a service technician.

[0142] Furthermore, in S1702, a job to be executed after the printing of job ID "1614" is completed is also selected. When determining whether to execute job ID "1615", the magnitude of the warning sign when printing the number of pages for job ID "1615" is predicted from the cumulative number of pages printed after printing job ID "1614" using the prediction curve 1803. Point 1805 indicates the magnitude of the warning sign when printing job ID "1615" after printing job ID "1614". Here, since the inspection level of job ID "1615" is 5, the magnitude of the warning sign at point 1805 is larger than the minimum size 1807 detected by inspection level 5. For this reason, the status of job ID "1615" is changed to the recovery waiting state.

[0143] In this way, when multiple pre-configured jobs are accumulated in the print job queue, the next job to be executed can be determined based on the print and inspection settings of that job and the predictive curve for any warning signs.

[0144] Figure 19 is a flowchart illustrating the details of the status change process (S1702) of a pending job executed by an external PC 101 of the image forming system 100 according to Embodiment 3. The process shown in this flowchart is realized by the CPU 211 of the external PC 101 executing a program loaded into memory 212.

[0145] First, in S1901, CPU211 acquires a record of the precursor. Next, in S1902, CPU211 calculates a prediction curve of the magnitude of the precursor from the record of the precursor. Next, in S1903, CPU211 acquires the status of the first job in the print job queue. Then, in S1904, CPU211 determines whether the acquired job is in print waiting state. If it is determined that it is not in print waiting state, it proceeds to S1910; if it is determined that it is in print waiting state, it proceeds to S1905.

[0146] In S1905, CPU211 calculates the number of pages to be printed from the print settings information of the job. Furthermore, if there are jobs that are in the "print waiting" state prior to the current job, the number of pages to be printed for those jobs is added together to calculate the total number of pages to be printed when the current job is completed. Next, in S1906, CPU211 obtains the inspection level from the inspection settings information of the job. Then, in S1907, CPU211 uses the number of pages to be printed and the prediction curve to determine whether the predicted size of the warning sign at the time of print completion exceeds the detection size of the inspection level set in the inspection settings. If it determines that it exceeds the limit, it proceeds to S1908, where CPU211 changes the status of the job to "recovery waiting" and proceeds to S1909. On the other hand, if it determines that it does not exceed the limit, it proceeds to S1909 with the job status remaining in "print waiting". In S1909, CPU211 determines whether it has obtained the status of all jobs in the queue. If it determines that it has not, it proceeds to S1910, obtains the status of the next job after the current job, and proceeds to S1904. Once the status of all jobs in the queue has been retrieved, the process of changing the status of this pending job is terminated.

[0147] As described above, according to Embodiment 3, if the warning signs are not resolved by automatic recovery when multiple configured jobs are accumulated in the print job queue, the status of subsequent jobs waiting to be printed is changed according to the prediction of the inspection result prediction module. This prevents jobs that would be interrupted and require rework due to consecutive NGs from being executed. Furthermore, by prioritizing jobs with fewer print jobs or jobs with less stringent inspection levels, printing can continue even while waiting for a service technician to arrive.

[0148] (Other embodiments) The present invention can also be realized by supplying a program that implements one or more of the functions of the above-described embodiments to a system or device via a network or storage medium, and by having one or more processors in the computer of that system or device read and execute the program. It can also be realized by a circuit (e.g., an ASIC) that implements one or more functions.

[0149] This specification and drawings disclose the following image forming system, information processing device, control method thereof, and program.

[0150] <Item 1> An image forming system comprising a printing device, an inspection device for inspecting printed materials printed by the printing device, and an information processing device for controlling the printing device and the inspection device, The aforementioned information processing device is A print setting means for setting the print settings for a job to be printed by the aforementioned printing device, The system includes an inspection setting means for performing inspection settings for the inspection in the inspection device for the job, The inspection device, A reading means that reads the printed material printed by the printing device according to the job and generates a read image, The system includes a precursor detection means for detecting precursors to defects in the printed material that are included in the read image, The aforementioned information processing device further, A prediction means predicts whether the defect will occur when printing according to the print settings and inspection settings, based on the print settings set by the print setting means, the inspection settings set by the inspection setting means, and the precursors detected by the precursor detection means. The system includes a notification means that notifies when the prediction means predicts that the defect will occur, The image forming system is characterized in that the inspection settings include an inspection threshold for determining whether the precursor is a defect in the printed material.

[0151] <Item 2> The image forming system according to item 1, characterized in that the aforementioned precursor is an abnormal area detected by comparing the read image with a reference image, and corresponds to an abnormal area whose shape and position are common to the aforementioned abnormal area.

[0152] <Item 3> The image forming system according to item 1 or 2, characterized in that the inspection threshold corresponds to the smallest size of a defect that can be detected by the inspection device.

[0153] <Item 4> The image forming system according to any one of items 1 to 3, characterized in that the notification means notifies that it is predicted that the defect will occur when printing with the print settings and the inspection settings.

[0154] <Item 5> The image forming system according to item 4, further characterized in that the notification means also notifies the inspection threshold at which it is predicted that the defect will occur.

[0155] <Item 6> The image forming system according to any one of items 1 to 5, characterized in that the print settings set by the print setting means include at least image data of the original and the number of copies to be printed.

[0156] <Item 7> The image forming system according to any one of items 1 to 6, characterized in that the precursor detection means identifies the component of the printing apparatus that is the cause of the precursor when it detects the precursor.

[0157] <Item 8> The image forming system according to any one of items 1 to 7, characterized in that the precursor detection means records the size of the abnormal area corresponding to the precursor in correspondence with the number of read images of the printed material printed by the printing device after the precursor has been detected.

[0158] <Item 9> The image forming system according to item 8, characterized in that the precursor detection means obtains a prediction curve that predicts the magnitude of the precursor relative to the number of prints to be printed by the printing device, based on the number of read images and the size of the abnormal area corresponding to the precursor.

[0159] <Item 10> The image forming system according to any one of items 1 to 9, characterized in that when the inspection device detects one or more types of warning signs, it instructs the printing device to perform an automatic recovery to eliminate the warning signs after the job is completed.

[0160] <Item 11> The image forming system according to item 9, characterized in that when the inspection device has detected one or more types of precursors, and the prediction curve obtained after the job is completed and a predetermined number of copies are printed by the printing device exceeds the inspection threshold, the inspection device instructs the printing device to perform an automatic recovery to eliminate the precursors.

[0161] <Item 12> The image forming system according to item 9, characterized in that the prediction means predicts that a defect will occur when printing with the print settings if, when one or more types of precursors are detected, the prediction curve obtained when printing the number of sheets set by the print setting means exceeds the inspection threshold set by the inspection setting means.

[0162] <Item 13> The image forming system according to any one of items 1 to 12, further characterized in that when one or more precursors are detected, the inspection setting means prevents the setting of an option for the inspection threshold of the inspection setting in which the prediction means predicts the occurrence of the defect.

[0163] <Item 14> The aforementioned information processing device is The system further includes means for obtaining the amount of toner used in the job based on the print settings, The image forming system according to item 12, characterized in that the prediction means predicts whether the defect will occur by changing the prediction curve based on the amount of toner used. <Item 15> The aforementioned information processing device further, The image forming system according to item 14, characterized in that the amount of toner used is recorded in the job history, and when changing the amount of increase in the prediction curve, the amount of toner used recorded in the job history is referred to.

[0164] <Item 16> The aforementioned information processing device further, The system includes a holding means for holding one or more jobs having the print settings set by the print setting means and the inspection settings set by the inspection setting means, The image forming system according to item 9, characterized in that it sequentially executes the jobs held in the holding means.

[0165] <Item 17> The image forming system according to item 16, characterized in that, when one or more precursors are detected, the prediction means predicts that a defect will occur when printing with the print settings if the prediction curve obtained when printing the number of copies set by the print setting means exceeds the inspection threshold set by the inspection setting means for each of the multiple jobs held in the holding means, and prevents the execution of the jobs for which a defect is predicted to occur.

[0166] <Item 18> An information processing device that controls a printing device and an inspection device for inspecting printed materials printed by the printing device, A print setting means for setting the print settings for a job to be printed by the aforementioned printing device, An inspection setting means for performing inspection settings for the inspection in the inspection device for the aforementioned job, A prediction means predicts whether a defect will occur when printing according to the print settings and the inspection settings, based on the print settings set by the print setting means, the inspection settings set by the inspection setting means, and the signs of potential defects in the printed material contained in the read image obtained by reading the printed material with the inspection device, The system includes a notification means that notifies when the prediction means predicts that the defect will occur, The information processing device is characterized in that the inspection setting includes an inspection threshold for determining whether the precursor is a defect in the printed material.

[0167] <Item 19> The information processing device according to item 18, characterized in that the aforementioned precursor is an abnormal location detected by the inspection device by comparing the read image of the printed material with a reference image, and the abnormal location corresponds to an abnormal location that has the same shape and position.

[0168] <Item 20> A control method for controlling an information processing device that controls a printing device and an inspection device that inspects printed materials printed by the printing device, The print setting means includes a print setting step for setting the print settings for a job to be printed by the printing device, The inspection setting means includes an inspection setting step of performing inspection settings for the inspection in the inspection device for the job, The prediction means includes a prediction step that predicts whether a defect will occur when printing according to the print settings and the inspection settings, based on the print settings set in the print setting step, the inspection settings set in the inspection setting step, and signs of potential defects in the printed material included in the read image obtained by reading the printed material with the inspection device, The notification means includes a notification step that notifies when it is predicted in the prediction step that the defect will occur, The control method is characterized in that the inspection setting includes an inspection threshold for determining whether the precursor is a defect in the printed material.

[0169] <Item 21> A program for causing a computer to perform each step of the control method described in claim 20.

[0170] The present invention is not limited to the embodiments described above, and various modifications and variations are possible without departing from the spirit and scope of the invention. Accordingly, the following claims are attached to make the scope of the invention public. [Explanation of Symbols]

[0171] 101…External PC, 102…Server, 103…Printing device, 104…Inspection device, 105…Stacker, 311…Printing settings module, 312…Inspection settings module, 313…Inspection result prediction module, 321…Inspection module, 322…Predictive diagnostic module

Claims

1. An image forming system comprising a printing device, an inspection device for inspecting printed materials printed by the printing device, and an information processing device for controlling the printing device and the inspection device, The aforementioned information processing device is A print setting means for setting the print settings for a job to be printed by the aforementioned printing device, The system includes an inspection setting means for performing inspection settings for the inspection in the inspection device for the job, The inspection device, A reading means that reads the printed material printed by the printing device according to the job and generates a read image, The system includes a precursor detection means for detecting precursors to defects in the printed material that are included in the read image, The aforementioned information processing device further, A prediction means predicts whether the defect will occur when printing according to the print settings and inspection settings, based on the print settings set by the print setting means, the inspection settings set by the inspection setting means, and the precursors detected by the precursor detection means. The system includes a notification means that notifies when the prediction means predicts that the defect will occur, The image forming system is characterized in that the inspection settings include an inspection threshold for determining whether the precursor is a defect in the printed material.

2. The image forming system according to claim 1, characterized in that the aforementioned precursor is an abnormal area detected by comparing the read image with a reference image, and the shape and position of the abnormal area are the same for the abnormal area.

3. The image forming system according to claim 1, characterized in that the inspection threshold corresponds to the smallest size of a defect that can be detected by the inspection device.

4. The image forming system according to claim 1, characterized in that the notification means notifies that it is predicted that the defect will occur when printing with the print settings and inspection settings.

5. The image forming system according to claim 4, further characterized in that the notification means also notifies the inspection threshold at which it is predicted that the defect will occur.

6. The image forming system according to claim 1, characterized in that the print settings set by the print setting means include at least image data of the original and the number of copies to be printed.

7. The image forming system according to claim 1, characterized in that the precursor detection means identifies the component of the printing apparatus that is the cause of the precursor when it detects the precursor.

8. The image forming system according to claim 1, characterized in that the precursor detection means records the size of the abnormal area corresponding to the precursor in correspondence with the number of read images of the printed material printed by the printing device after the precursor has been detected.

9. The image forming system according to claim 8, characterized in that the precursor detection means obtains a prediction curve that predicts the magnitude of the precursor relative to the number of prints to be printed by the printing device, based on the number of read images and the size of the abnormal area corresponding to the precursor.

10. The image forming system according to claim 1, characterized in that when the inspection device detects one or more types of warning signs, it instructs the printing device to perform an automatic recovery to eliminate the warning signs after the job is completed.

11. The image forming system according to claim 9, characterized in that when the inspection device has detected one or more types of precursors, and the prediction curve obtained after the job is completed and a predetermined number of copies have been printed by the printing device exceeds the inspection threshold, the inspection device instructs the printing device to perform an automatic recovery to eliminate the precursors.

12. The image forming system according to claim 9, characterized in that the prediction means predicts that a defect will occur when printing with the print settings if, when one or more types of precursors are detected, the prediction curve obtained when printing the number of sheets set by the print setting means exceeds the inspection threshold set by the inspection setting means.

13. The image forming system according to claim 1, further characterized in that when one or more precursors are detected, the inspection setting means prevents the selection of an inspection threshold for the inspection setting in which the prediction means predicts the occurrence of the defect.

14. The aforementioned information processing device is The system further includes means for obtaining the amount of toner used in the job based on the print settings, The image forming system according to claim 12, characterized in that the prediction means predicts whether the defect will occur by changing the prediction curve based on the amount of toner used.

15. The aforementioned information processing device further, The image forming system according to claim 14, characterized in that the amount of toner used is recorded in the job history, and when changing the amount of increase in the prediction curve, the amount of toner used recorded in the job history is referred to.

16. The aforementioned information processing device further, The system includes a holding means for holding one or more jobs having the print settings set by the print setting means and the inspection settings set by the inspection setting means, The image forming system according to claim 9, characterized in that it sequentially executes the jobs held in the holding means.

17. The image forming system according to claim 16, characterized in that when one or more precursors are detected, the prediction means predicts that a defect will occur when printing with the print settings if the prediction curve obtained when printing the number of copies set by the print setting means exceeds the inspection threshold set by the inspection setting means for each of the plurality of jobs held in the holding means, and prevents the execution of the jobs for which a defect is predicted to occur.

18. An information processing device that controls a printing device and an inspection device for inspecting printed materials printed by the printing device, A print setting means for setting the print settings for a job to be printed by the aforementioned printing device, An inspection setting means for performing inspection settings for the inspection in the inspection device for the aforementioned job, A prediction means predicts whether a defect will occur when printing according to the print settings and the inspection settings, based on the print settings set by the print setting means, the inspection settings set by the inspection setting means, and the signs of potential defects in the printed material contained in the read image obtained by reading the printed material with the inspection device, The system includes a notification means that notifies when the prediction means predicts that the defect will occur, The information processing device is characterized in that the inspection setting includes an inspection threshold for determining whether the precursor is a defect in the printed material.

19. The information processing device according to claim 18, characterized in that the aforementioned precursor is an abnormal location detected by the inspection device by comparing the read image of the printed material with a reference image, and the abnormal location corresponds to an abnormal location that has the same shape and position as the aforementioned abnormal location.

20. A control method for controlling an information processing device that controls a printing device and an inspection device that inspects printed materials printed by the printing device, The print setting means includes a print setting step for setting the print settings for a job to be printed by the printing device, The inspection setting means includes an inspection setting step of performing inspection settings for the inspection in the inspection device for the job, The prediction means includes a prediction step that predicts whether a defect will occur when printing according to the print settings and the inspection settings, based on the print settings set in the print setting step, the inspection settings set in the inspection setting step, and signs of potential defects in the printed material included in the read image obtained by reading the printed material with the inspection device, The notification means includes a notification step that notifies when it is predicted in the prediction step that the defect will occur, The control method is characterized in that the inspection setting includes an inspection threshold for determining whether the precursor is a defect in the printed material.

21. A program for causing a computer to perform each step of the control method described in claim 20.

Images