Image forming apparatus, image forming method, and program

Abstract

The purpose is to notify users of the remaining lifespan of a used unit when replacing an internal unit of an image forming apparatus with a used unit and installing the used unit. [Solution] The system includes: an installation status detection unit that detects whether or not the installation of a unit used for image formation has been completed; a pattern image forming unit that forms a pattern image used for calculating remaining lifespan when the installation status detected by the installation status detection unit indicates that the installation has not been completed; a receiving unit that receives a judgment result based on the pattern image formed by the pattern image forming unit; a remaining lifespan calculation unit that calculates the remaining lifespan of the unit based on the judgment result received by the receiving unit when the unit is a used unit; and a remaining lifespan notification unit that notifies the remaining lifespan of the unit calculated by the remaining lifespan calculation unit.

Description

Technical Field

[0001] The present invention relates to an image forming apparatus, an image forming method, and a program.

Background Art

[0002] In an image forming apparatus using an electrophotographic printing method, there is known a technique for detecting the life (reaching the replacement time) of a unit inside the apparatus and notifying the user of the life of the unit.

[0003] Patent Document 1 discloses a configuration for determining and notifying the life of an image carrier based on a detection result obtained by irradiating light on the surface of the image carrier with an optical sensor in order to determine or notify information regarding the life of an image carrier having an uneven shape formed on its surface.

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, according to the conventional technology, when a service technician replaces an internal unit of an image forming apparatus with a used unit and installs the used unit, it is not possible to notify the remaining life (remaining life) of the used unit at the time of replacement, so there is a problem that it is not possible to easily manage the next maintenance time.

[0005] The present invention has been made in view of the above, and an object thereof is to notify the remaining life of a used unit at the time of replacement when replacing an internal unit of an image forming apparatus with a used unit and installing the used unit.

Means for Solving the Problems

[0006] To solve the above-mentioned problems and achieve the objective, the present invention comprises: an installation status detection unit that detects whether or not the installation of a unit used for image formation has been completed; a pattern image forming unit that forms a pattern image used for calculating remaining lifespan when the installation status detected by the installation status detection unit indicates that the installation has not been completed; a receiving unit that receives a judgment result based on the pattern image formed by the pattern image forming unit; a remaining lifespan calculation unit that calculates the remaining lifespan of the unit based on the judgment result received by the receiving unit when the unit is a used unit; and a remaining lifespan notification unit that notifies the remaining lifespan of the unit calculated by the remaining lifespan calculation unit. [Effects of the Invention]

[0007] According to the present invention, when replacing an internal unit of an image forming apparatus with a used unit and installing the used unit, it is possible to notify the user of the remaining lifespan of the used unit at the time of replacement. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 shows an example of an image forming apparatus according to the first embodiment. [Figure 2] Figure 2 shows an example of the hardware configuration of an image forming apparatus. [Figure 3] Figure 3 shows an example of a functional block of an image forming apparatus. [Figure 4] Figure 4 is a diagram illustrating the function of the installation status detection unit according to the first embodiment. [Figure 5] Figure 5 shows an example of a pattern image and toner pattern. [Figure 6] Figure 6 shows an example of a concentration sample. [Figure 7] Figure 7 shows the relationship between the amount of toner deposited on the intermediate transfer belt and the number of printed pages. [Figure 8] Figure 8 shows the relationship between the actual amount of adhesive applied and the density of the printed image. [Figure 9]Figure 9 illustrates an example of how the remaining lifespan is calculated by the remaining lifespan calculation unit. [Figure 10] Figure 10 is a flowchart showing an example of the installation process of the transfer apparatus according to the first embodiment. [Figure 11] Figure 11 is a diagram illustrating the function of the installation status detection unit according to the second embodiment. [Modes for carrying out the invention]

[0009] Embodiments of the image forming apparatus, image forming method, and program will be described in detail below with reference to the attached drawings.

[0010] (First Embodiment) Figure 1 shows an example of an image forming apparatus 1 according to the first embodiment. As shown in Figure 1, the image forming apparatus 1 according to this embodiment includes an image forming unit A, a paper feeding unit B, an automatic document feeder (ADF) C, a reading unit D (flatbed scanner), a fuser 20, a pair of paper output rollers 13, a paper output tray 14, a pair of reversing rollers 16, a duplex unit 17, and the like.

[0011] Image forming unit A includes four imaging units 4Y, 4M, 4C, and 4K, an exposure device 9, a transfer device 3, etc. These are examples of units used in image formation.

[0012] The image forming apparatus 1 has four image-forming sections 4Y, 4M, 4C, and 4K located in the center of the apparatus body. Each image-forming section 4Y, 4M, 4C, and 4K has the same configuration except that it contains different colored developers corresponding to the color separation components of a color image: yellow (Y), magenta (M), cyan (C), and black (K).

[0013] Each image-forming unit 4Y, 4M, 4C, and 4K includes a drum-shaped photoreceptor 5 as a latent image carrier, a charging device 6 for charging the surface of the photoreceptor 5, a developing device 7 for supplying toner to the surface of the photoreceptor 5, and a cleaning device 8 for cleaning the surface of the photoreceptor 5.

[0014] In FIG. 1, only the photosensitive member 5, charging device 6, developing device 7, and cleaning device 8 provided in the black image forming section 4K are labeled, and since the other image forming sections 4Y, 4M, and 4C have the same configuration as the black image forming section 4K, their labels are omitted.

[0015] The image forming apparatus 1 is provided with an exposure device 9 that exposes the surface of the photosensitive member 5 below each of the image forming sections 4Y, 4M, 4C, and 4K. The exposure device 9 includes a laser light source (not shown), a polygon mirror 51a, an f-θ lens 51b, a plurality of reflection mirrors 51c, etc., and irradiates the surface of each photosensitive member 5 with laser light based on image data to form an electrostatic latent image on the surface of each photosensitive member 5.

[0016] The image forming apparatus 1 is provided with a transfer device 3 above each of the image forming sections 4Y, 4M, 4C, and 4K. The transfer device 3 includes an intermediate transfer belt 30 as an intermediate transfer member, four primary transfer rollers 31, a secondary transfer roller 36, and a secondary transfer backup roller 32. Further, the transfer device 3 includes a cleaning backup roller 33, a tension roller 34, and a belt cleaning device 35.

[0017] The intermediate transfer belt 30 is an endless belt and is stretched by the secondary transfer backup roller 32, the cleaning backup roller 33, and the tension roller 34. Here, the intermediate transfer belt 30 is configured to circulate (rotate) in the direction indicated by the arrow in the figure when the secondary transfer backup roller 32 is rotationally driven.

[0018] The four primary transfer rollers 31 each sandwich the intermediate transfer belt 30 between themselves and the photosensitive member 5 to form a primary transfer nip. Further, a power supply is connected to each primary transfer roller 31, and a predetermined direct current voltage (DC) or a predetermined alternating current voltage (AC) is applied to each primary transfer roller 31.

[0019] <000The secondary transfer roller 36 forms a secondary transfer nip by sandwiching the intermediate transfer belt 30 between itself and the secondary transfer backup roller 32. Also, similar to the primary transfer roller 31, a power supply is connected to the secondary transfer roller 36, and a predetermined direct current voltage (DC) or alternating current voltage (AC) is applied to the secondary transfer roller 36.

[0020] The optical sensor 50 irradiates light onto the intermediate transfer belt 30 on which a toner pattern, which will be described later, is formed, reads the reflected light, and detects the reflection density of the toner pattern.

[0021] The belt cleaning device 35 has a cleaning brush and a cleaning blade disposed so as to contact the intermediate transfer belt 30. The waste toner recovered by this belt cleaning device 35 is accommodated in a waste toner container via a waste toner transfer hose.

[0022] The image forming apparatus 1 has a bottle accommodating portion 2 provided at the upper part of the apparatus main body, and four toner bottles 2Y, 2M, 2C, 2K for accommodating replenishing toner are detachably mounted in the bottle accommodating portion 2. Toner is replenished from each of the toner bottles 2Y, 2M, 2C, 2K to each of the developing devices 7 via a replenishing path (not shown) provided between each toner bottle 2Y, 2M, 2C, 2K and each of the above-mentioned developing devices 7.

[0023] The image forming apparatus 1 includes a paper feeding unit B at the lower part of the apparatus main body. The paper feeding unit B has a paper feeding tray 10 for accommodating paper P (recording sheet) as a recording medium, a paper feeding roller 11 for carrying out the paper P from the paper feeding tray 10, and the like.

[0024] In addition to plain paper, the recording medium includes thick paper, postcards, envelopes, thin paper, coated paper (such as coated paper and art paper), tracing paper, OHP sheets, and the like. Also, the image forming apparatus 1 may include a manual paper feeding mechanism. In the present embodiment, the thick paper refers to paper having a basis weight of 160 g / m 2 or more.

[0025] The image forming apparatus 1 has a transport path R inside the apparatus body for transporting paper P from the paper feed tray 10 through a secondary transfer nip and out of the apparatus body. In the transport path R, a pair of registration rollers 12 are provided upstream of the secondary transfer roller 36 in the transport direction of the paper P, and serve as timing rollers to transport the paper P to the secondary transfer nip at the appropriate transport timing.

[0026] The image forming apparatus 1 is equipped with a fixing device 20 located downstream of the secondary transfer roller 36 in the transport direction of the paper P. This fixing device pressurizes and heats the paper P, which is carrying an unfixed toner image, to fix the toner image to the paper P.

[0027] The image forming apparatus 1 is provided with a pair of paper discharge rollers 13 downstream of the fixing device 20 in the paper transport direction for discharging the paper P outside the apparatus body. The image forming apparatus 1 is also provided with a paper discharge tray 14 on the top surface of the apparatus body for storing the paper P that has been discharged outside the apparatus body.

[0028] The image forming apparatus 1 has a branching member 15 between the paper discharge roller 13 and the fixing device 20. The branching member 15 is rotatably mounted on the main body of the image forming apparatus 1 and is configured to open to the first state shown in Figure 1 in single-sided mode, where an image is fixed only to the first side of the paper P. Furthermore, in double-sided mode, where an image is fixed to the second side of the paper P after an image has been fixed to the first side, the branching member 15 is configured to close to the second state shown in Figure 1 in the direction of the arrow.

[0029] In other words, the branching member 15 is configured to selectively guide the paper P, which is transported downstream of the fixing device 20, to either an external discharge path that discharges it to the output tray 14 outside the main body of the device, or a reverse path for double-sided printing. Here, the external discharge path is the path through which the paper P passes the output roller 13, and the reverse path is the path through which the paper P passes inside the duplex unit 17 (double-sided reverse path 40), which will be described later.

[0030] The double-sided reversal path 40 includes a reversal roller 16 that switches back the paper P, which is provided downstream of the branching member 15, and a double-sided unit 17 provided between the reversal roller 16 and the registration roller 12. This double-sided unit 17 is equipped with transport rollers 42 to 44 and constitutes a reversal path for double-sided printing. After the image has been fixed to the first side, the paper P is switched back by the reversal roller 16 and transported to the registration roller 12 via the transport rollers 42 to 44.

[0031] The automatic document feeder C is located above the reading unit D and automatically feeds and transports documents. Documents are transported one by one by the automatic document feeder C. The reading unit D exposes the document when it passes the reading position and reads the reflected light. Alternatively, the reading unit D may also read the document using flatbed scanning, where the document is fixed in place.

[0032] These reading processes are performed by the scanning processing unit, which will be described later. The read image data is then copied onto paper P by the printing processing unit, which will be described later, or transmitted to external devices via the network interface, which will be described later, etc.

[0033] The control panel 70 displays the current settings, selected values, modes, etc., and accepts input from the user.

[0034] The image forming apparatus 1 receives print job data from the reading unit D, an external DFE (Digital Front End) device, a personal computer (hereinafter referred to as "PC"), a facsimile, etc. The image forming apparatus 1 executes printing (image forming operation) in response to execution instructions based on the received print job data or operations from the user on the operation panel 70, etc. The print job data includes job information indicating job attributes such as the number of copies to be printed, the number of pages, the type of paper, and the type of printing, as well as image data. The type of paper includes information such as plain paper, gloss paper, matte paper, and textured paper, and the type of printing includes information such as whether it is color printing or monochrome printing, and whether it is single-sided printing or double-sided printing. Note that the print job is an example of an image forming job.

[0035] Next, the image forming operation of the image forming apparatus 1 according to an embodiment of the present invention will be described.

[0036] When the image formation operation is started, the image forming apparatus 1 rotates each photoreceptor 5 in each image formation section 4Y, 4M, 4C, and 4K clockwise as shown in the diagram, and the surface of each photoreceptor 5 is uniformly charged to a predetermined polarity by the charging device 6. Laser light is irradiated onto the surface of each charged photoreceptor 5 from the exposure device 9, and an electrostatic latent image is formed on the surface of each photoreceptor 5.

[0037] At this time, the image information exposed to each photoreceptor 5 is monochrome image information obtained by decomposing a desired full-color image into yellow, magenta, cyan, and black color information. When toner is supplied to the electrostatic latent image formed on each photoreceptor 5 by each developing device 7, the electrostatic latent image is manifested (made visible) as an image.

[0038] Furthermore, when the image formation operation is started, the image forming apparatus 1 rotates the secondary transfer backup roller 32 counterclockwise in the figure, causing the intermediate transfer belt 30 to travel in a circular motion in the direction indicated by the arrow in the figure.

[0039] Furthermore, the image forming apparatus 1 applies a constant voltage or constant current controlled voltage with the opposite polarity to the charging polarity of the toner to each primary transfer roller 31, thereby forming a transfer electric field at the primary transfer nip between each primary transfer roller 31 and each photoreceptor 5.

[0040] Subsequently, as each photoreceptor 5 rotates, the image forming apparatus 1, when the image of each color on the photoreceptor 5 reaches the primary transfer nip, uses the transfer electric field formed at the primary transfer nip to sequentially transfer the images on each photoreceptor 5 onto the intermediate transfer belt 30.

[0041] In this way, the image forming apparatus 1 loads a full-color image onto the surface of the intermediate transfer belt 30. Any toner on each photoreceptor 5 that could not be transferred to the intermediate transfer belt 30 is removed by the cleaning device 8. Then, the surface of each photoreceptor 5 is destaticized by the static elimination device, and its surface potential is reset.

[0042] The image forming apparatus 1 starts the rotational drive of the paper feed roller 11 and feeds the paper P from the paper feed tray 10 to the transport path R. Once the paper P is fed into the transport path R, its transport is temporarily stopped by the registration roller 12.

[0043] Subsequently, the image forming apparatus 1 starts rotating the registration roller 12 at a predetermined timing and transports the paper P to the secondary transfer nip in time with the image on the intermediate transfer belt 30 reaching the secondary transfer nip.

[0044] At this time, the secondary transfer roller 36 is subjected to a transfer voltage with the opposite polarity to the toner charge polarity of the image on the intermediate transfer belt 30, thereby forming a transfer electric field at the secondary transfer nip. This transfer electric field then transfers the image on the intermediate transfer belt 30 onto the paper P all at once. Any remaining toner on the intermediate transfer belt 30 that was not transferred to the paper P at this time is removed by the belt cleaning device 35 and transported to the waste toner container.

[0045] Subsequently, the paper P is transported to the fuser 20, where the image on the paper P is fixed. The paper P transported from the fuser 20 is guided in the discharge direction and the re-feed direction via a branching member 15 that switches between a path for discharging the paper P outside the main body of the device and a double-sided reversal path 40.

[0046] In single-sided mode, the branching member 15 opens to the first state described above. As a result, the paper P is discharged by the paper discharge roller 13 onto the paper discharge tray 14 outside the main body of the image forming apparatus 1.

[0047] In double-sided mode, the branching member 15 closes to the second state described above. As a result, the paper P, after the image has been fixed to the first side, is guided to the double-sided reversal path 40. The paper P guided to the double-sided reversal path 40 is switched back by a pair of reversal rollers 16, transported to the double-sided unit 17, and then transported again to a pair of registration rollers 12 for re-feeding.

[0048] As a result, the paper P is transported to the fixing device 20, where the fixing device 20 fixes the image to the second surface of the paper P in the same way as the first surface. Then, the paper P is discharged by the paper discharge roller 13 onto the paper discharge tray 14 outside the main body of the image forming apparatus 1.

[0049] The above description concerns the image formation operation when forming a full-color image on paper P. However, it is also possible to form a monochrome image using any one of the four image formation units 4Y, 4M, 4C, or 4K. Furthermore, it is possible to form a two-color or three-color image using two or three image formation units.

[0050] Figure 2 shows an example of the hardware configuration of the image forming apparatus 1.

[0051] The image forming apparatus 1 includes a controller 210, a short-range communication circuit 220, an engine control unit 230, an operation panel 70, and a network interface 250.

[0052] Of these, the controller 210 includes the main components of the computer: the CPU (Central Processing Unit) 201, system memory (MEM-P) 202, northbridge (NB) 203, southbridge (SB) 204, ASIC (Application Specific Integrated Circuit) 206, local memory (MEM-C) 207 (storage unit), HDD (Hard Disk Drive) controller 208, and HD209 (storage unit). A Solid State Drive (SSD) may also be used for the storage unit.

[0053] Furthermore, the NB203 and ASIC206 are connected via an AGP (Accelerated Graphics Port) bus 221.

[0054] Of these, the CPU201 is a control unit that performs overall control of the image forming apparatus 1. The NB203 is a bridge for connecting the CPU201 with the MEM-P202, SB204, and AGP bus 221, and includes a memory controller that controls reading and writing to the MEM-P202, as well as a PCI (Peripheral Component Interconnect) master and an AGP target.

[0055] MEM-P202 includes a ROM (Read Only Memory) 202a, which is a memory for storing programs and data that realize the various functions of the controller 210, and a RAM (Random Access Memory) 202b, which is used for program and data deployment and drawing during memory printing. The programs stored in RAM 202b may be configured to be provided as installable or executable files recorded on a computer-readable recording medium such as a CD-ROM, CD-R, or DVD.

[0056] SB204 is a bridge for connecting NB203 to PCI devices and peripheral devices. ASIC206 is an integrated circuit (IC) for image processing applications that has hardware elements for image processing and acts as a bridge connecting the AGP bus 221, PCI bus 222, HDD controller 208, and MEM-C207, respectively.

[0057] The ASIC206 includes a PCI target and an AGP master, an arbiter (ARB) that forms the core of the ASIC206, a memory controller that controls the MEM-C207, multiple DMACs (Direct Memory Access Controllers) that perform image data rotation and other operations using hardware logic, and a PCI unit that performs data transfer via the PCI bus 222 between the scan processing unit 231 and the print processing unit 232. The ASIC206 may also be connected via interfaces such as USB (Universal Serial Bus) or IEEE1394 (Institute of Electrical and Electronics Engineers 1394).

[0058] MEM-C207 is local memory used as a copy image buffer and code buffer. HD209 is storage for storing image data, font data used during printing, forms, etc. HD209 controls data reading or writing to HD209 according to the control of CPU201.

[0059] The AGP bus 221 is a bus interface for graphics accelerator cards proposed to accelerate graphics processing. The AGP bus 221 enables high-speed graphics accelerator cards by providing high-throughput direct access to the MEM-P202.

[0060] Furthermore, the short-range communication circuit 220 includes a short-range communication antenna 220a. The short-range communication circuit 220 is a communication circuit such as NFC or Bluetooth (registered trademark).

[0061] Furthermore, the engine control unit 230 is composed of a scan processing unit 231 and a print processing unit 232.

[0062] The controller 210 controls the entire image forming apparatus 1, for example, drawing, communication, input from the operation panel 70, image forming operations, and document reading. The scan processing unit 231 reads the document and generates image data. The print processing unit 232 is equipped with a transfer means for transferring an image using a colorant such as a toner image onto a transport medium such as paper P, a fixing means for fixing the image, a heating means or a drying means, etc., and performs image formation (printing) on ​​paper P. Furthermore, the scan processing unit 231 or the print processing unit 232 performs image processing such as error diffusion and gamma conversion.

[0063] Note that paper P is just one example of a transport medium. The transport medium can be anything other than paper, such as film or a sheet of plastic, as long as it is placed in the paper feed tray 10 of the image forming apparatus 1 and transported and printed according to the output instruction for paper P.

[0064] Furthermore, the network interface 250 is an interface for data communication using a communication network. The short-range communication circuit 220 and the network interface 250 are electrically connected to the ASIC 206 via the PCI bus 222.

[0065] The operation panel 70 includes a panel display unit 70a, such as a touch panel, which displays current settings, selected values, modes, etc., and accepts user input; and operation keys 70b, which consist of a numeric keypad that accepts setting values ​​for image formation conditions such as density settings, and a start key that accepts copy start instructions. The operation panel 70 accepts input of judgment results based on the pattern image described later and displays the calculated remaining lifespan of the transfer device 3. The panel display unit 70a accepts touch input from the user, and the user can use their finger or a pen to input numerical values ​​into input boxes displayed on the screen, select from pull-down menus, turn checkboxes ON / OFF, etc. In addition to a numeric keypad, the operation keys 70b may also include input means such as a trackball or touchpad.

[0066] Although Figures 1 and 2 show an example in which the image forming apparatus 1 has an electrophotographic image forming mechanism, the image forming apparatus 1 in this embodiment may have other image forming mechanisms such as an inkjet method or a 3D printing method. In that case, for example, an ejection unit that ejects the material to be ejected, such as ink, is an example of a unit used for image formation. Furthermore, the image forming apparatus 1 is not limited to an MFP (Multifunction Peripheral), but may also be a copier or a facsimile machine.

[0067] Figure 3 shows an example of the functional blocks of the image forming apparatus 1. The image forming apparatus 1 comprises a system control unit 101, a display control unit 102, a network I / F control unit 103, an external I / F control unit 104, a storage unit 105, a mechanism control unit 106, a print job receiving unit 107, an image processing control unit 108, and a printing control unit 109. Each of these units is realized by a CPU 201 or ASIC 206 executing processing defined in a program stored in MEM-P202 or MEM-C207, etc.

[0068] The system control unit 101 controls the entire image forming apparatus 1. The system control unit 101 includes a job information processing unit 111, an installation status detection unit 112, a pattern image forming unit 113, an adhesion amount detection unit 114, a reception unit 115, an initial information storage unit 116, a remaining lifespan calculation unit 117, and a remaining lifespan notification unit 118.

[0069] The job information processing unit 111 extracts job information and image data contained in the print job data transmitted from the DFE device, etc.

[0070] The installation status detection unit 112 detects the installation status of the units used for image formation, such as the transfer device 3 (hereinafter referred to as "units"), indicating whether the installation has been completed. For example, the installation status is "before installation" while the unit is being adjusted for image density or set for remaining life after replacement. The installation status is "completed" after these tasks are completed. In this embodiment, by detecting the installation status, the system controls the system to run the installation process only once during the work performed by a service technician, as described later, to set the remaining life. This prevents an inappropriate remaining life from being set for a unit whose installation has been completed.

[0071] Figure 4 is a diagram illustrating the function of the installation status detection unit 112 according to the first embodiment. Here, Figure 4(a) is a diagram showing an example of the functional block of the installation status detection unit 112, and Figure 4(b) is a diagram showing an example of data stored in a storage medium such as flash memory of the unit. As shown in Figure 4(a), the installation status detection unit 112 has a unit status storage unit 1120. The unit status storage unit 1120 stores information on the installation status of the unit and the new / used status, indicating whether the unit is a used unit or not, in the storage medium. Here, a used unit refers to a unit that is not new, such as a reused or recycled item. A new unit is called a new unit.

[0072] In the example shown in Figure 4(b), the unit status storage unit 1120 stores installation status data at address 55h of the storage medium and installation count data (the number of times the unit has been installed for reuse) at address 57h. For example, an installation status value of 00h indicates that the unit has been installed. If the installation status value is anything other than 00h, it indicates that the unit has not yet been installed.

[0073] When the unit installation is complete, the unit status storage unit 1120 reads the installation count from address 57h, adds 1 to that value, and writes the result to address 57h. Note that the installation count for a new unit is set to 0, and is overwritten to 1 when the first installation is complete. Alternatively, the unit status storage unit 1120 may omit storing the installation count and store only the installation status on the storage medium.

[0074] The pattern image forming unit 113 forms a pattern image to be used for calculating remaining life when the installation status detected by the installation status detection unit 112 indicates that the installation has not yet been performed. Specifically, the pattern image forming unit 113 reads a pattern image stored in memory such as MEM-P202 and uses the print processing unit 232 to transfer the toner pattern to the intermediate transfer belt 30 and form (print) the pattern image on the paper P. Here, the toner pattern is the toner image corresponding to the pattern image.

[0075] Figure 5 shows an example of a pattern image and toner pattern. Figure 5(a) shows an example of a toner pattern formed on the intermediate transfer belt 30. The toner pattern is formed at three locations on the photoreceptor 5: in front (F), behind (R), and in the center (C) of the laser scanning direction (hereinafter referred to as the "main scanning direction"), that is, in the end region and the central region perpendicular to the direction of movement of the intermediate transfer belt 30. In Figure 5(a), in each region, a toner pattern consisting of color patches of K, C, M, and Y is formed from left to right.

[0076] Figure 5(b) shows an example of a pattern image formed on paper P. The pattern image is formed when the toner pattern on the intermediate transfer belt 30 is transferred to paper P, and as shown in Figure 5(b), it is formed as a pattern consisting of color patches of K, C, M, and Y in three locations in the front, central, and rear regions of the main scanning direction, from left to right.

[0077] The adhesion amount detection unit 114 uses an optical sensor 50 to detect the amount of toner adhering to the toner pattern formed on the intermediate transfer belt 30. As shown in Figure 5(a), reflective optical sensors 50F, 50C, and 50R are arranged corresponding to each region where the toner pattern is formed, and the reflection density of the toner pattern is detected. Here, the subscripts indicate the positions in front, center, and behind the main scanning direction, respectively. These subscripts will be omitted as appropriate below. The adhesion amount detection unit 114 obtains the reflection density of each pattern from the output of the optical sensor 50 and detects the amount of toner adhering to the intermediate transfer belt 30.

[0078] The reception unit 115 receives the judgment result based on the pattern image formed by the pattern image forming unit 113. Specifically, a service technician or the like inputs an estimated image density value, determined based on the pattern image and density sample, into the operation panel 70 as the judgment result, and the reception unit 115 receives the input judgment result. The estimated image density value is an example of a judgment result regarding the density of the pattern image.

[0079] Figure 6 shows an example of a density sample S. The density sample S consists of rows of color patches for each color, K, C, M, and Y, from left to right. Each row of color patches has six density levels in the vertical direction. Here, a density level with a value of 1 represents the lightest density, and a density level with a value of 6 represents the darkest density. Service technicians compare the density of each color patch in the pattern image with the density sample S, determine the density of each color, and input the result into the control panel 70. Note that the number of density levels is not limited to six; it may be more or less than six.

[0080] The initial information storage unit 116 stores the estimated toner deposition amount detected by the deposition amount detection unit 114 and the estimated image density of the pattern image (the judgment result received by the reception unit 115) for a new unit in a memory such as the MEM-P202.

[0081] The remaining lifespan calculation unit 117 calculates the remaining lifespan of a used unit based on the amount of toner deposited detected by the deposit amount detection unit 114, the estimated image density of the pattern image, and the data stored in the initial information storage unit 116.

[0082] The remaining life notification unit 118 notifies the remaining life of the used unit calculated by the remaining life calculation unit 117. The remaining life notification unit 118 notifies the remaining life value by, for example, displaying it on the operation panel 70, sending it to a service technician via email, or printing it on paper P. Service technicians can manage the timing of the next maintenance by setting the notified remaining life in the memory of the image forming apparatus 1, storing it on their own terminal, etc.

[0083] Next, using Figures 7 to 9, we will explain how to calculate the remaining lifespan when the transfer device 3, which is an example of a unit, is a used unit.

[0084] Figure 7 shows the relationship between the amount of toner deposited on the intermediate transfer belt 30 and the number of printed pages. In the graph in Figure 7(a), the vertical axis represents the ratio r of the amount of toner deposited by the optical sensor 50 (detected amount of toner deposited) to the actual amount of toner deposited (actual amount of toner deposited), and the horizontal axis represents the number of printed pages. In the graph in Figure 7(b), the vertical axis represents the actual amount of toner deposited, and the horizontal axis represents the number of printed pages.

[0085] Conventionally, a phenomenon called belt filming has been known, in which toner components and lubricants applied to the photoreceptor 5 adhere to the intermediate transfer belt 30. When belt filming occurs, the optical properties of the belt surface change, making it impossible for the optical sensor 50 to accurately detect the amount of toner adhering to the intermediate transfer belt 30. In other words, a detection discrepancy occurs between the actual amount of adhering and the detected amount of adhering.

[0086] As the printing operation is repeated, the amount of material adhering to the intermediate transfer belt 30 increases, and therefore, the detection misalignment due to belt filming generally gradually increases as the number of printed sheets increases. Furthermore, it is known that the greater the detection misalignment, the higher the detection result outputted by the optical sensor 50. For this reason, the ratio r increases from the ideal value (1), where there is no detection misalignment, as the number of printed sheets increases, as shown by the arrow in Figure 7(a).

[0087] Furthermore, the image forming apparatus 1 adjusts the amount of toner to adhere to the target amount based on the detected amount of toner. Therefore, if the detected amount of toner is higher than the target amount, the actual amount of toner adhered is adjusted to be lower than the target amount. As a result, the actual amount of toner adhered decreases from the target amount as the number of printed pages increases, as shown by the arrow in Figure 7(b).

[0088] The remaining life calculation unit 117 calculates an estimated value of the actual amount of toner deposited in a used unit using the correlation between the actual amount deposited and the print image density. Figure 8 is a diagram showing the relationship between the actual amount deposited and the print image density. In the graph of Figure 8, the vertical axis represents the actual amount deposited, and the horizontal axis represents the density level. Here, the print image density is the density determined by comparing the density of the image printed on paper P with the toner density corresponding to the actual amount deposited with the density sample S. In the example of Figure 8, the print image density is the density determined using the six density levels shown in Figure 6.

[0089] As shown in Figure 8(a), there is a correlation between the actual amount of adhesive deposited and the density of the printed image. When installing a used unit, service technicians visually compare the pattern image printed by the pattern image forming unit 113 with the density sample S to determine the density of the printed image and input the result (estimated value of the image density) into the operation panel 70. The remaining life calculation unit 117 uses the correlation between the actual amount of adhesive deposited and the density of the printed image to calculate an estimated value of the actual amount of adhesive deposited in the used unit from the estimated value of the image density, as shown in Figure 8(b).

[0090] Next, the remaining life calculation unit 117 obtains an estimated value of the ratio r from the estimated actual amount of adhesion and the detected amount of adhesion, and calculates the remaining life using the relationship between the ratio r and the number of printed sheets as described above.

[0091] Figure 9 illustrates an example of the remaining life calculation by the remaining life calculation unit 117. The graph in Figure 9 shows the relationship between the ratio r and the number of printed pages, similar to the graph in Figure 7(a). For new units, the unit's lifespan is set to the number of printed pages = L pages, based on the limit value of the increase in the ratio r. The limit value of the increase in the ratio r is, for example, the limit value at which the deviation in print image density exceeds the acceptable range due to the discrepancy between the detected amount of adhesion and the detected amount of adhesion.

[0092] Ideally, the ratio of new units at the initial value of the number of printed sheets (0 sheets) is 1, as shown in Figure 7(a). In this embodiment, the relationship between the ratio r and the number of printed sheets is determined using the ratio of new units at the initial value, which is calculated from the detected amount of adhesion of new units stored in memory by the initial information storage unit 116 and the actual amount of adhesion estimated from the density of the pattern image. Note that the image forming apparatus 1 may be configured without including the initial information storage unit 116. In such cases, or if the initial information storage unit 116 does not store data on new units in memory, the relationship between the ratio r and the number of printed sheets may be determined by setting the ratio of new units at the initial value to 1.

[0093] As shown in Figure 9, the remaining lifespan of a used unit can be calculated by subtracting the estimated number of printed pages at the time of installation (estimated number of printed pages E), which is estimated from the estimated ratio r, from the lifespan L of a new unit. The remaining lifespan calculation unit 117 calculates the remaining lifespan for each color patch as described above, and calculates the average value of the values ​​calculated for each color as the remaining lifespan. Alternatively, the remaining lifespan calculation unit 117 may calculate the minimum, maximum, median, etc., of each color as the remaining lifespan instead of the average value of each color.

[0094] Figure 10 is a flowchart showing an example of the installation process for the transfer device 3 according to the first embodiment. First, the power to the image forming apparatus 1 is turned on (step S10), and the installation status detection unit 112 detects the installation status of the transfer device 3. If the installation status of the transfer device 3 is complete (step S11: Yes), the process ends.

[0095] On the other hand, if the installation status of the transfer device 3 is not complete (step S11: No), the process proceeds to the installation flow from step S12 onwards. Thus, the installation flow of this embodiment is executed when the installation of the unit by a service technician or the like is not yet complete, and is not executed for units that have already been installed.

[0096] In step S12, the image forming apparatus 1 adjusts the image density (calibration) and sets the image forming conditions (developing voltage, charging voltage, writing light intensity, toner density, etc.). Next, the pattern image forming unit 113 forms a toner pattern on the intermediate transfer belt 30 as shown in Figure 5(a), and the adhesion amount detection unit 114 detects the amount of toner adhesion as the detected adhesion amount (step S13). The pattern image forming unit 113 also prints a pattern image corresponding to the toner pattern as shown in Figure 5(b) (step S14). At this time, the image forming conditions set above are used for image formation.

[0097] Next, the reception unit 115 receives the judgment result (estimated image density) based on the pattern image from a service technician or the like (step S15). If the transfer device 3 is a new unit (step S16: Yes), the initial information storage unit 116 stores the toner adhesion amount and the judgment result (step S17). On the other hand, if the transfer device 3 is not a new unit (step S16: No), the remaining life calculation unit 117 calculates the remaining life based on the toner adhesion amount and the judgment result, and the remaining life notification unit 118 notifies the calculated remaining life (step S18). Also, the unit status storage unit 1120 changes the installation status of the transfer device 3 to "installed" (step S19).

[0098] Thus, according to this embodiment, when replacing an internal unit of an image forming apparatus with a used unit and installing the used unit, the remaining lifespan of the used unit at the time of replacement can be notified.

[0099] (Second Embodiment) The second embodiment involves storing the unit's installation status using one or more fuses. In the following description of the second embodiment, the parts that overlap with the first embodiment will be omitted, and the parts that differ from the first embodiment will be described.

[0100] Figure 11 is a diagram illustrating the function of the installation status detection unit 112 according to the second embodiment. Here, Figure 11(a) is a diagram showing an example of the functional block of the installation status detection unit 112, and Figure 11(b) is a diagram showing the relationship between the state of the two fuses (fuse a and fuse b) in the unit and the installation status of the unit.

[0101] As shown in Figure 11(a), the installation status detection unit 112 has a fuse a blowing unit 1121 and a fuse b blowing unit 1122. The fuse a blowing unit 1121 blows fuse a to a broken state when the installation of a new unit is completed. The fuse b blowing unit 1122 blows fuse b to a broken state when the installation of a used unit is completed.

[0102] As shown in Figure 11(b), in a new unit before installation, fuse a is in a conductive state and fuse b is in a broken state. In a used unit before installation, fuse a is in a broken state and fuse b is in a conductive state. In a completed unit, regardless of whether it is new or used, both fuses a and b are in a judgment state. If a completed unit is recycled, fuse b will be replaced with a conductive one by a service technician.

[0103] The installation status detection unit 112 detects the installation status of the unit based on the continuity state of two fuses, as shown in Figure 11(b). That is, the installation status detection unit 112 can use the continuity state of two fuses to detect whether the unit installation is complete and whether the unit is new before installation. Alternatively, the unit may have one fuse, indicating that the installation is not complete when the fuse is continuity and complete when the fuse is broken. Furthermore, the unit may have three or more fuses to store the number of times the unit has been installed for reuse.

[0104] Thus, according to this embodiment, when replacing an internal unit of an image forming apparatus with a used unit and installing the used unit, the remaining lifespan of the used unit at the time of replacement can be notified. Furthermore, the installation status of the unit can be stored using one or more fuses.

[0105] Although embodiments of the present invention have been described above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These novel embodiments and their variations are included in the scope and spirit of the invention, as well as in the claims of the invention and its equivalents. Furthermore, components from different embodiments and modifications may be combined as appropriate.

[0106] The programs executed in the image forming apparatus 1 of each embodiment described above are provided as installable or executable files recorded on a computer-readable recording medium such as a CD-ROM, flexible disk (FD), CD-R, or DVD (Digital Versatile Disk).

[0107] Furthermore, the program executed by the image forming apparatus 1 of each embodiment may be stored on a computer connected to a network such as the Internet and provided by being downloaded via the network. Alternatively, the program executed by the image forming apparatus 1 of each embodiment may be provided or distributed via a network such as the Internet.

[0108] Furthermore, the programs for each embodiment may be pre-installed and provided in ROM or the like.

[0109] The program executed in the image forming apparatus 1 of each embodiment is configured as a module including the above-mentioned functional units (job information processing unit 111, installation status detection unit 112, pattern image forming unit 113, adhesion amount detection unit 114, reception unit 115, etc.). In actual hardware, the CPU (processor) reads the program from the above-mentioned recording medium and executes it, thereby loading each of the above-mentioned units onto the main memory, and generating each functional unit on the main memory.

[0110] Furthermore, each function of each embodiment described above can be realized by one or more processing circuits. Hereinafter, "processing circuit" as used herein includes processors programmed to execute each function by software, such as processors implemented by electronic circuits, as well as devices such as ASICs, DSPs (Digital Signal Processors), FPGAs (Field Programmable Gate Arrays), and conventional circuit modules designed to execute each function described above.

[0111] Examples of the present invention are as follows: <1> An installation status detection unit that detects whether or not the installation of the unit used for image formation has been completed, If the installation status detected by the installation status detection unit indicates that the installation is not complete, a pattern image forming unit forms a pattern image used for calculating the remaining lifespan. A receiving unit that receives a judgment result based on the pattern image formed by the pattern image forming unit, If the unit is a used unit, a remaining lifespan calculation unit calculates the remaining lifespan of the unit based on the determination result received by the receiving unit, A remaining lifespan notification unit notifies the remaining lifespan of the unit calculated by the remaining lifespan calculation unit, This is an image forming apparatus characterized by comprising the following: <2> The unit further comprises a unit status storage unit for storing the installation status of the unit. <1> This is the image forming apparatus described in [reference]. <3> The unit status storage unit stores the installation status and the new / used status, indicating whether the unit is a used unit or not, in the storage medium of the unit. <2> This is the image forming apparatus described in [reference]. <4> The unit status storage unit further stores in the storage medium the number of times the unit has been installed for reuse. <3> This is the image forming apparatus described in [reference]. <5> The unit status storage unit stores the installation status using one or more fuses that the unit has. <2> This is the image forming apparatus described in [reference]. <6> The unit further includes a deposit amount detection unit that detects the amount of toner deposited on the toner pattern of the pattern image formed on the intermediate transfer belt of the unit, The aforementioned determination result is a determination result regarding the density of the pattern image, The remaining life calculation unit calculates the remaining life of the unit based on the determination result regarding the amount of toner deposited detected by the deposit amount detection unit and the density of the pattern image. <1> ~ <5> The image forming apparatus is one of the following: <7> The pattern image forming unit outputs a pattern image in which color patches are formed for each of the multiple colors. The receiving unit receives the judgment result for each of the multiple colors, <6> This is the image forming apparatus described in [reference]. <8> The adhesion amount detection unit has an optical sensor installed opposite the intermediate transfer belt, The pattern image forming unit detects toner patches for forming the color patches to be formed on the intermediate transfer belt, <7> This is the image forming apparatus described in [reference]. <9> If the unit is not a used unit, the system further includes an initial information storage unit that stores the determination result regarding the amount of toner deposited and the density of the pattern image detected by the deposit amount detection unit. The remaining life calculation unit calculates the remaining life of the unit based on the toner deposition amount stored in the initial information storage unit and the judgment result, <6> ~ <8> The image forming apparatus is one of the following: <10> An image forming method performed in an image forming apparatus, An installation status detection step that detects whether or not the installation of the unit used for image formation has been completed, If the installation status detected by the installation status detection step indicates that the installation is not complete, a pattern image formation step is performed to form a pattern image used for calculating the remaining lifespan. A receiving step for receiving a judgment result based on the pattern image formed by the pattern image formation step, If the unit is a used unit, a remaining lifespan calculation step is performed to calculate the remaining lifespan of the unit based on the judgment result received in the acceptance step, A remaining lifespan notification step that notifies the remaining lifespan of the unit calculated by the remaining lifespan calculation step, This is an image forming method characterized by including [a specific element]. <11> Computers, Installation status detection means for detecting whether or not the installation of the unit used for image formation has been completed, When the installation status detected by the installation status detection means indicates that the installation is not yet complete, a pattern image forming means is provided to form a pattern image used for calculating the remaining lifespan. A receiving means for receiving a judgment result based on the pattern image formed by the pattern image forming means, If the unit is a used unit, a remaining lifespan calculation means calculates the remaining lifespan of the unit based on the determination result received by the receiving means, A remaining lifespan notification means that notifies the remaining lifespan of the unit calculated by the remaining lifespan calculation means, This is a program designed to function as such. [Explanation of Symbols]

[0112] 1. Image forming apparatus 3. Transfer device 50 Optical Sensors 70 Control Panel 111 Job Information Processing Unit 112 Installation Status Detection Unit 113 Pattern image forming unit 114 Adhesion amount detection unit 115 Reception Department 116 Initial information storage unit 117 Remaining life calculation section 118 Remaining life notification section 1120 Unit Status Memory Unit 1121 Fuse a melting point 1122 Fuse b melting point [Prior art documents] [Patent Documents]

[0113] [Patent Document 1] Japanese Patent Publication No. 2017-021233

Claims

1. An installation status detection unit that detects whether or not the installation of the unit used for image formation has been completed, If the installation status detected by the installation status detection unit indicates that the installation is not complete, a pattern image forming unit forms a pattern image used for calculating the remaining lifespan. A receiving unit that receives a judgment result based on the pattern image formed by the pattern image forming unit, If the unit is a used unit, a remaining lifespan calculation unit calculates the remaining lifespan of the unit based on the determination result received by the receiving unit, A remaining lifespan notification unit notifies the remaining lifespan of the unit calculated by the remaining lifespan calculation unit, An image forming apparatus characterized by comprising:

2. The image forming apparatus according to claim 1, further comprising a unit status storage unit for storing the installation status of the aforementioned unit.

3. The image forming apparatus according to claim 2, wherein the unit status storage unit stores the installation status and the new / used status indicating whether the unit is a used unit or not in the storage medium of the unit.

4. The image forming apparatus according to claim 3, wherein the unit status storage unit further stores in the storage medium the number of times the unit has been installed for reuse.

5. The image forming apparatus according to claim 2, wherein the unit status storage unit stores the installation status using one or more fuses provided by the unit.

6. The unit further includes a deposit amount detection unit that detects the amount of toner deposited on the toner pattern of the pattern image formed on the intermediate transfer belt of the unit, The aforementioned determination result is a determination result regarding the density of the pattern image, The image forming apparatus according to any one of claims 1 to 5, wherein the remaining lifespan calculation unit calculates the remaining lifespan of the unit based on the determination result regarding the amount of toner deposited detected by the amount of deposited unit and the density of the pattern image.

7. The pattern image forming unit outputs a pattern image in which color patches are formed for each of the multiple colors. The image forming apparatus according to claim 6, wherein the receiving unit receives a judgment result for each of the plurality of colors.

8. The adhesion amount detection unit has an optical sensor installed opposite the intermediate transfer belt, The image forming apparatus according to claim 7, wherein the pattern image forming unit detects toner patches for forming the color patches to be formed on the intermediate transfer belt.

9. If the unit is not a used unit, the system further includes an initial information storage unit that stores the determination result regarding the amount of toner deposited and the density of the pattern image detected by the deposit amount detection unit. The image forming apparatus according to claim 6, wherein the remaining lifespan calculation unit calculates the remaining lifespan of the unit based on the amount of toner deposited and the judgment result stored in the initial information storage unit.

10. An image forming method performed in an image forming apparatus, An installation status detection step that detects whether or not the installation of the unit used for image formation has been completed, If the installation status detected by the installation status detection step indicates that the installation is not complete, a pattern image formation step is performed to form a pattern image used for calculating the remaining lifespan. A receiving step for receiving a judgment result based on the pattern image formed by the pattern image formation step, If the unit is a used unit, a remaining lifespan calculation step is performed to calculate the remaining lifespan of the unit based on the judgment result received in the acceptance step, A remaining lifespan notification step that notifies the remaining lifespan of the unit calculated by the remaining lifespan calculation step, An image forming method characterized by including the following.

11. Computers, Installation status detection means for detecting whether or not the installation of the unit used for image formation has been completed, When the installation status detected by the installation status detection means indicates that the installation is not yet complete, a pattern image forming means is provided to form a pattern image used for calculating the remaining lifespan. A receiving means for receiving a judgment result based on the pattern image formed by the pattern image forming means, If the unit is a used unit, a remaining lifespan calculation means calculates the remaining lifespan of the unit based on the determination result received by the receiving means, A remaining lifespan notification means that notifies the remaining lifespan of the unit calculated by the remaining lifespan calculation means, A program that makes it function as such.

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