Image forming apparatus, control method, and program

Abstract

Make effective use of continuous sheets. [Solution] The image forming apparatus includes a printing unit that prints multiple images on multiple lanes of a continuous sheet. The printed images are inspected, and if an abnormality is detected in an image, when reprinting the image, the images to be printed are rearranged so that the length of the continuous sheet used is shorter when printing the abnormal image and other images not printed on the continuous sheet together, compared to when the abnormal image and other images not printed on the continuous sheet are printed without rearranging them.

Description

Technical Field

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

Background Art

[0002] There is an image forming apparatus that prints band-shaped images such as masking tape on a continuous sheet in a length equal to or longer than a certain value, divided into a plurality of lanes. In such printing, a plurality of band-shaped images different in color, width, length and the like are printed in the plurality of lanes.

[0003] When printing band-shaped images on a continuous sheet, arrangement is performed in consideration of the lengths of the plurality of band-shaped images in order to effectively utilize the continuous sheet. This will be specifically described with reference to Figure 1. Figure 1 is a diagram showing that the continuous sheet can be effectively utilized by the arrangement of images.

[0004] In "Before Rearrangement" in Figure 1, images A and B are arranged in lanes 1 and 2, and two images C are arranged in lane 3. On the other hand, in "After Rearrangement", images A and C are arranged in lanes 1 and 3, and two images B are arranged in lane 2. As shown in Figure 1, there is a difference in the usage amount of the continuous sheet between before and after the rearrangement. In this way, the continuous sheet can be effectively utilized by performing appropriate arrangement.

[0005] As a technique related to such image arrangement, Patent Document 1 discloses a technique of performing optimization processing for optimizing the arrangement of a plurality of images on the plurality of images when a print job is interrupted.

Related Art Documents

Patent Documents

[0006]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0007] If an abnormality such as dirt is detected in a strip-shaped image printed on a continuous sheet, the image forming apparatus will reprint the image. This will be explained in detail using Figure 2. Figure 2 shows an example of the arrangement before reprinting and an example of the rearrangement to accommodate reprinting due to dirt. In Figure 2, "X" indicates dirt. In lane 1, the arrangement was to print image C after image A, but due to the dirt, the arrangement changes so that image A is printed again before image C is printed. In this case, as shown in the figure, relatively large margins are created in lanes 2 and 3. In other words, in this arrangement example, it is possible that the continuous sheet is not being used effectively.

[0008] The object of the present invention is to provide an image forming apparatus, a control method, and a program that can effectively utilize continuous sheets. [Means for solving the problem]

[0009] The image forming apparatus according to the present invention comprises a printing unit that prints multiple images on multiple lanes of a continuous sheet, an inspection unit that reads and inspects the images printed on the continuous sheet, and a control unit that, when an abnormality is detected in any of the images during inspection by the inspection unit, controls the printing unit to reprint the abnormal image on the continuous sheet on which the abnormal image was printed. In the reprinting of the image by the printing unit by the control unit, the images to be printed are rearranged and printed such that the length of the continuous sheet used is shorter when the abnormal image and other images not printed on the continuous sheet are printed together, compared to when the abnormal image and other images not printed on the continuous sheet are printed without rearranging them.

[0010] The control method according to the present invention is a control method for an image forming apparatus comprising a printing unit that prints multiple images on multiple lanes of a continuous sheet, and an inspection unit that reads and inspects the images printed on the continuous sheet, wherein if an abnormality is detected in any of the images during inspection by the inspection unit, the control is made to have the abnormal image reprinted by the printing unit on the continuous sheet on which the abnormal image was printed, and in the reprinting of the image by the printing unit, the images to be printed are rearranged and printed such that the length of the continuous sheet used is shorter when the abnormal image and other images not printed on the continuous sheet are printed together, compared to when the abnormal image and other images not printed on the continuous sheet are printed without rearranging them.

[0011] The present invention provides a computer for an image forming apparatus, which includes a printing unit that prints multiple images on multiple lanes of a continuous sheet, and an inspection unit that reads and inspects the images printed on the continuous sheet. The computer is controlled by the inspection unit to reprint the image with the abnormality detected in the continuous sheet on which the abnormality detected image was printed, if an abnormality is detected in any of the images during inspection. The computer is then controlled by the printing unit to reprint the image with the abnormality detected in the continuous sheet on which the abnormality detected image was printed, and to rearrange the images to be printed so that the length of the continuous sheet used is shorter compared to printing the image with the abnormality detected in the continuous sheet and other images not printed on the continuous sheet without rearranging them. [Effects of the Invention]

[0012] According to the present invention, continuous sheets can be effectively utilized. [Brief explanation of the drawing]

[0013] [Figure 1] This figure shows examples of image placement before and after rearrangement. [Figure 2] This figure shows an example of the layout before reprinting and an example of the layout after reprinting due to staining. [Figure 3]This is a diagram schematically showing the overall configuration of an image forming apparatus according to the present embodiment. [Figure 4] This is a diagram showing the configuration of a control system of an image forming unit included in the image forming apparatus according to the present embodiment. [Figure 5] This is a diagram showing a printing position and an inspection position on roll paper. [Figure 6] This is a diagram for explaining Relocation Example 1. [Figure 7] This is a diagram for explaining Relocation Example 2. [Figure 8] This is a diagram for explaining Relocation Example 3. [Figure 9] This is a diagram for explaining Relocation Example 4. [Figure 10] This is a screen for setting an operation at the time of abnormality detection. [Figure 11] This is a screen for setting an operation in a case where the usage amount of roll paper does not change even after relocation is performed. [Figure 12] This is a diagram for explaining Relocation Example 5. [Figure 13] This is a diagram for explaining Relocation Example 6. [Figure 14] This is a diagram for explaining Relocation Example 7. [Figure 15] This is a diagram for explaining Relocation Example 8. [Figure 16] This is a diagram for explaining Relocation Example 9. [Figure 17] This is a diagram for explaining Relocation Example 10. [Figure 18] This is a diagram for explaining Relocation Example 11. [Figure 19] This is a diagram for explaining Relocation Example 12. [Figure 20] This is a flowchart showing the flow of arrangement processing. [Figure 21] This is a flowchart showing the flow of relocation processing (Part 1). [Figure 22] This is a flowchart showing the flow of relocation processing (Part 2). [Figure 23]This is a flowchart showing the process of rearrangement (part 3). [Figure 24] This is a flowchart showing the flow of the rearrangement process (part 4). [Figure 25] This is a flowchart showing the flow of the rearrangement process (part 4). [Figure 26] This flowchart shows the processing flow that provides the location where an anomaly was detected in the image. [Figure 27] This figure shows an example of the detection location provided. [Modes for carrying out the invention]

[0014] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

[0015] [Overall configuration of the image forming apparatus] Hereinafter, with reference to Figures 3 to 4, an example of the configuration of an image forming apparatus (hereinafter referred to as "image forming apparatus U") according to one embodiment of the present invention will be described.

[0016] Figure 3 is a schematic diagram showing the overall configuration of the image forming apparatus U according to this embodiment. Figure 4 is a diagram showing the configuration of the control system of the image forming unit 1 included in the image forming apparatus U according to this embodiment.

[0017] The image forming apparatus U is a roll-to-roll type image forming apparatus that uses a roll of paper P as a continuous sheet and forms an image on the roll of paper P. As shown in Figure 3, the image forming apparatus U is configured by connecting a paper feeding unit 2, an image forming unit 1, and a winding unit 3 from the upstream side along the transport direction of the roll of paper P.

[0018] The paper feeding unit 2 is a device that feeds roll paper P to the image forming unit 1. Inside the housing of the paper feeding unit 2, the roll paper P is wound in a roll shape around a paper feeding roller 2a and held rotatably. The paper feeding unit 2 transports the roll paper P wound around the paper feeding roller 2a to the image forming unit 1 at a constant speed, for example, via multiple transport roller pairs. The paper feeding operation of the paper feeding unit 2 is controlled by the control unit 100 provided in the image forming unit 1. The paper feeding unit 2 also has an optical sensor 2b that detects the thickness from the axis of the paper feeding roller 2a to the outermost part of the wound roll paper P.

[0019] The image forming unit 1 forms a color image using electrophotographic process technology. Specifically, the image forming unit 1 first transfers the toner images of each toner color—Y (yellow), M (magenta), C (cyan), and K (black)—formed on the photoreceptor drum 413 to the intermediate transfer belt 421. After superimposing the four toner images on the intermediate transfer belt 421, the image forming unit 1 secondarily transfers them to the roll paper P fed from the paper feeding unit 2, thereby forming a color image on the roll paper P.

[0020] Furthermore, the image forming unit 1 employs a tandem system in which photoreceptor drums 413 corresponding to four colors, Y, M, C, and K, are arranged in series in the direction of travel of the intermediate transfer belt 421, and the toner images of each toner color are sequentially transferred to the intermediate transfer belt 421 in a single step.

[0021] As shown in Figure 4, the image forming unit 1 comprises an image reading unit 10, an operation display unit 20, an image processing unit 30, an image forming unit 40, a paper transport unit 50, a fixing unit 60, an inline scanner 70, an inspection unit 80, a communication unit 81, a storage unit 82, and a control unit 100.

[0022] The control unit 100 includes a CPU (Central Processing Unit) 100a, a ROM (Read Only Memory) 100b, a RAM (Random Access Memory) 100c, etc. The CPU 100a reads a program corresponding to the processing content from the ROM 100b, loads it into the RAM 100c, and works in cooperation with the loaded program to centrally control the operation of each block of the image forming unit 1. At this time, various data stored in the storage unit 82 are referenced. The storage unit 82 is composed of, for example, a non-volatile semiconductor memory (so-called flash memory) or a hard disk drive.

[0023] The control unit 100 transmits and receives various types of data to and from external devices (e.g., personal computers (not shown)) connected to a communication network via the communication unit 81. Examples of communication networks include LANs (Local Area Networks) and WANs (Wide Area Networks). For example, the control unit 100 receives image data (input image data) transmitted from an external device and forms an image on the roll paper P based on this image data. The communication unit 81 is composed of a communication control card, such as a LAN card.

[0024] As shown in Figure 3, the image reading unit 10 is configured to include an automatic document feeder 11 called an ADF (Auto Document Feeder) and a document image scanning device 12 (scanner), etc.

[0025] The automatic document feeder 11 transports the documents D placed in the document tray using a transport mechanism and sends them to the document image scanner 12. The automatic document feeder 11 makes it possible to continuously scan images (including both sides) of multiple documents D placed in the document tray all at once.

[0026] The document image scanning device 12 optically scans a document transported from the automatic document feeder 11 onto the contact glass or a document placed on the contact glass. The document image scanning device 12 forms an image of the reflected light from the document onto the light-receiving surface of the CCD (Charge Coupled Device) sensor 12a and reads the document image. The image reading unit 10 generates input image data based on the reading result by the document image scanning device 12. This input image data is subjected to predetermined image processing by the image processing unit 30.

[0027] As shown in Figure 3, the operation display unit 20 is composed of, for example, a liquid crystal display (LCD) with a touch panel, and functions as a display unit 21 and an operation unit 22. The display unit 21 displays various operation screens, image status, operating status of each function, printing information, etc., according to display control signals input from the control unit 100. The operation unit 22 is equipped with various operation keys such as a numeric keypad and a start key, accepts various input operations from the user, and outputs operation signals to the control unit 100.

[0028] The image processing unit 30 includes circuits and other components that perform digital image processing on the input image data according to initial settings or user settings. For example, under the control of the control unit 100, the image processing unit 30 performs gradation correction based on gradation correction data (gradation correction table). In addition to gradation correction, the image processing unit 30 also performs various correction processes such as color correction and shading correction, as well as compression processing, on the input image data. The image forming unit 40 is controlled based on the image data that has undergone these processes.

[0029] The image forming unit 40 is an example of a printing unit. As shown in Figure 3, the image forming unit 40 includes toner image forming units 41Y, 41M, 41C, 41K, and an intermediate transfer unit 42, etc., for forming an image using colored toners of Y, M, C, and K components based on input image data.

[0030] The toner image forming units 41Y, 41M, 41C, and 41K for the Y, M, C, and K components have similar configurations. For the convenience of illustration and explanation, common components are indicated by the same reference numeral, and when distinguishing them, Y, M, C, or K is added to the reference numeral. In Figure 3, only the components of the toner image forming unit 41Y for the Y component are given reference numerals, while the components of the other toner image forming units 41M, 41C, and 41K are omitted.

[0031] The toner image forming unit 41 includes an exposure device 411, a developing device 412, a photoreceptor drum 413, a charging device 414, a drum cleaning device 415, and a toner recovery unit 200, etc.

[0032] The photoreceptor drum 413 is made of an organic photoreceptor, for example, in which a photosensitive layer made of a resin containing an organic photoconductor is formed on the outer surface of a drum-shaped metal substrate. The control unit 100 rotates the photoreceptor drum 413 at a constant peripheral speed by controlling the drive current supplied to the drive motor (not shown) that rotates the photoreceptor drum 413.

[0033] The charging device 414 is, for example, a charging charger, which uniformly charges the surface of the photoconductive photoreceptor drum 413 to a negative polarity by generating a corona discharge.

[0034] The exposure apparatus 411 is composed of, for example, a semiconductor laser, and irradiates the photoreceptor drum 413 with laser light corresponding to the image of each toner color component. As a result, an electrostatic latent image of each toner color component is formed in the image region of the surface of the photoreceptor drum 413 that has been irradiated with laser light, due to the potential difference with the background region.

[0035] The developing device 412 is a two-component inverted type developing device that visualizes the electrostatic latent image and develops it as a toner image by depositing the developer of each toner color component onto the surface of the photoreceptor drum 413.

[0036] The developing roller 412A of the developing device 412 carries the developer while rotating and supplies the toner contained in the developer to the photoreceptor drum 413. Specifically, the developing roller 412A receives a developing bias from the developing bias application unit 412B, and a potential difference is generated between it and the surface of the photoreceptor drum 413, thereby forming a toner image on the surface of the photoreceptor drum 413.

[0037] The drum cleaning device 415 has an elastic, flat drum cleaning blade or the like that is in contact with the surface of the photoreceptor drum 413, and removes toner that remains on the surface of the photoreceptor drum 413 without being transferred to the intermediate transfer belt 421.

[0038] The intermediate transfer unit 42 includes an intermediate transfer belt 421, a primary transfer roller 422, a plurality of support rollers 423, a secondary transfer roller 424, and a belt cleaning device 426, etc.

[0039] The intermediate transfer belt 421 is an endless belt and is stretched in a loop around a plurality of support rollers 423. At least one of the plurality of support rollers 423 is a drive roller, and the others are driven rollers. For example, it is preferable that the roller 423A, which is located downstream in the belt travel direction from the primary transfer roller 422 for component K, is the drive roller. This makes it easier to maintain a constant belt travel speed in the primary transfer section. As the drive roller 423A rotates, the intermediate transfer belt 421 travels at a constant speed in the direction of arrow A.

[0040] The intermediate transfer belt 421 is a conductive and elastic belt with a high-resistance layer on its surface. The intermediate transfer belt 421 is rotationally driven by a control signal from the control unit 100.

[0041] The primary transfer roller 422 is positioned on the inner circumferential side of the intermediate transfer belt 421, facing the photoreceptor drum 413 for each toner color component. By pressing the primary transfer roller 422 against the photoreceptor drum 413 with the intermediate transfer belt 421 in between, a primary transfer nip is formed for transferring the toner image from the photoreceptor drum 413 to the intermediate transfer belt 421.

[0042] The secondary transfer roller 424 is positioned on the outer circumferential side of the intermediate transfer belt 421, opposite the backup roller 423B which is located downstream of the drive roller 423A in the belt travel direction. By pressing the secondary transfer roller 424 against the backup roller 423B with the intermediate transfer belt 421 in between, a secondary transfer nip is formed for transferring the toner image from the intermediate transfer belt 421 to the roll paper P.

[0043] As the intermediate transfer belt 421 passes over the primary transfer nip, the toner image on the photoreceptor drum 413 is sequentially superimposed onto the intermediate transfer belt 421 and primary transferred. Specifically, by applying a primary transfer bias to the primary transfer roller 422 and applying a charge with the opposite polarity to the toner to the back side of the intermediate transfer belt 421, that is, the side in contact with the primary transfer roller 422, the toner image is electrostatically transferred to the intermediate transfer belt 421.

[0044] Subsequently, as the roll paper P passes through the secondary transfer nip, the toner image on the intermediate transfer belt 421 is secondary transferred to the roll paper P. Specifically, a secondary transfer bias is applied to the secondary transfer roller 424, and a charge with the opposite polarity to the toner is applied to the back side of the roll paper P, that is, the side in contact with the secondary transfer roller 424, thereby electrostatically transferring the toner image to the roll paper P. The roll paper P, on which the toner image has been transferred, is then transported toward the fuser unit 60.

[0045] The belt cleaning device 426 removes residual transfer toner remaining on the surface of the intermediate transfer belt 421 after secondary transfer. Alternatively, instead of the secondary transfer roller 424, a so-called belt-type secondary transfer unit may be used, in which the secondary transfer belt is stretched in a loop between multiple support rollers, including the secondary transfer roller.

[0046] The fixing unit 60 comprises an upper fixing unit 60A having a fixing surface side member positioned on the fixing surface of the roll paper P, i.e., the side on which the toner image is formed; a lower fixing unit 60B having a back side support member positioned on the back side of the roll paper P, i.e., the side opposite the fixing surface; and a heating source, etc. When the back side support member is pressed against the fixing surface side member, a fixing nip is formed that grips and transports the roll paper P. The fixing unit 60 fixes the toner image to the roll paper P by heating and pressurizing the transported roll paper P with the fixing nip after the toner image has been secondarily transferred.

[0047] The inline scanner 70 captures and reads an image formed on the roll paper P using, for example, a built-in sensor. Examples of sensors include CCD sensors (Charge Coupled Devices) and CMOS sensors (Complementary Metal Oxide Semiconductors). The inline scanner 70 is positioned, for example, downstream of the fixing unit 60 in the transport path 53, facing the roll paper P. Furthermore, the inline scanner 70 is capable of capturing images in each wavelength band of the RGB spectrum, for example.

[0048] The inspection unit 80 reads images with the inline scanner 70 and performs inspection. During inspection, abnormalities such as dirt are detected in the images. If an abnormality is detected, the inspection unit 80 notifies the control unit 100 of the location where the abnormality was detected. If an abnormality is detected in any image during the inspection by the inspection unit 80, the control unit 100 controls the image forming unit 40 to reprint the abnormal image on the roll paper on which the abnormal image was printed. When the image forming unit 40 reprints the image by the control unit 100, it performs the following processing in the case where the abnormal image is printed together with other images that are not printed on the roll paper. That is, the control unit 100 rearranges the images to be printed so that the length of roll paper used is shorter compared to when the abnormal image is printed together with other images that are not printed on the roll paper.

[0049] The paper transport unit 50 includes a paper feeding unit 51, a paper discharge unit 52, and a transport path unit 53, etc. The transport path unit 53 has multiple transport roller pairs and transports the roll paper P fed from the paper feeding unit 2 to the image forming unit 40 and the fixing unit 60, and then sends it to the take-up unit 3. The multiple transport roller pairs of the transport path unit 53 include registration roller pairs that correct the tilt and misalignment of the roll paper P.

[0050] Furthermore, the paper feed section 51 is a separate paper feed section for plain paper, provided separately from the paper feed unit 2, and feeds paper that does not exceed the width of the main body of the image forming unit 1. The three paper feed tray units that make up the paper feed section 51 store paper identified based on basis weight, size, etc., according to pre-set types.

[0051] The roll paper P fed from the paper feeding unit 2 to the image forming unit 1 is transported to the image forming unit 40 by the transport path section 53. In the image forming unit 40, the toner image from the intermediate transfer belt 421 is transferred to one side of the roll paper P in a single secondary transfer, and a fixing process is performed in the fixing unit 60. The image-formed roll paper P is transported to the winding unit 3 by the paper discharge section 52, which is equipped with a pair of transport rollers.

[0052] The winding unit 3 is a device that winds up the roll paper P that has been transported from the image forming unit 1. Inside the housing of the winding unit 3, for example, the roll paper P is wound around the paper discharge roller 3a and held in a roll shape. That is, the winding unit 3 winds the roll paper P that has been transported from the image forming unit 1 onto the paper discharge roller 3a at a constant speed, passing through multiple transport roller pairs. The winding unit 3 also has an optical sensor 3b that detects the thickness from the axis of the paper discharge roller 3a to the outermost part of the winding roll paper P.

[0053] [Printing position and inspection position] In this embodiment, the image printed on the roll paper is a strip-shaped image having a predetermined length in the main scanning direction and a predetermined width in the sub-scanning direction. Figure 5 shows the printing position and inspection position on the roll paper. In Figure 5, the roll paper is transported to the left. Therefore, the right side of the printing position is the roll paper before printing. The inspection position is located downstream of the printing position. The closer the printing position and the inspection position are, the sooner abnormalities can be detected.

[0054] [Process to determine the arrangement of the roll paper to be used] In this embodiment, as described above, the images to be printed are rearranged and printed in such a way that the length of the roll paper used is shorter compared to printing without rearranging the image in which an anomaly was detected and other images not printed on the roll paper. Therefore, the control unit 100 first determines the arrangement to shorten the length of the roll paper.

[0055] An example of the arrangement determination process that determines this arrangement will be described below. The control unit 100 determines the maximum image length for each pattern in all patterns in which one or more images to be printed are assigned to each lane. For example, before rearrangement in Figure 1, the image lengths in lanes 1 and 2 are the sum of the lengths of image A and image B. Similarly, the image length in lane 3 is the sum of the lengths of image C and image C. The maximum value in the pattern shown in Figure 1 before rearrangement is the sum of the lengths of image C and image C in lane 3. In this way, the control unit 100 determines the maximum value for all patterns. This maximum value is proportional to the length of the roll paper used.

[0056] The control unit 100 determines the pattern in which the smallest of the calculated maximum values ​​is obtained as the rearrangement pattern. In this way, it is possible to find the arrangement that minimizes the length of roll paper used. However, it is not necessarily the case that the length of roll paper used will be shorter compared to not rearranging. For example, if only one image needs to be reprinted, the length of roll paper used will not be shortened regardless of how it is rearranged.

[0057] [Relocation example 1] Figure 6 is a diagram illustrating rearrangement example 1. The diagram showing the state before rearrangement in rearrangement example 1 is the diagram shown after rearrangement in Figure 2. In the example shown in Figure 6, the control unit 100 detects an abnormality in image A and reprints image A. At the time the abnormality is detected, the other image not printed on the roll paper is the second image A to be printed out of the two images A to be printed. The other image not printed on the roll paper is the second image B to be printed out of the two images B to be printed. The other image not printed on the roll paper is the second image C to be printed out of the two images C to be printed. In the following explanation, the Nth (M≧N)th image Z to be printed out of M images Z may be referred to as image ZN. For example, the second image A to be printed is referred to as "image A2".

[0058] As described above, the other images not printed on the roll paper when an anomaly is detected in image A1 are images A2, B2, and C2. Therefore, the images to be printed after an anomaly is detected are images A1, A2, B2, and C2. The control unit 100 arranges images A1, A2, B2, and C2 using the arrangement determination process described above, so that the length of the roll paper used is shorter compared to printing without rearrangement. In the following explanation, "images to be printed after an anomaly is detected" may be referred to as "images to be reprinted".

[0059] As a result, as is clear from Figures 6 and 2, the arrangement shown in Figure 6, which is rearranged by the arrangement determination process, uses a shorter length of roll paper. In this way, the image forming apparatus U according to this embodiment can make effective use of the roll paper.

[0060] [Relocation example 2] In the image reprinting process by the image forming unit 40 controlled by the control unit 100, the image to be printed is rearranged and printed each time an abnormality is detected in the image. Figure 7 is a diagram illustrating rearrangement example 2. In the diagrams described below, the "X" marked on the image indicates the location where an abnormality such as dirt was detected.

[0061] The state shown in (1) in Figure 7 indicates a state where an abnormality has been detected in image A1, and then an abnormality has been detected in image B1. The images to be reprinted at this time are images A2, B1, B2, and C2. The state in (2) in Figure 7 shows an example of repositioning determined by the control unit 100. In this way, the image forming apparatus U can effectively utilize the roll paper by repositioning the images to be printed each time an abnormality is detected in an image.

[0062] [Relocation example 3] When the image forming unit 40 reprints an image using the control unit 100, it interrupts the printing of the image in which an abnormality was detected, rearranges the images to be printed, and then prints them. Figure 8 is a diagram illustrating rearrangement example 3.

[0063] State (1) shown in Figure 8 indicates that an abnormality has been detected in image C2. State (2) shown in Figure 8 indicates that the control unit 100 has interrupted the printing of image C2. State (3) shown in Figure 8 indicates that the control unit 100 has reprinted image C2. In this way, the image forming apparatus U can suppress the consumption of unnecessary colorants by interrupting and reprinting.

[0064] [Relocation example 4] In the image reprinting by the image forming unit 40 by the control unit 100, the image is printed continuously for a predetermined length from the position where the anomaly was detected. Figure 9 is a diagram illustrating rearrangement example 4. The "predetermined length" corresponds to the length in the main scanning direction of the image where the anomaly was detected. In Figure 9, the "predetermined length" corresponds to the length in the main scanning direction of image C.

[0065] State (1) shown in Figure 9 indicates that an abnormality has been detected in image C2. State (2) shown in Figure 9 indicates that the control unit 100 has continued printing the image for a predetermined length from the position where the abnormality was detected. In this way, the image forming apparatus U can print an image without abnormalities by continuing to print the image in which an abnormality was detected.

[0066] [User Interface] Here, we will explain the setting screen displayed on the operation display unit 20 of the image forming apparatus U. Figure 10 is a screen for setting the operation when an anomaly is detected. This anomaly detection screen allows the user to select from three actions: "Do not rearrange", "Perform rearrangement", and "Perform rearrangement according to print distance". If "Do not rearrange" is selected, the control unit 100 will not perform rearrangement. If "Perform rearrangement" is selected, the control unit 100 will perform rearrangement. The "print distance" in "Perform rearrangement according to print distance" indicates the print distance to the anomaly detection location at the time of anomaly detection. This "print distance" can be set. If "Perform rearrangement according to print distance" is selected, the control unit 100 will perform rearrangement according to the set print distance.

[0067] Figure 11 shows a screen for setting the operation when the amount of roll paper used does not change even after rearranging. This rearrangement setting screen allows the user to select between two operations: "Reprint on the same lane" and "Cancel printing". If "Reprint on the same lane" is selected, the control unit 100 reprints on the same lane where the abnormality was detected. If "Cancel printing" is selected, the control unit 100 cancels printing. In this way, when the image forming unit 40 reprints an image by the control unit 100, if the length of the roll paper used does not decrease even after rearranging, rearrangement is not performed and the image in which the abnormality was detected is not reprinted. Note that "Cancel printing" also allows the selection of "Rearrange with the image to be printed in the next print process". "Rearrange with the image to be printed in the next print process" is a setting for rearranging the image in which the abnormality was detected with the image to be printed in the next print process.

[0068] [Relocation example 5] In the image formation unit 40's reprinting of images by the control unit 100, if rearranging does not shorten the length of the roll paper used, rearranging is not performed, and the image in which the abnormality was detected is reprinted on the same lane. Figure 12 is a diagram illustrating rearrangement example 5.

[0069] State (1) shown in Figure 12 indicates that an abnormality has been detected in image C2. In this case, only image C2 is to be reprinted. Therefore, the length of the roll paper used will not be shortened even if the layout is rearranged. State (2) shown in Figure 12 indicates that the control unit 100 has reprinted image C2, in which an abnormality was detected, on the same lane.

[0070] [Relocation example 6] In the image reprinting process by the image forming unit 40 controlled by the control unit 100, if an abnormality is detected a predetermined number of times in one lane, the images to be printed are rearranged and printed in the lanes excluding the one detected abnormality. Figure 13 is a diagram illustrating rearrangement example 6.

[0071] State (1) shown in Figure 13 indicates a state in which an abnormality is detected in image A1, and then another abnormality is detected in image A1 while it is being reprinted on the same lane 1. At this time, image B2 is positioned to be printed on lane 1. State (2) shown in Figure 13 indicates a state in which the control unit 100 has rearranged the printouts on lanes 2 and 3, excluding lane 1. By doing this, printing at locations that are likely to be faulty can be avoided, thereby reducing the consumption of unnecessary colorant rolls.

[0072] [Relocation example 7] When the image forming unit 40 reprints an image using the control unit 100, the images are rearranged based on the coverage rate. This rearrangement example is effective when it is possible to print an image with a relatively high coverage rate. If an image with low coverage is printed at a distance greater than a certain amount, toner degradation occurs in the developer unit, requiring a toner refresh process during printing. The rearrangement is performed using an image with a relatively high coverage rate to avoid such low coverage. Figure 14 is a diagram illustrating rearrangement example 7.

[0073] Images A, B, and C shown in Figure 14 are images with relatively low coverage rates that require toner refresh processing during printing. State (1) shown in Figure 14 indicates that an abnormality has been detected in image A1. State (2) shown in Figure 14 indicates that the control unit 100 performs a rearrangement using image D, which has a relatively high coverage rate, instead of image A2, in order to avoid toner refresh processing. In this way, toner refresh processing can be avoided.

[0074] [Relocation example 8] When the image forming unit 40 reprints an image using the control unit 100, the images are rearranged based on the distance over which the images are printed continuously. In this rearrangement example, the control unit 100 checks the RFP (refresh patch) setting information and the switch information for when it is desired to extend the continuous printing distance even if the image quality deteriorates, and then performs the rearrangement. Figure 15 is a diagram illustrating rearrangement example 8.

[0075] Images A, B, and C shown in Figure 15 are images with relatively low coverage rates that require toner refresh processing during printing. The "RFP" outside the lane indicates a refresh patch. The control unit 100 prints the RFP according to the printing distance of images A, B, and C, and therefore does not perform repositioning as in repositioning example 7.

[0076] [Relocation example 9] When the image forming unit 40 reprints an image using the control unit 100, the images are rearranged based on the remaining amount of roll paper. Figure 16 is a diagram illustrating rearrangement example 9. The control unit 100 detects an abnormality in image A and performs rearrangement. However, if there is no remaining roll paper at this time, images D and E, which fit within the remaining roll paper, are placed instead. This allows for efficient use of the roll paper.

[0077] [Relocation example 10] In the reprinting of images by the image forming unit 40 by the control unit 100, the images are rearranged based on the post-printing process. Figure 17 is a diagram illustrating rearrangement example 10. As shown in Figure 17, post-processing α is performed on lanes 1 and 2, and a different post-processing β is performed on lanes 3 and 4. Post-processing includes, for example, applying gold or silver foil. If an abnormality is detected, the control unit 100 performs rearrangement within the same lane as the post-processing. For example, as shown in Figure 17, if an abnormality is detected in image A, the post-processing will perform rearrangement within the same lane 1 or lane 2. This allows the control unit 100 to appropriately rearrange the images even when different post-processing is performed.

[0078] [Relocation example 11] When the image is reprinted by the image forming unit 40 by the control unit 100, it is rearranged based on a predetermined width. The "predetermined width" corresponds to the length of the image in the sub-scanning direction. Figure 18 is a diagram illustrating rearrangement example 11. As shown in Figure 18, the width of the image differs for each lane. In the example in Figure 18, it is assumed that the roll paper is cut in a later process. If an abnormality is detected, the control unit 100 performs rearrangement within lanes with the same width. For example, as shown in Figure 18, if an abnormality is detected in image A, rearrangement is performed within the same lane 1 range. This allows the control unit 100 to appropriately rearrange even if the widths are different.

[0079] [Relocation example 12] When the image forming unit 40 reprints an image using the control unit 100, the images are rearranged based on a predetermined length. Figure 19 is a diagram illustrating rearrangement example 12. As shown in Figure 19, if images A, B, and C have the same length, the control unit 100 rearranges images D, E, and F, which have the same length. This allows the control unit 100 to appropriately rearrange images even when they have the same length.

[0080] [flowchart] The placement process performed by the image forming apparatus U according to this embodiment will be described below using a flowchart. Figure 20 is a flowchart showing the flow of the placement process. In Figure 20, the control unit 100 performs a placement determination process, places the image (step S101), and starts printing according to the placement (step S102). The control unit 100 determines whether or not the inspection unit 80 has detected an abnormality (step S103).

[0081] If the inspection unit 80 does not detect any abnormalities (step S103: NO), the control unit 100 determines whether or not printing is complete (step S104). If printing is not complete (step S104: NO), the control unit 100 returns to step S103. If printing is complete (step S104: YES), the control unit 100 terminates the process.

[0082] If the inspection unit 80 detects an abnormality in step S103 (step S103: YES), the control unit 100 performs a rearrangement process (step S105) and proceeds to step S104.

[0083] Figure 21 is a flowchart showing the flow of the rearrangement process (part 1). In Figure 21, the control unit 100 calculates the remaining length of each image at the time the anomaly is detected (step S201). The remaining length refers to the remaining length to be printed for the image in which the anomaly was detected during printing. The control unit 100 determines whether or not printing of the other images other than the image in which the anomaly was detected has been completed (step S202).

[0084] If printing of other images is not yet complete (step S202: NO), the control unit 100 determines whether it is possible to replace the other images (step S203). If it is possible to replace the other images (step S203: YES), the control unit 100 rearranges the images (step S204) and terminates the process.

[0085] In step S202 above, if printing of other images has been completed (step S202: YES), the control unit 100 determines whether or not to continue printing (step S205). For information on continuing printing, please refer to rearrangement example 4. If printing is to be continued (step S205: YES), the control unit 100 continues printing (step S207) and terminates the process. If printing is not to be continued (step S205: NO), the control unit 100 performs a reprint (step S206) and terminates the process. In step S203 above, if it is not possible to replace other images (step S203: NO), the control unit 100 proceeds to step S205.

[0086] Figure 22 is a flowchart showing the flow of the rearrangement process (part 2). In Figure 22, the control unit 100 calculates the remaining length of each image at the time the anomaly is detected (step S301). The control unit 100 determines whether or not printing of the images other than the image in which the anomaly was detected has been completed (step S302).

[0087] If printing of other images is not yet complete (step S302: NO), the control unit 100 determines whether it is possible to replace the other images (step S303). If it is possible to replace the other images (step S303: YES), the control unit 100 rearranges the images (step S304) and terminates the process.

[0088] In step S302 above, if printing of other images has been completed (step S302: YES), the control unit 100 determines whether the remaining length is less than or equal to the set value (step S305). The set value refers to the value set in "print distance to abnormal detection position" as explained in Figure 10. If the remaining length is less than or equal to the set value (step S305: YES), the control unit 100 continues printing (step S306) and terminates the process. If the remaining length is greater than the set value (step S305: NO), the control unit 100 determines whether it is set to reprint if rearrangement is ineffective (step S307). Refer to Figure 11 for this setting.

[0089] If reprinting is configured to occur if rearranging is ineffective (step S307: YES), the control unit 100 performs reprinting (step S308) and terminates the process. If reprinting is not configured to occur if rearranging is ineffective (step S307: NO), the control unit 100 terminates the process without printing.

[0090] Figure 23 is a flowchart showing the flow of the repositioning process (part 3). In Figure 23, the control unit 100 stores the location where the abnormality was detected (step S401). The control unit 100 determines whether or not an abnormality has already been detected in the same lane (step S402). If no abnormality has already been detected in the same lane (step S402: NO), the control unit 100 repositions (step S403) and terminates the process.

[0091] If an abnormality has already been detected in the same lane (step S402: YES), the control unit 100 determines whether or not an abnormality has been detected at the same location (step S404). If no abnormality has been detected at the same location (step S404: NO), the control unit 100 performs a rearrangement in the lanes excluding the lane where the abnormality was detected (step S405) and terminates the process. If an abnormality is detected at the same location (step S404: YES), the control unit 100 sets it as a location to be excluded (step S406) and proceeds to step S405.

[0092] Figures 24 and 25 are flowcharts showing the flow of the rearrangement process (part 4). In Figure 24, the control unit 100 calculates the remaining length of each image at the time the abnormality is detected (step S501). The control unit 100 determines whether the coverage rate of the image to be printed is within a specified range (step S502). The specified range is the range in which toner refresh processing is not required during printing. If the coverage rate is not within the specified range (step S502: NO), the control unit 100 rearranges based on the coverage rate (step S503) and terminates the process.

[0093] In step S502 above, if the coverage rate is within the specified range (step S502: YES), the control unit 100 determines whether or not a continuous printing distance setting has been made (step S504). If a continuous printing distance setting has been made (step S504: YES), the control unit 100 rearranges the images based on the distance at which they will be printed continuously (step S505) and terminates the process.

[0094] In step S504 above, if the continuous printing distance setting has not been made (step S504: NO), the control unit 100 determines whether or not there is remaining roll paper (step S506). If there is no remaining roll paper (step S506: NO), the control unit 100 rearranges the roll paper based on the remaining amount (step S507) and terminates the process.

[0095] In step S506 above, if there is remaining roll paper (step S506: YES), the control unit 100 determines in step S601 of Figure 25 whether or not there is a subsequent process (step S601). If there is a subsequent process (step S601: YES), the control unit 100 rearranges the paper based on the subsequent process after printing (step S602) and terminates the process.

[0096] In step S601 above, if there are no subsequent processes (step S601: NO), the control unit 100 determines whether the width of the images is different (step S603). If the widths are different (step S603: YES), the control unit 100 rearranges the images based on the widths (step S604) and terminates the process.

[0097] In step S603 above, if the image widths are the same (step S603: NO), the control unit 100 determines whether the trimming widths are different (step S605). If the trimming widths are different (step S605: YES), the control unit 100 rearranges the images based on the trimming widths (step S606) and terminates the process.

[0098] In step S605 above, if the trimming width is the same (step S605: NO), the control unit 100 rearranges the image based on the remaining distance to be printed (step S607) and terminates the process.

[0099] Figure 26 is a flowchart showing the processing flow for providing the location where an anomaly was detected in the image. In Figure 26, the control unit 100 performs placement determination processing, places the image (step S701), and starts printing according to the placement (step S702). The control unit 100 determines whether or not the inspection unit 80 has detected an anomaly (step S703).

[0100] If the inspection unit 80 does not detect an abnormality (step S703: NO), the control unit 100 determines whether printing is complete or not (step S704). If printing is not complete (step S704: NO), the control unit 100 returns to step S703. If printing is complete (step S704: YES), the control unit 100 provides the detection location where the abnormality was detected (step S706) and terminates the process.

[0101] If the inspection unit 80 detects an abnormality in step S703 (step S703: YES), the control unit 100 stores the detection location (step S705) and proceeds to step S704. Along with the processing in step S705, rearrangement is performed.

[0102] Figure 27 shows an example of the detection locations provided. As shown in Figure 27, for each location where an anomaly is detected, a value indicating the position in the main scanning direction and a value indicating the position in the sub-scanning direction are provided. Such detection locations may be provided to the next process via communication or, for the user, by printing.

[0103] As described above, according to this embodiment, the image to be printed is rearranged so that the length of the roll paper used is shortened, thus making effective use of the roll paper.

[0104] Furthermore, the above embodiments are merely examples of how the present invention may be implemented, and the technical scope of the present invention should not be limited by them. In other words, the present invention can be implemented in various ways without departing from its gist or its main features.

[0105] Furthermore, although the above embodiments described an example of a color image forming apparatus utilizing electrophotographic process technology, the present invention is also applicable to a color image forming apparatus utilizing inkjet technology. [Explanation of Symbols]

[0106] U Image forming apparatus 1. Image forming apparatus main unit 2 Paper feed unit 3. Winding Unit 50 Paper transport section 70 Inline Scanners 80 Inspection Department

Claims

1. A printing unit that prints multiple images on multiple lanes of a continuous sheet, The inspection unit reads images printed on continuous sheets to perform quality checks, The inspection unit, when it detects an abnormality in any image during inspection, includes a control unit that controls the printing unit to reprint the image with the abnormality on the continuous sheet on which the image with the abnormality was printed. In the reprinting of an image by the printing unit by the control unit, when printing the image in which an abnormality was detected and other images not printed on the continuous sheet, the image forming apparatus rearranges the images to be printed so that the length of the continuous sheet used is shorter compared to when the image in which an abnormality was detected and other images not printed on the continuous sheet are printed without rearranging them.

2. The image forming apparatus according to claim 1, wherein, in the reprinting of an image by the printing unit by the control unit, the image to be printed is rearranged and printed each time an abnormality is detected in the image.

3. The image forming apparatus according to claim 1, wherein, in the reprinting of an image by the printing unit by the control unit, printing of the image in which an abnormality has been detected is interrupted, and the images to be printed are rearranged and printed.

4. The image to be printed is a strip-shaped image with a predetermined length in the main scanning direction. The image forming apparatus according to claim 1, wherein the control unit reprints the image in the printing unit, and prints the image for a predetermined length starting from the position where the abnormality was detected.

5. The image forming apparatus according to claim 1, wherein, in the reprinting of an image in the printing section by the control unit, if rearranging does not shorten the length of the continuous sheet used, rearranging is not performed, and the image in which an abnormality was detected is reprinted in the same lane.

6. The image forming apparatus according to claim 1, in which the control unit reprints an image in the printing unit, if rearranging does not shorten the length of the continuous sheet used, rearranging is not performed, and the image in which an abnormality is detected is not reprinted.

7. The image forming apparatus according to claim 1, wherein, in the reprinting of an image in the printing section by the control unit, if an abnormality is detected in one lane a predetermined number of times, the image to be printed is rearranged and printed in the lanes excluding the lane mentioned above.

8. The image forming apparatus according to claim 1, wherein the control unit rearranges the image in the printing unit based on the coverage rate during reprinting.

9. The image forming apparatus according to claim 1, wherein the control unit repositions the image based on the distance for continuous printing when reprinting the image in the printing unit.

10. The image forming apparatus according to claim 1, wherein the control unit re-prints the image in the printing unit based on the remaining amount of continuous sheets.

11. The image forming apparatus according to claim 1, wherein the reprinting of the image by the printing unit by the control unit is rearranged based on the post-printing process.

12. The image to be printed is a strip-shaped image with a predetermined width in the sub-scanning direction. The image forming apparatus according to claim 1, wherein the control unit re-prints the image in the printing unit, and rearranges it based on the predetermined width.

13. The image to be printed is a strip-shaped image with a predetermined length in the main scanning direction. The image forming apparatus according to claim 1, wherein the control unit re-prints the image in the printing unit, and rearranges it based on the predetermined length.

14. The image forming apparatus according to claim 1, which can provide the location where an anomaly is detected in an image to a device for post-processing.

15. A control method for an image forming apparatus comprising a printing unit that prints multiple images on multiple lanes of a continuous sheet, and an inspection unit that reads and inspects the images printed on the continuous sheet, During inspection by the inspection unit, if an abnormality is detected in any image, the printing unit is controlled to reprint the image with the abnormality on the continuous sheet on which the abnormal image was printed. In the reprinting of images in the aforementioned printing unit, when printing the image in which an anomaly was detected along with other images not printed on the continuous sheet, the images to be printed are rearranged so that the length of the continuous sheet used is shorter compared to printing the image in which the anomaly was detected along with other images not printed on the continuous sheet without rearranging them. Control method.

16. The computer of an image forming apparatus, which includes a printing unit that prints multiple images on multiple lanes of a continuous sheet, and an inspection unit that reads and inspects the images printed on the continuous sheet, During inspection by the inspection unit, if an abnormality is detected in any image, the printing unit is controlled to reprint the image with the abnormality on the continuous sheet on which the abnormal image was printed. In the reprinting of images in the aforementioned printing unit, when printing the image in which an anomaly was detected along with other images not printed on the continuous sheet, the images to be printed are rearranged so that the length of the continuous sheet used is shorter compared to printing the image in which the anomaly was detected along with other images not printed on the continuous sheet without rearranging them. A program that executes a process.

Images