Image diagnosis system and image diagnosis method

Abstract

To solve the problem in which: since a user cannot grasp the printing number of charts for diagnosis before printing the charts for diagnosis, image diagnosis may be interrupted due to paper shortage during the printing of the charts for diagnosis.SOLUTION: An image diagnostic system displays, on an operating unit, a screen for receiving an instruction for image diagnosis, in accordance with the operating unit receiving an instruction for starting image diagnosis, causes an image forming unit to form an image for diagnosis on a sheet, causes a reading unit to read the image for diagnosis that has been formed and output, and diagnoses a malfunction portion of the image forming unit on the basis of an image obtained through the reading. The screen includes the number of images for diagnosis to be output.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to an image diagnosis system and an image diagnosis method. [Background technology]

[0002] There is an image diagnosis technology in which an image forming apparatus is provided with a printing unit and an image reading unit, and a diagnostic chart printed by the printing unit is read by the image reading unit, and fault locations within the apparatus are diagnosed from the image data. Patent Document 1 discloses a technology in which an image of a recording medium on which patterns including a horizontal band chart and a vertical band chart are printed is read, and items requiring image diagnosis are identified based on the read image. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-133020 Summary of the Invention [Problem to be solved by the invention]

[0004] However, Patent Document 1 does not include a means for notifying the user of the number of diagnostic charts to be printed before printing the diagnostic charts. As a result, the user cannot know the number of diagnostic charts to be printed before printing the diagnostic charts, and image diagnosis may be interrupted in the middle of printing the diagnostic charts due to a lack of paper. [Means for solving the problem]

[0005] The image diagnostic system of the present invention includes an operation unit that displays information, an image forming unit that forms an image on a sheet of paper, and a reading unit that reads the image formed by the image forming unit, and, in response to an instruction to start image diagnosis received by the operation unit, causes the image forming unit to form a diagnostic image on a sheet of paper, causes the reading unit to read the formed and output diagnostic image, and I gota diagnostic means for diagnosing a defective portion of the image forming unit based on the image; a repair means for causing the image forming section to form a repair image on paper, causing the reading section to read the formed and output repair image, and repairing a defective portion identified by the diagnosis by the diagnosing section based on the read and acquired image; and a display control means for causing the operation section to display a first screen including the number of output sheets of the diagnostic image before starting the image diagnosis, and for causing the operation section to display a second screen including the number of output sheets of the repair image after executing the image diagnosis if the defective portion identified by the repair means can be repaired. It is characterized by: [Effects of the Invention]

[0006] According to the present invention, it is possible to grasp the number of diagnostic images to be output before executing a diagnosis. [Brief explanation of the drawings]

[0007] [Figure 1] A diagram showing an example of a network configuration including a printing system. [Figure 2] 1 is a cross-sectional view showing an example of the hardware configuration of an image forming apparatus; [Figure 3] Block diagram showing the internal configuration of the image forming device, external controller, and client PC [Figure 4] Flowchart showing the procedure for image diagnosis processing [Figure 5] Figure showing an example of a diagnostic item selection screen [Figure 6] A diagram showing an example of notification of the number of test charts used in image diagnostic processing [Figure 7] Figure showing an example of notification of the number of test charts used in the automatic recovery process [Figure 8] Schematic diagram of a table used to calculate the number of test charts used in image diagnostic processing [Figure 9] Schematic diagram of a table used to calculate the number of test charts used in automatic recovery processing [Figure 10] A diagram showing an example of a test chart used in image diagnostic processing. [Figure 11] Figure showing an example of a diagnostic item selection screen [Figure 12] FIG. 10 is a diagram showing an example of notification of the range of the number of test charts used in image diagnostic processing in a modified example of the first embodiment. [Figure 13] FIG. 10 is a diagram showing an example of a warning message when notifying the number of test charts to be used in image diagnostic processing in a modified example of the first embodiment. [Figure 14]FIG. 10 is a flowchart showing the procedure of a simple image diagnosis process in the second embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Note that the same components are given the same reference numerals and the description thereof will be omitted.

[0009] [First embodiment] <Overall system configuration> Fig. 1 is a diagram showing an example of a network configuration including a printing system (image diagnostic system) according to this embodiment. As shown in Fig. 1, the printing system 100 includes an image forming apparatus 101 and an external controller 102. The image forming apparatus 101 and the external controller 102 are communicatively connected via an internal LAN 105 and a video cable 106. The external controller 102 is communicatively connected to a client PC 103 via an external LAN 104.

[0010] The client PC 103 can issue a print instruction to the external controller 102 via the external LAN 104. A printer driver is installed in the client PC 103, and has the function of converting image data to be printed into a page description language (PDL) that can be processed by the external controller 102. A user who wishes to print can issue a print instruction via the printer driver from various applications installed on the client PC 103 by operating the client PC 103. The printer driver transmits PDL data, which is print data, to the external controller 102 based on the print instruction from the user. Upon receiving the PDL data from the client PC 103, the external controller 102 analyzes and interprets the received PDL data. Based on the interpretation result, the external controller 102 performs rasterization processing to generate a bitmap image (print image data) with a resolution matching the image forming apparatus 101, and issues a print instruction by submitting a print job to the image forming apparatus 101.

[0011] Next, the image forming apparatus 101 will be described. In the image forming apparatus 101, devices with multiple different functions are connected and configured to be capable of complex printing processes such as bookbinding. The image forming apparatus 101 has a printing unit 107 (image forming unit), a diagnostic unit 108, a stacker 109, and a finisher 110. Each module will be described below.

[0012] The printing unit 107 prints an image in accordance with a print job and ejects the printed recording material. The printed recording material ejected from the printing unit 107 is transported inside each device in the order of the diagnosis unit 108, stacker 109, and finisher 110. In this embodiment, the image forming device 101 of the printing system 100 is an example of an image forming device, but the printing unit 107 included in the image forming device 101 may also be referred to as the image forming device. The printing unit 107 forms (prints) an image using toner (color material) on the recording material fed and transported from a paper feed unit arranged below the printing unit 107.

[0013] The diagnostic unit 108 is a device that diagnoses whether or not there is a defect in the image forming apparatus 101 based on the printed recording material on which an image has been printed by the printing unit 107 and which has been transported through a transport path. Specifically, the diagnostic unit 108 reads the image printed on the transported printed recording material and performs diagnosis from the obtained read image. The defect is diagnosed by extracting a diagnostic area from the read image and checking the difference in read signal values ​​within the extracted diagnostic area. Detailed processing by the diagnostic unit will be described later. Note that the use of the diagnostic unit is not limited to the example described above. The diagnostic unit may also be equipped with an inspection function that inspects the printed recording material for printing defects.

[0014] The stacker 109 is a device capable of stacking a large number of printed recording materials. The finisher 110 is a device capable of performing finishing processes such as stapling, punching, and saddle stitching on the conveyed printed recording materials.

[0015] The recording material processed by the finisher 110 is discharged to a predetermined discharge tray.

[0016] 1, an external controller 102 is connected to the image forming apparatus 101, but this embodiment can also be applied to a different configuration. For example, a configuration may be used in which the image forming apparatus 101 is connected to an external LAN 104, and print data is sent from a client PC 103 to the image forming apparatus 101 without going through the external controller 102. In this case, data analysis and rasterization of the print data are performed by the image forming apparatus 101.

[0017] <Hardware Configuration of Image Forming Apparatus 101> 2 is a cross-sectional view showing an example of the hardware configuration of the image forming apparatus 101. A specific example of the operation of the image forming apparatus 101 will be described below with reference to FIG.

[0018] <Description of the paper feed deck> The printing unit 107 is equipped with multiple paper feed decks. In this embodiment, six types of decks are provided: paper feed decks 361, 362, 363, 364, 365, and 366. Each paper feed deck stores various recording materials (paper). Of the recording materials stored in each paper feed deck, the topmost recording material is separated one by one and fed to the conveying path 303. The paper feed deck also acquires paper information about the stored paper based on sensors and instructions from the user. In this embodiment, the paper information refers to the paper size, basis weight, surface properties, and color of the paper. This paper information is acquired and stored in the HDD, which will be described later. Paper size refers to the finished dimensions of the paper as defined by ISO 216. In this embodiment, in addition to A size and B size, photo paper size can also be identified. Basis weight is information expressed as the weight of cardboard, which is the standard for paper, and is calculated based on the weight of 1 m 2 In this embodiment, the mass per unit area is 79 g / m 2 or less (thin paper), 80 g / m 2 More than 127g / m 2 Below (plain paper), 128g / m 2 More than 200g / m 2or less (cardboard), 201g / m 2 The above (heavy paper 2) is distinguished into four stages. Surface properties are information that expresses differences in paper type due to the unevenness of the paper surface. In this embodiment, there are seven types: fine paper, single-sided coated paper, double-sided coated paper, matte coated paper, embossed paper, film paper, and recycled paper.

[0019] Finally, paper color is information that represents the whiteness of the paper as defined by, for example, ISO 12470. In this embodiment, a whiteness of 70% or more is determined to be white, and anything lower is determined to be colored paper. Table 1 shows a schematic example of the paper information that can be stored.

[0020] The paper size is automatically acquired by reading the position of a guide (not shown) inside the paper feed deck with a sensor. Other information is acquired by the user selecting and inputting it from a paper information change screen (described later). Note that, although the present embodiment has been described as an example in which only some of the paper information is acquired by a sensor provided in the paper feed deck, this is not limited to the above example. For example, a configuration may be adopted in which a sheet of paper stored in the paper feed deck is passed through, and the paper information is determined based on the image read by a reading device (described later).

[0021] [Table 1]

[0022] A deck ID and paper information are stored for each of the six types of paper feed decks. Note that the level at which paper information is determined is not limited to the example above. It is sufficient that the resolution is sufficient to determine whether or not the compatibility conditions of the image diagnostic test chart, which will be described later, are met, and the determination may be made at a finer level. Furthermore, as a more preferable example, although the example in which a sensor is installed in the paper feed deck and information is acquired automatically has been described, a configuration in which the user registers the paper information themselves is also possible.

[0023] Each of the image forming stations 304 to 307 includes a photosensitive drum (photoconductor) and forms a toner image on the photosensitive drum using toner of a different color. Specifically, the image forming stations 304 to 307 form a toner image using toner of yellow (Y), magenta (M), cyan (C), and black (K), respectively.

[0024] The toner images of each color formed at the image forming stations 304 to 307 are transferred onto the intermediate transfer belt 308 in order, superimposed on top of each other (primary transfer). The toner images transferred onto the intermediate transfer belt 308 are transported to a secondary transfer position 309 as the intermediate transfer belt 308 rotates. At the secondary transfer position 309, the toner image is transferred from the intermediate transfer belt 308 onto the recording material transported along the transport path 303 (secondary transfer). After the secondary transfer, the recording material is transported to a fixing unit 311. The fixing unit 311 includes a pressure roller and a heating roller. Heat and pressure are applied to the recording material as it passes between these rollers, thereby fixing the toner image to the recording material. After passing through the fixing unit 311, the recording material is transported via a transport path 312 to a connection point 315 between the printing unit 107 and the diagnostic unit 108. In this manner, a color image is formed (printed) on the recording material.

[0025] If further fixing processing is required depending on the type of recording material, the recording material that has passed through fixing unit 311 is guided to conveyance path 314 provided with fixing unit 313. Fixing unit 313 performs further fixing processing on the recording material conveyed along conveyance path 314. The recording material that has passed through fixing unit 313 is conveyed to connection point 315. Furthermore, if an operating mode for double-sided printing is set, an image is printed on the first side of the recording material, and the recording material conveyed along conveyance path 312 or conveyance path 314 is guided to reversing path 316. The recording material that has been reversed by reversing path 316 is guided to double-sided conveyance path 317 and conveyed to secondary transfer position 309. As a result, a toner image is transferred to the second side of the recording material, which is opposite to the first side, at secondary transfer position 309. Thereafter, the recording material passes through fixing unit 311 (and fixing unit 313), completing the formation of a color image on the second side of the recording material.

[0026] When the image formation (printing) in the printing unit 107 is completed, the printed recording material is conveyed to the connection point 315 and then conveyed into the diagnosis unit .

[0027] The diagnosis unit 108 includes image reading units 331 and 332 each having a CIS (Contact Image Sensor) on a conveying path 330 along which the printed recording material from the printing unit 107 is conveyed. The image reading units 331 and 332 are disposed in positions facing each other across the conveying path 330. The image reading units 331 and 332 are configured to read the top surface (first surface) and bottom surface (second surface) of the recording material, respectively. Note that the image reading units may be configured with a CCD (Charge Coupled Device) or a line scan camera instead of a CIS, for example.

[0028] The diagnosis unit 108 performs image diagnosis processing (image diagnosis) to determine whether or not there is a defect in the image forming apparatus 101 based on the image printed on the printed recording material being transported on the transport path 330. Specifically, the diagnosis unit 108 performs a reading process to read the image on the printed recording material using the image reading units 331 and 332 at the timing when the printed recording material being transported reaches a predetermined position.

[0029] The diagnostic unit 108 performs image diagnostic processing based on a user instruction. The image diagnostic processing is preferably performed, for example, before the start of printing work or when printing defects continue. The recording materials that have passed through the diagnostic unit 108 are transported to a stacker 109 in order.

[0030] The stacker 109 includes a stack tray 341 as a tray on which printed recording materials conveyed from the diagnostic unit 108, which is disposed upstream in the conveying direction of the printed recording materials, are stacked. The printed recording materials that have passed through the diagnostic unit 108 are conveyed along a conveying path 344 within the stacker 109. The printed recording materials conveyed along the conveying path 344 are guided to a conveying path 345, whereby the printed recording materials are stacked on the stack tray 341.

[0031] The stacker 109 further includes an escape tray 346 as a paper discharge tray. In this embodiment, the escape tray 346 is used to discharge recording materials on which a test chart used in image diagnosis by the diagnosis unit 108 is printed. Printed recording materials conveyed along the conveying path 344 are guided to a conveying path 347 and conveyed to the escape tray 346. Printed recording materials conveyed in the stacker 109 without being stacked or discharged are conveyed via a conveying path 348 to the finisher 110 at the subsequent stage.

[0032] The stacker 109 further includes an inverting unit 349 for inverting the orientation of the printed recording material being conveyed. The inverting unit 349 is used, for example, to make the orientation of the recording material input into the stacker 109 the same as the orientation of the printed recording material when it is stacked on the stack tray 341 and output from the stacker 109. Note that the inverting operation by the inverting unit 349 is not performed on printed recording materials that are not stacked in the stacker 109 but are conveyed to the finisher 110.

[0033] The finisher 110 executes a finishing function specified by a user on printed recording materials conveyed from a diagnostic unit 108 disposed upstream in the conveyance direction of the printed recording materials. In this embodiment, the finisher 110 has finishing functions such as a staple function (one-point or two-point binding), a punch function (two-hole or three-hole), and a saddle stitch binding function. The finisher 110 has two paper output trays 351 and 352. When a finishing process is not performed by the finisher 110, printed recording materials conveyed to the finisher 110 are discharged to the paper output tray 351 via a conveyance path 353. When a finishing process such as stapling is performed by the finisher 110, printed recording materials conveyed to the finisher 110 are guided to a conveyance path 354. The finisher 110 uses a finishing processing unit 355 to perform a finishing process specified by the user on the printed recording material being transported along the transport path 354, and discharges the printed recording material after the finishing process has been performed onto a paper output tray 352.

[0034] <Functional configuration diagram> FIG. 3 is a schematic functional block diagram of the image forming apparatus 101, the external controller 102, and the client PC 103. As shown in FIG.

[0035] The printing unit 107 of the image forming apparatus 101 includes a communication I / F (interface) 201, a network I / F 204, a video I / F 205, a CPU 206, a memory 207, an HDD unit 208, and a UI display unit 225. The printing unit 107 also includes an image processing unit 202 and a print unit 203. These are connected to each other via a system bus 209 so that they can send and receive data. The communication I / F 201 is connected to the diagnostic unit 108, stacker 109, and finisher 110 via a communication cable 260. The CPU 206 communicates with each device via the communication I / F 201 to control the respective devices. The network I / F 204 is connected to the external controller 102 via the internal LAN 105 and is used for communicating control data and the like. The video I / F 205 is connected to the external controller 102 via a video cable 106 and is used for communicating image data and other data. Note that the printing unit 107 (image forming apparatus 101) and the external controller 102 may be connected only by the video cable 106, as long as the external controller 102 can control the operation of the image forming apparatus 101. The HDD unit 208 stores various programs and data. The CPU 206 controls the overall operation of the printing unit 107 by executing the programs stored in the HDD unit 208. The memory 207 stores programs and data required for the CPU 206 to perform various processes. The memory 207 operates as a work area for the CPU 206. The UI display unit 225 accepts various setting inputs and operation instructions from the user, and is used to display various information such as setting information and the processing status of a print job. For example, it accepts various instructions from the user, such as instructions to execute a diagnosis, settings, and paper information settings.

[0036] The diagnosis unit 108 includes a communication I / F 211, a CPU 214, a memory 215, an HDD unit 216, image reading units 331 and 332, and a UI display unit 241. These devices are connected via a system bus 219 so as to be able to send and receive data to and from each other. The communication I / F 211 is connected to the printing unit 107 via a communication cable 260. The CPU 214 performs communication necessary for controlling the diagnosis unit 108 via the communication I / F 211. The CPU 214 controls the operation of the diagnosis unit 108 by executing a control program stored in the memory 215. The memory 215 stores a control program for the diagnosis unit 108. The image reading units 331 and 332 read images of the conveyed recording material in accordance with instructions from the CPU 214. The CPU 214 diagnoses the presence or absence of a defective portion of the image forming apparatus 101 based on the diagnostic read images read by the image reading units 331 and 332. The UI display unit 241 is used to display the diagnosis results, setting screens, etc. The operation unit also serves as the UI display unit 241 and is operated by the user to accept various instructions from the user, such as changing the settings of the diagnosis unit 108 and instructions to perform image diagnosis. The HDD unit 216 stores various setting information and image data required for image diagnosis. The various setting information and image data stored in the HDD unit 216 can be reused.

[0037] The stacker 109 controls whether the printed recording material conveyed along the conveying path is discharged to a stack tray, discharged to an escape tray, or conveyed to a finisher 110 connected downstream in the conveying direction of the printed recording material.

[0038] The finisher 110 controls the transport and discharge of printed recording materials, and performs finishing processes such as stapling, punching, or saddle stitching.

[0039] The external controller 102 includes a CPU 251, a memory 252, an HDD unit 253, a keyboard 256, a display unit 254, network I / Fs 255 and 257, and a video I / F 258. These devices are connected via a system bus 259 so that they can send and receive data to and from each other. The CPU 251 executes programs stored in the HDD unit 253 to control the overall operation of the external controller 102, such as receiving print data from the client PC 103, RIP processing, and sending print data to the image forming apparatus 101. The memory 252 stores programs and data required for the CPU 251 to perform various processes. The memory 252 operates as a work area for the CPU 251.

[0040] The HDD unit 253 stores various programs and data. The keyboard 256 is used for inputting operation instructions for the external controller 102 from the user. The display unit 254 is, for example, a display, and is used for displaying information about applications currently running in the external controller 102 and an operation screen. The network I / F 255 is connected to the client PC 103 via the external LAN 104 and is used for communicating data such as print instructions. The network I / F 257 is connected to the image forming apparatus 101 via the internal LAN 105 and is used for communicating data such as print instructions. The external controller 102 is configured to be able to communicate with the printing unit 107, the diagnostic unit 108, the stacker 109, and the finisher 110 via the internal LAN 105 and a communication cable 260. The video I / F 258 is connected to the image forming apparatus 101 via the video cable 106 and is used for communicating data such as image data (print data).

[0041] The client PC 103 includes a CPU 261, a memory 262, an HDD unit 263, a display unit 264, a keyboard 265, and a network I / F 266. These devices are connected via a system bus 269 so that they can send and receive data to and from each other. The CPU 261 controls the operation of each device via the system bus 269 by executing a program stored in the HDD unit 263. This enables various processes to be performed by the client PC 103. For example, the CPU 261 generates print data and issues print instructions by executing a document processing program stored in the HDD unit 263. The memory 262 stores programs and data required for the CPU 261 to perform various processes. The memory 262 operates as a work area for the CPU 261.

[0042] The HDD unit 263 stores various applications such as a word processing program, programs such as a printer driver, and various data. The display unit 264 is, for example, a display, and is used to display information about applications running on the client PC 103 and an operation screen. The keyboard 265 is used to input operation instructions for the client PC 103 from the user. The network I / F 266 is communicably connected to the external controller 102 via the external LAN 104. The CPU 261 communicates with the external controller 102 via the network I / F 266.

[0043] <Image diagnosis processing> The image diagnosis processing according to this embodiment will be described with reference to the drawings. FIG. 4 is a flowchart showing the print operation executed by the printing unit 107 and the procedure of the image diagnosis processing executed by the diagnosis unit 108. Note that FIG. 4 shows the overall flow from the work before the start of image diagnosis to the execution of the diagnosis. The symbol "S" in the explanation of the flowchart represents a step. This also applies to the explanation of the following flowcharts. The processing of each step in FIG. 4 is executed by the CPU 206 of the printing unit 107 and the CPU 214 of the diagnosis unit 108.

[0044] In S401, the printing system 100 receives an image diagnosis instruction from a user or service technician via the UI display unit 241, which also serves as the operation unit, and confirms the settings for the image diagnosis process. In this embodiment, the image diagnosis process can be started, for example, after the main body is powered on and started. After startup, a notification prompting the user to start the diagnosis is displayed on one or more of the UI display unit 241, the display unit 254 of the external controller 102, and the UI display unit 225 of the printing unit 107, prompting the user to start the diagnosis. The start timing of the image diagnosis process is not limited to the above example. If the printing system 100 also includes an inspection function that inspects printed recording materials for print defects, the system may prompt the user to start the image diagnosis process if the inspection function detects consecutive defects. Furthermore, a timer may be set to display a notification prompting the user to perform the image diagnosis process at a time other than when the main body is started, and the notification may be displayed at the set time.

[0045] When the user confirms the notification prompting the start of diagnosis, the CPU 214 displays a screen on the UI display unit 241 for accepting the user's selection of diagnostic conditions, accepts the user's selection of diagnostic conditions, and stores the accepted diagnostic conditions in the HDD 216. A schematic diagram of the screen for accepting the user's diagnostic conditions is shown in FIG. 5. The user is prompted to select the shape of the defect to be diagnosed and the color material to be diagnosed for each defect shape as diagnostic items. As shown in FIG. 5, check boxes are provided for each condition, and when the user presses the Next button 501, the checked conditions are stored in the HDD 216 as diagnostic conditions. Once the diagnostic conditions are stored, the process proceeds to step S402, where the next paper feed deck is selected.

[0046] In S402, the CPU 251 of the external controller 102 accepts the selection of a paper feed deck that stores paper for printing a diagnostic test chart (diagnostic image). The CPU 251 displays on the UI display unit 241 a screen for accepting the selection of the position of a paper feed deck installed in the image forming apparatus 101. The user selects the deck position that stores paper for printing a test chart from among the paper feed decks installed in the image forming apparatus 101.

[0047] In S403, the CPU 251 of the external controller 102 performs a process of calculating the number of test charts required for image diagnosis. In the process of calculating the number of test charts, the number of test charts to be output in the test chart printing process in S406 is calculated based on the image diagnosis conditions. Details of the process of calculating the number of test charts required for image diagnosis will be described later.

[0048] In S404, the CPU 251 of the external controller 102 notifies the user of the number of test charts. The notification of the number of test charts is performed, for example, by displaying a screen such as that shown in FIG. 6 on the UI display unit 241 and controlling the display of the number of test charts (number of output sheets) calculated in S403 in field 601. Thereafter, the process proceeds to S405, where an instruction to start or cancel image diagnosis is accepted. This process allows the user to confirm the number of test charts to be output before the output of the image diagnosis test charts begins.

[0049] In S405, the CPU 214 accepts an instruction to start or cancel image diagnosis. An instruction to start image diagnosis is, for example, pressing button 602 shown in Fig. 6. If the instruction to start image diagnosis is accepted (YES in S405), the process proceeds to S406, where printing of a test chart begins. An instruction to cancel is, for example, pressing button 603 shown in Fig. 6. If the instruction to cancel is accepted (NO in S405), the process proceeds to S419, where a response is displayed and the image diagnosis process ends.

[0050] In S406, the CPU 251 of the external controller 102 reads a pre-saved test chart, rasterizes it into a bitmap, and creates the rasterized bitmap of the test chart as a reference image. The test chart is an image (hereinafter also referred to as a test image) for diagnosing a malfunction of the image forming apparatus. FIG. 10 is a diagram showing an example of a test chart used in the image diagnosis processing of this embodiment. An image area 1001 indicates an area where an image using color materials is formed. For example, a monochrome image with an area ratio of 50% is used for the image area. Four types of test charts, one for each monochrome color of C (cyan), M (magenta), Y (yellow), and K (black), are printed for the number of sheets calculated in S403. The CPU 251 transmits the bitmap data of the rasterized test chart from the video I / F 258 to the video I / F 205 of the printing unit 107 via the video cable 106. The CPU 206 of the printing unit 107 performs halftone processing on the bitmap data of the test chart received via the video I / F 205, and the print unit 203 prints the test chart based on the image data after halftone processing. Note that the configuration of the test chart is an example and is not limited to the above example. As long as the conditions are such that defects in the printed area are apparent using a differential image (described later), the ratio or area ratio of the image area to the non-image area may be different, and the image area may use two or more color materials.

[0051] In S407, the CPU 214 of the diagnosis unit 108 executes a process of reading the printed test chart using the image reading units 331 and 332. The read image of the test chart is saved as a diagnostic image in the HDD unit 216 of the diagnosis unit 108. Once the diagnostic image has been saved, the process proceeds to S408.

[0052] In S408, the CPU 214 compares the reference image with the scanned image to determine defects in the printing unit. In this embodiment, the reference image is compared with the scanned image to calculate a difference value. If the calculated difference value exceeds a predetermined threshold, a difference is determined to exist, and 1 is set as the differential image data. Conversely, if the calculated difference value is below the threshold, 0 is set as the differential image data. Note that the method for calculating the differential image data is not limited to the above example. In this embodiment, an example is described in which the reference image is compared with the scanned image to calculate the difference value. However, the difference value may be calculated by calculating an average value from the scanned image and using it as a reference signal, or a value assumed as a reference signal may be stored in the HDD unit 216 in advance. Furthermore, a correction unit may be provided to correct the nonlinearity between the signal value and luminance of the scanned image acquired by the image scanning unit 311, and the signal value of the scanned image may be corrected before calculating the differential image data. The differential image data, which is binary data indicating whether or not a difference exists, is saved in the HDD unit 216, and the process proceeds to S409.

[0053] When the creation of the differential image data is completed, in S409, the CPU 214 determines whether the image forming apparatus 101 is normal. This determination is made based on whether data including a 1 exists in the differential image data. If the CPU 214 obtains a determination result that the image forming apparatus 101 is normal (YES in S409), the process proceeds to S417. In S417, the CPU 214 displays the diagnosis result "No problem" indicating that the diagnosis result is normal on the UI display unit 241 of the diagnosis unit 108. On the other hand, if the CPU 214 obtains a determination result that the image forming apparatus 101 is not normal (the differential image data includes a 1) (NO in S409), the process proceeds to S410. In the process from S410, a part in the image forming apparatus 101 that is experiencing a problem is identified based on the scanned image data and the differential image data, and instructions are given to take corrective action.

[0054] In S410, the CPU 214 extracts feature quantities from the scanned image data and differential image data to identify defective parts in the printing unit 107. The CPU 214 extracts feature quantities for identifying defective parts in the printing unit 107 from the scanned image data and differential regions determined to have differences in S408 from the differential image data. The feature information of the differential region obtained through this extraction process includes, for example, color material information indicating which color (yellow, magenta, cyan, or black) the defect occurs in. The feature information of the differential region also includes contrast information, which indicates whether the defect density contrast is a difference in the darker direction (positive direction) or the lighter direction (negative direction) or expressed as a positive or negative numerical value. The feature information of the differential region also includes size information, such as the width (size in the main scanning direction) and height (size in the sub-scanning direction) of the defect, and shape information, such as the shape of dots, vertical streaks, and horizontal streaks. Other examples of the feature information of the differential region include coordinate information indicating the position of the test chart in the printing unit 107 in a direction perpendicular to the transport direction, and periodic information indicating that defects with similar characteristics occur periodically in the transport direction of the test chart in the printing unit 107. The extracted features are saved in the HDD unit 216, and the process proceeds to S411.

[0055] In S411, based on the characteristic information of the differential region obtained in S410, the CPU 214 identifies the part (site) that is the cause of the image defect in the printing unit 107 and the image reading unit 331. From the differential region, a combination of the same color with high similarity is selected, and the part that is defective is identified from the periodic information of the selected combination.

[0056] In S412, the CPU 214 determines how to address the image defect based on the part that caused the defect identified in S411. The addressable measures are divided into those that are automatically reversible and those that are not. Examples of automatically reversible measures include measures that are automatically reversible by the printing unit 107, such as cleaning the wires and grids of the corona chargers, which are means for charging the photosensitive drums provided in the image forming stations 304 to 307 of the printing unit 107. Examples of non-automatically reversible measures include the following two examples. First, measures that require user intervention, such as cleaning dirt from the reading glass surfaces of the image reading units 331 and 332 of the diagnostic unit 108 or adjusting the recording material to be used, and measures that require service technician intervention, such as replacing parts. Second, measures that require intervention, such as reading abnormalities in the image reading unit or fibers or foreign matter that were present in the recording material before image formation, are included.

[0057] Next, in S413, the CPU 214 determines whether the action determined in S412 is an action that can be automatically restored. If the CPU 214 obtains a determination result that the action determined is an action that can be automatically restored (YES in S413), the process proceeds to S414.

[0058] In S414, the CPU 251 of the external controller 102 performs a process of calculating the number of test charts (repair images) required for automatic restoration (automatic restoration). In the process of calculating the number of test charts, the number of test charts to be output in the automatic restoration process in S418 is calculated based on the automatic restoration conditions. The process of calculating the number of test charts will be described in detail later.

[0059] In S415, the CPU 251 of the external controller 102 notifies the user of the number of test charts required for automatic recovery. The notification of the number of test charts is performed, for example, by displaying a screen such as that shown in FIG. 7 on the UI display unit 241, and displaying the number of test charts calculated in S414 in field 701. Then, the process proceeds to S416, where an instruction to start or cancel automatic recovery is accepted. This process allows the user to confirm the number of test charts to be output before the output of the test charts for automatic recovery begins.

[0060] In S416, the CPU 214 accepts an instruction to start automatic recovery or to cancel. An instruction to start automatic recovery is, for example, pressing button 702 shown in Fig. 7. If an instruction to start image diagnosis is accepted (YES in S416), the process proceeds to S418, where printing of a test chart is started. An instruction to cancel is, for example, pressing button 703 shown in Fig. 7. If an instruction to cancel is accepted (NO in S416), the process proceeds to S419, where a response is displayed and the image diagnosis process is terminated.

[0061] In S418, the CPU 214 executes automatic recovery control to address the cause of the image defect.

[0062] On the other hand, if the CPU 214 obtains a determination result that the determined response is not an automatically reversible response (NO in S413), the process proceeds to S419. In S419, the CPU 214 displays the image diagnosis result and the response method on the UI display unit 241 of the diagnosis unit 108. When any one of the processes in S417, S418, and S419 described above is completed, the flow (image diagnosis process) shown in FIG. 4 ends.

[0063] <Calculating the number of test charts required for diagnostic imaging> In S403, the number of test charts required for image diagnosis is calculated according to the diagnostic conditions. In this embodiment, the diagnostic conditions include diagnostic item information, diagnostic color information, paper size information, and model information. In this embodiment, the defect shape is specified as a diagnostic item. There are three types of defect shapes: vertical streaks, horizontal streaks, and dots. In the diagnosis of vertical streaks, defects on the streaks in the sub-scanning direction are diagnosed and the causative part is identified. Since there is no need to check for periodicity, one chart per diagnostic color is sufficient. On the other hand, in the diagnosis of horizontal streaks and dots, multiple charts may need to be output to determine periodicity. The number of charts required to determine periodicity varies depending on the part cycle of the image forming device and the length of the paper used in the sub-scanning direction.

[0064] Therefore, the number of sheets is determined by referring to a table of diagnostic conditions stored in advance. FIG. 8 is a schematic diagram of a table that determines the required number of sheets from diagnostic item information, diagnostic color information, paper size information, and model information. For example, if the diagnostic conditions for model A are to diagnose horizontal streaks in C (cyan) using A4 paper, the number of sheets 801 is referenced and the required number is determined to be 15. If multiple conditions are turned on, the numbers determined for each condition are added together. For example, if the diagnostic conditions for model A are to diagnose horizontal streaks in C (cyan) and K (black) using A4 paper, the number of sheets 801 and the number of sheets 802 are referenced and added together to determine the required number to be 30. On the other hand, even if the conditions are different, if the same chart is used and only the number of sheets differs, the larger number is selected as the required number without adding them up. For example, when the diagnostic conditions for model A are to diagnose vertical streaks and dots in C (cyan) using A4 paper, the number of sheets required for vertical streaks is 1 sheet (803), and the number of sheets required for dots is 15 sheets (804). If the charts used in these diagnostics are the same and only the number of sheets differs, the required number is determined to be the larger of 15 sheets. In this case, the first sheet of the chart to be output is used for diagnosing vertical streaks, and sheets 1 through 15 are used for diagnosing dots.

[0065] The method for setting diagnostic conditions is not limited to referring to a table, and any method that can calculate the required number of sheets may be used. For example, a method may be used in which parts information for each model is stored in advance and calculated.

[0066] Furthermore, although the present embodiment describes an example in which the shape of a defect is specified as a diagnostic item, it is also possible to select the parts to be diagnosed. For example, parts to be diagnosed, such as "photosensitive drum" and "intermediate transfer belt," are displayed on the UI as diagnostic items, and the number of charts required for diagnosis is calculated and displayed according to the parts selected by the user.

[0067] <Calculation of the number of test charts required for automatic recovery> In S414, the number of test charts required for automatic recovery is calculated based on the recovery conditions. In this embodiment, the recovery conditions include automatic recovery item information, paper size information, and model information. In this embodiment, the determination result obtained in S412 that automatic recovery is possible is accepted as the automatic recovery item. The number of test charts required for automatic recovery varies depending on the automatic recovery item information, paper size information, and model information. For example, if the cause of the dots is the photosensitive drum and recovery is achieved by idling the photosensitive drum, test charts are output to confirm that the dots have disappeared after recovery. The number of sheets required to confirm that periodic defects have disappeared varies depending on the part cycle of the image forming device and the length of the paper used in the sub-scanning direction. Furthermore, depending on the automatic recovery item, test charts may be required not only for confirmation but also for adjustments for recovery.

[0068] Therefore, the number of sheets is determined by referencing a table of recovery conditions stored in advance. FIG. 9 is a schematic diagram of a table that determines the required number of sheets from automatic recovery item information, paper size information, and model information. For example, in model A, if the automatic recovery is performed using A4 paper and secondary transfer current adjustment, the number of sheets 901 and 902 are referenced, and the number of sheets used for adjustment and the number of sheets used for confirmation are summed to determine the required number as three. If multiple conditions are ON, the numbers determined for each condition are summed. For example, in model A, if the recovery conditions are to use A4 paper and secondary transfer current adjustment and drum idle rotation, the numbers 901, 902, 903, and 904 are referenced and summed to determine the required number as five. Furthermore, if a retry is performed if recovery is not successful during the automatic recovery process check, the required number may be determined by taking into account the maximum number of retries. For example, if the maximum number of retries is three, the required number is multiplied by three.

[0069] The method for setting the restoration conditions is not limited to referring to a table, and any method that can calculate the required number of parts may be used. For example, a method in which parts information for each model is stored in advance and used for calculation may be used.

[0070] As described above, an example has been described in which the number of charts is determined according to the diagnostic conditions and the number of sheets of paper to be used in the image diagnosis is notified to the user. By notifying the user, it is possible to prevent unintended paper consumption by the user.

[0071] <Modification of the first embodiment> In the present embodiment, an example has been described in which, after accepting a user's selection of diagnostic conditions on the diagnostic condition selection screen shown in FIG. 5, the screen shown in FIG. 6 is displayed when the button 501 is pressed to notify the user of the number of sheets of paper to be used in the image diagnosis. However, this embodiment is not limited to the above example. For example, instead of displaying the notification screen shown in FIG. 6, the number of sheets of paper to be used in the image diagnosis may be displayed and notified on the diagnostic condition selection screen as shown in FIG. 11. The number of test charts required for the image diagnosis described above is calculated sequentially according to the state of the diagnostic items selected by the user, and displayed in 1101. Furthermore, as shown in 1102, the number of test charts required for each diagnostic item and diagnostic color may be displayed in a selection field.

[0072] In this embodiment, the number of test charts required for image diagnosis and the number of test charts required for automatic recovery are calculated after the diagnosis conditions and recovery conditions are determined. However, the present invention is not limited to this example. For example, in a configuration in which a cassette is selected after the number of test charts required for image diagnosis is notified, the paper size is not yet determined when the calculation process for the number of test charts required for image diagnosis is performed. Therefore, in the diagnosis of horizontal streaks C for model A, the range of 8 to 15 sheets can be selected. In this case, the possible range may be notified, as shown in 601 of FIG. 12.

[0073] In this embodiment, the calculated number of test charts required for image diagnosis and the number of test charts required for automatic recovery are displayed to notify the user, but the effects of this embodiment are not limited to the above example. For example, if the number of sheets of paper in the cassette selected in S402 is less than the calculated number of test charts required for image diagnosis, a warning message may be displayed as shown in Fig. 13 to prompt the user to replenish the paper.

[0074] In this embodiment, the calculated number of test charts required for image diagnosis and the calculated number of test charts required for automatic recovery are always notified, but the effect of this embodiment is not limited to the above example. For example, the notification of the number of test charts in S404 and the notification of the number of test charts in S415 may be performed only when the number of test charts exceeds a predetermined number.

[0075] [Second embodiment] The image diagnostic processing according to this embodiment will be described. In the first embodiment, an example was described in which the number of test charts is calculated by receiving diagnostic items and diagnostic colors selected by a user when performing image diagnostic processing. However, the effects of this embodiment are not limited to the above example. For example, a configuration may be adopted in which diagnostic items and diagnostic colors are automatically determined by performing a simple image diagnosis using a smaller number of test charts before performing image diagnosis.

[0076] 14 is a flowchart showing the procedure of the print operation executed by the printing unit 107 and the simple image diagnosis processing executed by the diagnosis unit 108. The processing of each step in FIG. 14 is executed by the CPU 206 of the printing unit 107 and the CPU 214 of the diagnosis unit 108.

[0077] In S1401, the printing system 100 receives an image diagnosis instruction from a user or service technician via the UI display unit 241, which also serves as an operation unit. The CPU 251 of the external controller 102 then reads a pre-stored test chart, rasterizes it into a bitmap, and creates the rasterized bitmap of the test chart as a reference image. The test chart is an image for diagnosing a malfunction of the image forming apparatus (hereinafter also referred to as a test image). FIG. 9 shows an example of a test chart used in the image diagnosis process of this embodiment. An image area 901 indicates an area where an image using color materials is formed. For example, a monochrome image with an area ratio of 50% is used for the image area, and four types of test charts, one for each monochrome color in CMYK, are printed on one sheet each. The CPU 251 transmits the bitmap data of the rasterized test chart from the video I / F 258 to the video I / F 205 of the printing unit 107 via the video cable 106. The CPU 206 of the printing unit 107 performs halftone processing on the bitmap data of the test chart received via the video I / F 205, and the print unit 203 prints the test chart based on the image data after halftone processing. Note that the configuration of the test chart is an example and is not limited to the above example. As long as the conditions are such that defects in the printed area are apparent using a differential image (described later), the ratio or area ratio of the image area to the non-image area may be different, or the image area may use two or more color materials. Furthermore, multiple image areas using different color materials may be provided on one sheet.

[0078] In S1402, the CPU 214 determines diagnostic items and diagnostic colors that require image diagnosis based on the feature information of the difference region obtained in S410. The diagnostic items and diagnostic colors that require image diagnosis are determined based on the color material information (yellow, magenta, cyan, or black) extracted in S410, indicating which color the defect will occur in, and shape information such as the shape of the dots, vertical stripes, and horizontal stripes. For example, if a yellow vertical stripe is extracted, the diagnostic item and diagnostic color for the vertical stripe Y are turned ON, and image diagnosis processing is started. If a yellow vertical stripe and a magenta vertical stripe are extracted, the diagnostic items and diagnostic colors for the vertical stripes Y and M are turned ON, and image diagnosis processing is started. Furthermore, if a yellow vertical stripe and a magenta dot are extracted, the diagnostic item and diagnostic color for the vertical stripe Y and the dot M are turned ON, and image diagnosis processing is started.

[0079] 4 in the first embodiment is performed, and in S403, the number of test charts required for the image diagnosis is calculated based on the diagnostic items and diagnostic colors determined in S1402, and the number of test charts is notified in S404. This makes it possible to notify the user of the number of sheets of paper to be used in the image diagnosis and prevent unintended paper consumption by the user, even in a configuration in which the diagnostic items and diagnostic colors are automatically determined by performing a simple image diagnosis.

[0080] <Other embodiments> The present invention can also be realized by supplying a program that realizes one or more functions of the above-described embodiments to a system or device via a network or a storage medium, and having one or more processors in the computer of the system or device read and execute the program. It can also be realized by a circuit (e.g., ASIC) that realizes one or more functions.

Claims

1. an operation unit that displays information; an image forming unit that includes a plurality of parts and that forms an image on a sheet; a reading unit that reads the image formed by the image forming unit; a diagnostic means for causing the image forming unit to form a diagnostic image on paper in response to an instruction to start image diagnosis received by the operation unit, causing the reading unit to read the formed and output diagnostic image, and diagnosing a defective portion of the image forming unit based on the read and acquired image; a repair unit that causes the image forming unit to form a repair image on a sheet, causes the reading unit to read the formed and output repair image, and repairs a defective portion identified by the diagnosis by the diagnosing unit based on the read and acquired image; and and a display control means for causing the operation unit to display a first screen including the number of diagnostic images to be output before the image diagnosis is started, and for causing the operation unit to display a second screen including the number of repair images to be output after the image diagnosis is performed, if the identified defective portion can be repaired by the repair means. An imaging diagnostic system characterized by:

2. The image diagnostic system according to claim 1 , wherein the number of diagnostic images to be output is determined based on the diagnostic items of the image diagnosis.

3. The image diagnostic system according to claim 1 , wherein the number of diagnostic images to be output is determined based on a model of the device that performs the image diagnosis.

4. 2. The diagnostic imaging system according to claim 1, wherein the number of sheets of the diagnostic image to be output is determined based on the size of a sheet of paper on which the diagnostic image is to be formed.

5. 2. The image diagnostic system according to claim 1, wherein, when a defective portion of the image forming unit is identified as a result of diagnosis by the diagnosing means, the repairing means carries out repair.

6. The image diagnostic system described in Claim 1, characterized in that after performing the image diagnosis, if the identified defective area cannot be repaired by the repair means, the display control means does not display the second screen on the operation unit, and displays a third screen including the identified defective area as the diagnosis result by the diagnostic means.

7. 2. The image diagnostic system according to claim 1, wherein the diagnostic items determined by said diagnostic means are one or more of vertical streaks, horizontal streaks, and mottling.

8. The imaging diagnostic system described in Claim 1, characterized in that the second screen includes a selectable instruction to start repairing the identified defective area by the repair means.

9. The imaging diagnostic system described in Claim 1, characterized in that the first screen includes a selectable instruction to start the imaging diagnosis by the diagnostic means.

10. a diagnostic step of causing the image forming unit to form a diagnostic image on paper in response to an instruction to start image diagnosis received by the operation unit, causing the reading unit to read the formed and output diagnostic image, and diagnosing a defective portion of the image forming unit based on the read and acquired image; a repair step of causing the image forming unit to form a repair image on paper, causing the reading unit to read the formed and output repair image, and repairing the defective portion identified by the diagnosis in the diagnosis step based on the read and acquired image; a display control step of displaying a first screen including the number of diagnostic images to be output on the operation unit before starting the diagnostic step, and after executing the diagnostic step, if the identified defective area can be repaired by the repair step, displaying a second screen including the number of repair images to be output on the operation unit.

11. The image diagnostic method according to claim 10, wherein the number of diagnostic images to be output is determined based on the diagnostic items of the image diagnosis.

12. The image diagnostic method according to claim 10, wherein the number of diagnostic images to be output is determined based on a model of the device that will perform the image diagnosis.

13. 11. The image diagnostic method according to claim 10, wherein the number of sheets of the diagnostic image to be output is determined based on the size of paper on which the diagnostic image is to be formed.

14. 11. The image diagnostic method according to claim 10, wherein, when a defective portion of the image forming unit is identified as a result of the diagnosis in the diagnosis step, repair is performed in the repair step.

15. The image diagnostic method described in Claim 10, characterized in that, after performing the image diagnosis, if the identified defective area cannot be repaired by the repair step, the display control step does not display the second screen on the operation unit, and displays a third screen including the identified defective area as the diagnosis result by the diagnosis step.

16. 11. The image diagnostic method according to claim 10, wherein the diagnostic items in said diagnosing step are one or more of vertical streaks, horizontal streaks, and mottling.

17. The imaging diagnostic method described in Claim 10, characterized in that the second screen includes a selectable instruction to start repairing the identified defective area by the repair step.

18. The image diagnostic method described in Claim 10, characterized in that the first screen includes a selectable instruction to start the image diagnosis by the diagnostic step.

Images