Image Forming Alignment Through Sheet Shape Sensing
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Solution Overview
Problem
Existing image forming apparatuses struggle to accurately align images due to misalignment between the image forming portion and the imaging portion, leading to improper positioning of images on sheets.
Innovation Solution
The apparatus employs a sensing method that involves conveying a sensing sheet, acquiring shape data, adjusting image positions based on reference points, and masking overlapping regions to sense the amount of misalignment between the image forming and imaging portions, using a first and second adjustment process to align images accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the imaging portion is positioned upstream of the image forming portion to capture sheet shape data, then the sheet shape can be detected before image formation, but misalignment occurs between the imaging portion and image forming portion in the width direction
Solution Approach 1:
The patent replaces mechanical alignment adjustment with image processing methods. Specifically, the system captures images of the sheet at different positions, generates a composite image, and uses image correlation algorithms to calculate the misalignment amount between the imaging portion and image forming portion. This computational approach substitutes for complex mechanical alignment mechanisms.
Solution Approach 2:
The patent creates a virtual model (composite image) of the sheet by combining multiple images captured by the imaging portion. This composite image serves as a reference copy that represents the actual sheet position and shape, allowing the system to compare and calculate misalignment without physically moving or adjusting the imaging portion.
2Device complexity
If misalignment between imaging portion and image forming portion is not corrected, then the system structure remains simple, but images are improperly positioned on the sheet
Solution Approach 1:
The patent eliminates complex mechanical alignment adjustment mechanisms by using image processing and computational methods. The system captures images, generates composite images, and uses algorithmic processing to determine and correct misalignment, replacing what would otherwise require precision mechanical adjustment systems.
Solution Approach 2:
The system performs self-alignment by automatically capturing images, generating composite images, calculating misalignment amounts, and adjusting image formation parameters without external intervention. The imaging portion and image forming portion essentially self-correct their relative positioning through the image processing feedback loop.
3Manufacturing precision
If multiple images are captured and processed to determine misalignment, then positioning accuracy is improved, but processing time and computational load increase
Solution Approach 1:
The patent performs preliminary actions by capturing multiple images of the sheet at different positions before the actual image formation process. These preliminary images are used to generate a composite image and calculate misalignment, so that the correction parameters are ready before production begins, minimizing time loss during actual operation.
Solution Approach 2:
The system rapidly processes the captured images through automated composite image generation and misalignment calculation algorithms, minimizing the time spent on processing. The computational steps are executed efficiently to quickly determine positioning corrections without becoming a bottleneck in the production workflow.
Data Source
AI summary
An image forming apparatus acquires shape data indicating a shape of a sensing sheet conveyed along a conveyance route, adjusts a position of a first image in first image data including the first image on the basis of a positional relationship between a sheet region in the acquired shape data and a first reference position in the shape data, forms an image based on the adjusted first image data on the sensing sheet, and senses an amount of positional misalignment of an imaging portion to be used to acquire the shape data by using the sensing sheet on which the image has been formed.