Image Forming Apparatus Color Registration Calibration
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Solution Overview
Problem
Conventional color image forming apparatuses face inefficiencies in color registration, leading to image edge blurring due to complex interactions between factors like developing device replacement and increased print volume, making real-time color registration calibration challenging and time-consuming.
Innovation Solution
An image forming apparatus with multiple photoconductors for different colors, an exposure unit, a developing unit, an intermediate transfer body, and a controller that forms test-pattern sets for color registration calibration using sensing units to acquire and apply position shift corrections in real time, reducing the time required for color registration and calibrating color position shifts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional color registration methods are used, then color alignment can be achieved, but the process requires additional work during printing and real-time application is impossible
Solution Approach 1:
The system performs preliminary color registration calibration by forming test patterns on the intermediate transfer body before actual printing. The sensing unit detects these test patterns to calculate position shift values, which are then stored and applied during subsequent printing operations. This preliminary calibration eliminates the need for continuous color registration adjustments during printing, thereby maintaining high reliability while improving productivity.
Solution Approach 2:
The system implements a feedback mechanism where the sensing unit continuously monitors the position of test patterns on the intermediate transfer body. Based on the detected position shifts, the controller automatically adjusts the exposure timing for each photoconductor to compensate for misalignment. This closed-loop feedback system ensures accurate color registration without requiring manual intervention during printing operations.
2Measurement precision
If additional color registration work is implemented during printing, then position shift can be judged, but time required for color registration increases
Solution Approach 1:
The system performs color registration calibration in advance by forming test patterns and detecting their positions before actual printing begins. The calculated position shift values are stored in memory and automatically applied during printing operations. This preliminary measurement approach achieves precise position shift detection without consuming additional time during the printing process itself.
Solution Approach 2:
The system uses the intermediate transfer body itself as the measurement medium for detecting color position shifts. By forming test patterns directly on the intermediate transfer body and having the sensing unit detect them in real-time, the system performs self-diagnosis and self-calibration without requiring separate measurement devices or additional manual operations, thereby minimizing time loss.
3Reliability
If test pattern sets are formed for each image forming section, then color registration calibration is improved, but device complexity increases
Solution Approach 1:
The system uses a single intermediate transfer body to serve multiple functions: it acts as both the transfer medium for color images and the substrate for forming test patterns. The same intermediate transfer body that receives toner images from photoconductors also carries the test patterns formed by the exposure unit. This multi-functional use of the intermediate transfer body enables comprehensive color registration calibration without requiring additional specialized components or devices.
Solution Approach 2:
The system combines the test pattern formation process with the existing image formation process. The exposure unit that normally exposes photoconductors for image creation is also used to form test patterns on the intermediate transfer body. By merging these two functions into a single operational sequence, the system achieves improved color registration calibration without significantly increasing device complexity or requiring separate dedicated test pattern formation mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables real-time color registration calibration, improving the efficiency of the printing process by reducing the time needed for color registration and maintaining high reliability in color alignment, thereby preventing image edge blurring.
Implementation Method 1
an exposure unit configured to form an electrostatic latent image by emitting light to the plurality of photoconductors
Implementation Method 2
a sensing unit configured to sense the toner image formed on the intermediate transfer body
Data Source
AI summary
An image forming apparatus, which achieves reduced color registration time and real-time calibration of color position shift, and a control method for the same, is provided. The image forming apparatus includes plural photoconductors corresponding to plural colors, an exposure unit to form an electrostatic latent image by emitting light to the photoconductors, a developing unit to form a toner image by feeding toner to the photoconductors, an intermediate transfer body to which the toner image, formed on each photoconductor, is transferred, a sensing unit to sense the toner image formed on the intermediate transfer body, and a controller which forms images in respective image forming sections of the intermediate transfer body and test-pattern sets for color registration in respective blanks between the neighboring image forming sections, the controller implementing color registration calibration using color registration calibration values acquired from four test pattern sets among the formed test pattern sets.