Registration Sensor Control in Transfer Unit for Color Alignment
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Solution Overview
Problem
Conventional image forming apparatuses face challenges in accurately controlling color registration sensors due to mechanical design constraints, leading to heat generation, breakdowns, and time-consuming correction processes, especially when sensors are placed at the top of a fuse unit, requiring improved methods for precision and efficiency in registration control.
Innovation Solution
An apparatus and method that incorporate registration sensors into a transfer unit, utilizing sensor data storage and control units to manage sensor characteristics, allowing for real-time adjustment of light emission based on stored data, including pulse width modulation, and backup storage for data recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If registration sensors are placed at the top of the fuse unit, then the sensors can be integrated into the image forming apparatus, but heat generation and breakdown or error of the registration sensors occur
Solution Approach 1:
The registration sensors are extracted from the fuse unit and relocated to the transfer unit, specifically positioned away from the heat-generating fuse unit to eliminate thermal damage while maintaining sensor integration in the image forming apparatus
2Ease of manufacture
If registration sensors are placed into the set frame of the image forming apparatus, then the sensors can be positioned for registration control, but left-right precision must be maintained and structural height variation causes errors
Solution Approach 1:
The patent creates a virtual reference line by detecting the position of a reference mark on the transfer belt, then uses this copied reference information to correct the positions of multiple registration sensors, eliminating the need for precise mechanical positioning and compensating for structural height variations
Solution Approach 2:
The system changes the operational parameters of each sensor by applying individual correction values to the detection results, adjusting for position deviations caused by structural variations without requiring physical repositioning of the sensors
3Adaptability or versatility
If conventional registration control methods are used, then the system can operate with standard sensors, but output characteristics need to be gradually corrected which is time-consuming
Solution Approach 1:
The system performs preliminary detection of a reference mark to establish a virtual reference line before conducting registration sensor corrections, and pre-calculates correction values based on detected position deviations, eliminating the need for gradual iterative correction and reducing overall correction time
Solution Approach 2:
The system implements feedback by detecting the actual positions of registration sensors relative to the virtual reference line, comparing them with ideal positions, and applying correction values to compensate for deviations, enabling rapid adaptation to sensor characteristic differences
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
This approach enhances the precision and efficiency of color registration by allowing for continuous correction and adaptation of sensor settings, reducing the time required for registration alignment and ensuring accurate image formation despite mechanical variations and sensor changes.
Implementation Method 1
the registration sensors irradiate light onto a test pattern of the transfer belt and sense the amount of reflected light
Data Source
AI summary
A method and apparatus for controlling registration sensors are provided, in which a transfer unit transfers an electrostatic latent image onto a printing medium, at least one registration sensor senses image alignment errors by irradiating light to the transfer unit to sense reflected light, a sensor data storage unit stores characteristics data of the respective registration sensors, and a sensor control unit controls the registration sensors based on the characteristics data of the respective registration sensors, wherein the registration sensors are placed into the transfer unit. Accordingly, time for performing an algorithm of color registration can be reduced, and registration can be achieved correctly in a short time, irrespective of a set frame of the image forming apparatus.