JP2009058938A - Image forming apparatus and image forming method - Google Patents

Abstract

An image forming apparatus and an image forming method capable of appropriately managing the degree of consumption of consumables used for image formation.
A control unit writes flag information in a storage unit made up of a rewritable nonvolatile memory when receiving an image formation request, and stores it when an image forming process corresponding to the image formation request is completed. The flag information written in the unit 28 is erased. The toner consumption amount management unit 29 manages the toner consumption amount based on the image formation request and the flag information. Therefore, it is possible to determine whether or not the toner consumption amount has been normally updated based on the flag information. As a result, it is possible to appropriately manage the consumption level (toner consumption amount) of the consumables used for image formation. it can.
[Selection] Figure 1

Description

  The present invention relates to an image forming apparatus and an image forming method for forming an image corresponding to an image forming request on an image forming medium such as plain paper using an image forming material such as toner.

  2. Description of the Related Art Conventionally, in an image forming apparatus such as a copying machine or a printer, an image forming material such as toner or ink is contained in a container, and an image forming medium (for example, copy paper) is consumed while consuming the image forming material supplied from the container. For example, when an image is formed while a consumable item such as toner or a photoconductor in an electrophotographic image forming apparatus has reached the end of its life, the image is formed. Since the quality of the image is degraded, the lifetime of such consumables is managed to prevent the degradation of the image quality (see, for example, Patent Document 1).

  For example, in an electrophotographic image forming apparatus, the remaining amount of toner (image forming material) in a container is detected by a sensor, or the remaining amount is predicted from the number of image forming processes, and the remaining amount of toner. In addition, the user is notified of the necessity of replenishment.

JP 2003-91218 A

  By the way, instead of detecting using a sensor, an image forming material is used according to the number of executions of the image forming process corresponding to the image forming request and the content of the formed image (for example, the size and resolution of the paper as the image forming medium). Image formation in which the degree of consumption (consumption) of (toner) is estimated, and the life of the image forming material (the remaining amount in the container in the case of an image forming material such as toner) is managed based on the estimated degree of consumption A device is provided. In such a conventional device, the result of estimating the degree of consumption of consumables is stored in a rewritable nonvolatile memory. For example, if the power is turned off before the estimated result is written in the nonvolatile memory, The consumption level of the consumables in the image forming process executed in the first step is not stored in the non-volatile memory, and as a result, the lifetime of the consumables may not be appropriately managed. For example, there is a possibility that image quality may be deteriorated by not informing the user of the fact that the toner remaining in the container is insufficient.

  The present invention has been made in view of the above circumstances, and an object thereof is to provide an image forming apparatus and an image forming method capable of appropriately managing the degree of consumption of consumables used for image formation.

  In order to solve the above-described problems and achieve the object, the invention according to claim 1 is an image forming apparatus, wherein an image corresponding to an image forming request is formed on an image forming medium using an image forming material. In the forming apparatus, control means for executing an image forming process for forming the image on an image forming medium based on the image forming request, flag information indicating that the image forming request has been received, and at least an image forming material A rewritable non-volatile storage means capable of storing the consumption level of the consumables, and a management means for managing the consumption level of the consumables, wherein the control means further includes the image forming request. When accepted, the fact that the image formation request has been accepted is written in the storage means as flag information, and the management means further includes the image formation request and the flag. Based on the distribution, and updates the consumption degree of the consumable stored in the memory means, the later update, characterized by erasing the flag information.

  According to a second aspect of the present invention, in the image forming apparatus according to the first aspect, the flag information further includes a type of the image forming medium that has accepted the image forming request, and the management means Furthermore, when the type of the image forming medium is stored in the storage unit as the flag information when the control unit is not executing the image forming process, the flag information is referred to, and the type It is assumed that an image of the maximum size among the sizes that can be formed on the image forming medium is formed, and the consumption level of the consumables stored in the storage unit is updated.

  According to a third aspect of the present invention, in the image forming apparatus according to the first aspect, the flag information further includes a type of the image forming medium that has accepted the image forming request, and the image forming medium. When the image forming request is received, the control means further includes the type of the image forming medium included in the image forming request and the size of the image forming medium as flag information. It writes to the said memory | storage means, It is characterized by the above-mentioned.

  According to a fourth aspect of the present invention, in the image forming apparatus according to the third aspect, the management unit further provides the flag information when the control unit is not executing the image forming process. When the size of the image forming medium is stored in the storage unit, the flag information is referred to, and an image having a uniform density is formed in the image forming area of the size for the type of the image forming medium. The consumption level of the consumables stored in the storage means is updated.

  The invention according to claim 5 is the image forming apparatus according to claim 1, wherein the flag information further includes a type of image forming medium that has accepted the image forming request, a resolution of the image, and the like. When the image forming request is received, the control unit further stores the type of the image forming medium included in the image forming request and the resolution of the image as flag information in the storage unit. It is characterized by writing.

  Further, the invention according to claim 6 is the image forming apparatus according to claim 5, wherein the management unit is further configured as the flag information when the control unit is not executing the image forming process. When the resolution of the image is stored in the storage unit, the flag information is referred to and the image forming medium of the type is regarded as having been formed and stored in the storage unit. The consumption level of the consumable item is updated.

  The invention according to claim 7 is the image forming apparatus according to claim 1, wherein the flag information further includes a type of an image forming medium that has accepted the image forming request, and the control unit includes: Further, when the image formation request is received, the type of the image formation medium included in the image formation request is written as flag information in the storage unit, and the image formation medium included in the image formation request The size is written in the storage unit, and the management unit further determines the size of the image medium and the type of the image forming medium as the flag information when the control unit is not executing the image forming process. When stored in the storage unit, the storage unit is referred to, and the image forming medium of the type is averaged into an area where image formation is possible at the size. It assumes that the image of such density are formed, to update the exhaustion degree of the consumable stored in the memory means, the later update, characterized by erasing the flag information.

The invention according to claim 8 is the image forming apparatus according to claim 1, wherein the flag information further includes a type of image forming medium that has accepted the image forming request, and the control unit includes: Further, when the image formation request is received, the type of the image formation medium included in the image formation request is written in the storage unit as flag information, and the resolution of the image formation medium included in the image formation request Is stored in the storage unit, and the management unit further stores the resolution of the image and the type of the image forming medium as the flag information when the control unit is not executing the image forming process. If the image is stored in the storage unit, the storage unit is referred to, and the image of the resolution is regarded as being formed on the image forming medium of the type. Update the exhaustion degree of 耗品, the updated in, characterized by erasing the flag information.

  The invention according to claim 9 is the image forming apparatus according to claim 1, wherein the control unit further includes a case where the type of the image forming medium included in the image forming request is an adjustment image. In addition, it is written in the storage means that the type of the image medium that has received the image formation request is the image for adjustment.

  The invention according to a tenth aspect is the image forming apparatus according to the ninth aspect, wherein the management unit is further configured so that the control unit does not execute the image forming process of the adjustment image. When the storage unit stores the type of the image forming medium and the fact that the image formation request has been accepted as the flag information, the image forming process of the adjustment image is executed with reference to the storage unit. The consumption level of the consumables stored in the storage means is updated.

  The invention according to an eleventh aspect is the image forming apparatus according to the ninth aspect, wherein the control unit further periodically determines an elapsed time of the image forming process when the image forming process of the adjustment image is executed. Are written in the storage means.

  The invention according to a twelfth aspect is the image forming apparatus according to the eleventh aspect, wherein the management unit is further configured so that the control unit does not execute the image forming process of the adjustment image. When the storage means stores the fact that the type of the image medium is the adjustment image, the elapsed time of the image formation process, and the fact that the image formation request has been accepted as the flag information, the storage And the degree of consumption of the consumables stored in the storage means is updated by assuming that the image forming process of the adjustment image has been executed for the elapsed time.

  According to a thirteenth aspect of the present invention, there is provided an image forming method executed by an image forming apparatus, wherein the image forming apparatus performs an image forming process for forming the image on an image forming medium based on an image forming request. Control means to execute, flag information indicating that an image formation request has been received, rewritable nonvolatile storage means capable of storing at least the degree of consumption of consumables including an image forming material, and consumption of the consumables A management means for managing the degree, and when the control means accepts the image formation request, a control step of writing in the storage means as flag information that the image formation request has been accepted, and the management A unit updates a consumption level of the consumables stored in the storage unit based on the image formation request and the flag information, and the flag information is updated after the update. Characterized in that it comprises a and a management step of erasing.

  According to the first and thirteenth aspects of the present invention, flag information is written in the storage unit when the image formation request is received, and is written in the storage unit when the image forming process corresponding to the image formation request is completed. And the consumption level of the consumable item is managed based on the image formation request and the flag information, and it is possible to determine whether or not the consumption level of the consumable item has been normally updated based on the flag information. As a result, it is possible to appropriately manage the degree of consumption of consumables used for image formation.

  According to the second aspect of the present invention, when flag information is stored in the storage means when the image forming process is not executed, it is considered that an image having the maximum size among the sizes that can be formed is formed. Since the consumption level of the consumables is updated, it is possible to prevent deterioration in image quality by estimating the consumption level of the consumables more.

  According to the invention of claim 4, when the size of the image forming medium as flag information is stored in the storage means when the image forming process is not executed, the image forming area on the image forming medium of the size Since the consumption level of the consumables is updated assuming that an image having a uniform density is formed, it is possible to prevent deterioration in image quality by estimating the consumption level of the consumables more.

  According to the sixth aspect of the present invention, when the resolution as flag information is stored in the storage means when the image forming process is not executed, it is considered that the image of the resolution is formed and the consumable is consumed. Since the degree is updated, it is possible to prevent the deterioration of the image quality by appropriately estimating the degree of consumption of the consumables and to prevent the consumables from being replaced or replenished before reaching the end of their lifetime.

  According to the invention of claim 7, when the image forming request is received, the flag information and the size of the image forming medium included in the image forming request are written in the storage unit, and the image forming process corresponding to the image forming request is performed. When only the flag information written in the storage means when it is completed and the flag information is stored in the storage means when the image forming process is not executed, an image of the size stored in the storage means The consumption level of the consumables is updated assuming that an image having a uniform density is formed in the image-forming area of the forming medium. Therefore, the quality of the consumables can be estimated by appropriately estimating the consumption level of the consumables. Can be prevented.

  According to the eighth aspect of the present invention, when the image formation request is received, the flag information and the resolution included in the image formation request are written in the storage unit and the image formation process corresponding to the image formation request is completed. When only the flag information written in the storage means is erased and the flag information is stored in the storage means when the image forming process is not executed, the image of the resolution stored in the storage means is formed. Since the consumption level of consumables is updated, it is assumed that the consumables are properly estimated, so that the quality of the consumables can be estimated appropriately to prevent degradation of the image quality and prevent consumables from being replaced or replenished before they reach the end of their lives. be able to.

  According to the tenth aspect of the present invention, if the flag information is stored in the storage means when the image forming process for the adjustment image is not executed, it is considered that the image forming process for the adjustment image is executed. Since the consumption level of the consumables is updated, it is possible to prevent deterioration in image quality by estimating the consumption level of the consumables more.

  According to the twelfth aspect of the present invention, when flag information is stored in the storage unit when the image forming process of the adjustment image is not performed, the flag is based on the latest elapsed time written in the storage unit. Since the degree of consumption of the consumables is updated, it is possible to prevent the deterioration of the image quality by appropriately estimating the degree of consumption of the consumables and to prevent the consumables from being replaced or replenished before reaching the end of their lifetime.

Exemplary embodiments of an image forming apparatus and an image forming method according to the present invention are explained in detail below with reference to the accompanying drawings. In the embodiment described below, the case where the image forming apparatus of the present invention is applied to a tandem color laser beam printer will be described as an example. However, the present invention is not limited to this. For example, it can be applied to all image forming apparatuses employing an electrostatic photographic system such as a monochrome laser beam printer or a monochrome or color copying machine, and also applied to an image forming apparatus such as an ink jet printer. Is possible.

(Embodiment 1)
FIG. 3 is a schematic diagram illustrating the structure of the image forming apparatus according to the first embodiment. This image forming apparatus (tandem color laser beam printer) includes an exposure device on photoreceptors 1a, 1b, 1c, and 1d provided for each color of cyan: C, yellow: Y, magenta: M, and black: K. The electrostatic latent images formed by the laser beams 3a, 3b, 3c, and 3d output from the toner 3 are developed with a developer (toner) of each color by a developer (not shown) of each color, and a developer image (toner) Image), and a primary transfer is sequentially performed on the intermediate transfer belt 2 by a transfer device (not shown) provided for each color, and the full-color toner image transferred on the intermediate transfer belt 2 is secondarily transferred. It is transferred in a lump onto printing paper (hereinafter abbreviated as “paper”) by an apparatus (not shown). The intermediate transfer belt 2 is installed between a drive roller 8 that is driven and rotated by a motor (not shown) and a driven roller 7 that is driven and rotated, and is driven to rotate in the direction of the arrow in FIG. The Below the exposure unit 3, a waste toner box 5 for storing waste toner generated when the toner remaining on the intermediate transfer belt 2 after the primary transfer is cleaned by a cleaning device (not shown) is provided. A paper feed tray 6 that stores paper is provided below 5. The amount of waste toner stored in the waste toner box 5 is detected by the waste toner sensor 5a.

  Here, since the toner images formed on the photoreceptors 1a, 1b, 1c, and 1d of the respective colors are transferred at different positions on the intermediate transfer belt 2, there is a slight change in the moving speed of the intermediate transfer belt 2. In this case, the arrival time to the transfer position of the next color fluctuates, and as a result, the transfer position of each color shifts, and the image secondarily transferred to the sheet has a sub-scanning direction (movement direction of the intermediate transfer belt 2). Color misregistration will occur. Further, since the exposure unit 3 is also exposed with independent laser beams 3a, 3b, 3c, and 3d for each color, each component is displaced by an environmental change such as temperature, so that the main scanning direction (intermediate transfer belt 2). If the magnification in the direction orthogonal to the movement direction or the exposure start position changes, as a result, color misregistration in the main scanning direction occurs in the image secondarily transferred to the paper. For this reason, in a tandem printer, an image for misregistration adjustment (hereinafter referred to as “toner mark”) is formed on the intermediate transfer belt 2 before forming an actual color image. Is detected by the optical sensor 4 installed in front of the secondary transfer position, and a deviation amount and an adjustment amount of each color from the normal position are calculated from the detection result, and exposure by the exposure unit 3 is performed based on the adjustment amount. In general, the image forming apparatus according to the present exemplary embodiment also has the above-described misregistration adjustment function. However, since the toner mark and the color misregistration adjustment by the detection of the toner mark are well known in the art, a detailed description thereof is omitted.

  FIG. 4 is a block diagram illustrating a hardware configuration of a control system in the image forming apparatus according to the first embodiment. The control system includes a CPU 10, an operation panel 11, a ROM 12, an EEPROM 13, a RAM 14, an image memory 15, an input / output (I / O) interface 16, and an external interface 17 connected by a control bus and a data bus.

The CPU 10 executes a program stored in the ROM 12 to realize a control unit 20, a process control unit 27, and the like, which will be described later. The operation panel 11 has a display device such as an LCD panel and an input device (for example, a key switch) for accepting operation input. As will be described later, the CPU 10 (controls) various information including the consumption level of consumables. CPU 20 for receiving various settings (for example, selection of paper size, selection of print resolution, etc.) by the input device.
It is what you pass to. As will be described later, data on the consumption level (toner consumption) of consumables is written and held in an EEPROM 13 which is a rewritable nonvolatile memory. The I / O interface 16 is used to interface signals between various sensors such as the optical sensor 4 and the waste toner sensor 5a, electric components such as a motor and a clutch, and the CPU 10 to exchange signals. The external interface 17 corresponds to one or a plurality of types of methods such as 100BASE-TX, USB2.0, IEEE1284, and the like, and interfaces between the computer terminal and the CPU 10 connected by a communication cable. Note that image data (print image data) received from the computer terminal via the external interface 17 is stored in the image memory 15.

  FIG. 1 is a block diagram illustrating a functional configuration of the image forming apparatus according to the first embodiment. The image forming apparatus according to the present embodiment includes a control unit 20, an operation unit 24, a computer interface unit 21, a plotter unit 22, an image memory unit 23, a print job management unit 25, a color misregistration adjustment unit 26, a process control unit 27, and a storage unit. 28, a toner consumption amount management unit 29 is provided.

  The computer interface unit 21 has a function of communicating with a computer terminal of a user who makes an image formation request (print request), and corresponds to the external interface 17 in FIG. The plotter unit 22 includes the photoreceptors 1a to 1d, the exposure device 3, the intermediate transfer belt 2 and the like shown in FIG. 3, and executes the above-described image forming process under the control of the control unit 20, and stores it in the image memory 15. An image is formed on the basis of print image data or toner mark image data stored in the corresponding image memory unit 23. The print image data is actual data of the content itself to be printed on a predetermined paper, and specifically, document data, photo data, graphic data, data combining them, and the like. The above print request relates to information (data) relating to the size of the paper to be printed (for example, A4, A3, B5, B4, etc.) and the resolution at the time of printing (for example, 300 dpi, 600 dpi, etc.). Information (data) is also included.

  The operation unit 24 corresponds to the operation panel 11 in FIG. The print job management unit 25 has a function of managing the order of execution of print jobs related to print requests, and the control unit 20 has a function of controlling a series of operations of the above-described units. This is also realized by the CPU 10 shown in FIG. 4 executing the program stored in the ROM 12.

  The color misregistration adjusting unit 26 instructs the control unit 20 to form a toner mark for color misregistration adjustment on the intermediate transfer belt 2 and at the relative position of the toner mark for each color detected by the optical sensor 4. The color misregistration adjustment function is provided based on this. However, the specific content of such color misregistration adjustment is well known in the art as disclosed in, for example, Japanese Patent Application Laid-Open No. 11-65208 and Japanese Patent Application Laid-Open No. 2002-244393.

The process control unit 27 instructs the control unit 20 to form a pattern image for process control adjustment on the intermediate transfer belt 2 and adjusts the process control based on the density of the pattern image detected by the optical sensor 4. It has a function to perform. Generally, in an electrophotographic image forming apparatus, the characteristics of devices such as chargers, exposure devices, photoconductors, developers, and consumables fluctuate due to environmental changes such as temperature and humidity, and changes over time. It is known that the formation state of an image obtained by charging exposure becomes unstable due to fluctuations in characteristics of the apparatus and consumables. Therefore, in such an electrophotographic image forming apparatus, the image forming process conditions are controlled in accordance with fluctuations in the characteristics of the charger, the exposure device, the photoconductor, the developer, and the like so as to stabilize the image forming state. Yes. Specifically, the density of the pattern image detected by the optical sensor 4 is compared with a predetermined reference value, and the development bias (for example, the charging voltage in the charger) is increased or decreased so as to reduce the difference from the reference value. Thus, the density of the toner image is adjusted. Such control for stabilizing the image forming state (stabilizing the toner density) is referred to as process control. However, details of such process control are well known in the art as described in, for example, Japanese Patent Application Laid-Open No. 11-167248 and Japanese Patent Application Laid-Open No. 8-262820.

  The toner consumption amount management unit 29 has a function of managing the consumption level of consumables, that is, the toner consumption amount, which is the gist of the present invention, and is realized by executing a program by the CPU 10. Specifically, each time the image forming process is executed in the plotter unit 22, the toner consumption amount management unit 29 causes the paper size, resolution, and image type (document, photo, graphic, or toner mark for color misregistration adjustment, The toner consumption amount corresponding to the process control pattern image) is calculated for each color, and the toner consumption amount data for each color stored in the storage unit 28 including a rewritable nonvolatile memory (EEPROM 13) is updated. (Rewrite). Thus, in the image forming apparatus according to the present embodiment, each color toner is stored in a replaceable dedicated container (toner cartridge), and the toner cartridge itself is replaced when the toner in the toner cartridge decreases below a predetermined amount. There is a need to. Therefore, the toner consumption amount management unit 29 manages the consumption amount of each color toner, and if the remaining amount of toner in the toner cartridge obtained from the consumption amount is equal to or less than the specified amount, the toner consumption amount management unit 29 controls the control unit. The toner end signal is output to the control unit 20, and the control unit 20 that has received the toner end signal displays the toner end on the display device of the operation unit 24 (operation panel 11) to notify the user.

  Here, each time the image forming process is executed in the toner consumption amount management unit 29, for example, one sheet is printed, or a toner mark for color misregistration adjustment or a pattern image for process control is printed on the intermediate transfer belt 2. The toner consumption amount for each color is calculated every time the image is formed, and the toner consumption amount is added to update the data in the storage unit 28 (the cumulative value of the toner consumption amount for each color). If the power interruption due to a power failure or an erroneous operation occurs before the toner consumption amount management unit 29 is updated, the toner consumption amount stored in the storage unit 28 is the amount of toner consumed by the previous image forming process. If it is not added, the image quality may deteriorate due to the lack of toner before the toner end is displayed.

  Therefore, in the present embodiment, the control unit 20 stores flag information in the storage unit 28 when the control unit 20 receives an image formation request (print request or formation mark for color misregistration adjustment or a pattern image for process control). When the image forming process corresponding to the image forming request is completed, the flag information written in the storage unit 28 is erased, and the image forming process is performed immediately after returning from a power failure or power interruption as described above. When the flag information is stored in the storage unit 28 when not executed, the toner consumption data has not been updated because the previous image forming process (immediately before a power failure or power failure) was not completed. Based on the determination, the toner consumption amount management unit 29 calculates the toner consumption amount for each color under a predetermined condition and stores the toner consumption amount for each color stored in the storage unit 28. We are updating the amount of data.

  Next, the flow of processing from image request reception to toner end determination and flag information deletion of the image forming apparatus of the first embodiment will be described. FIG. 2 is a flowchart illustrating a processing procedure from image request reception to toner end determination and flag information deletion of the image forming apparatus according to the first embodiment.

The control unit 20 receives a print request whose order has been determined by the print job management unit 25, a toner mark formation request for color misregistration adjustment by the color misregistration adjustment unit 26, or a pattern image formation request for process control by the process control unit 27. It is determined whether or not it has occurred (step S1). If any image formation request has occurred, 2-bit flag information is written at a predetermined address in the storage unit 28 (step S2). The flag information is information indicating the type of the image forming medium that has accepted the image forming request. If the flag information is written in the storage unit, it indicates that an image formation request has been received for the image forming medium represented by the flag information. The type of image forming medium that has accepted the image formation request is, for example, any two bits such as “01” for a print request, “10” for a toner mark formation request, and “11” for a pattern image formation request. Can be identified by the information. Thereafter, the plotter unit 22 executes an image forming process under the control of the control unit 20 to form an image (print image, toner mark, pattern image) according to the image formation request (step S3). When the process is completed, the toner consumption management unit 29 calculates the toner consumption according to the content of the image formation request (step S4).

For example, the toner consumption amount is obtained by multiplying the number of pixels corresponding to the paper size and resolution included in the print request by the toner consumption amount per pixel. When the image formation request is a print request, for example, when A4 (210 mm × 297 mm) and 600 dpi, the toner consumption amount is

210 × 600 / 25.4 × 297 × 600 / 25.4 ≒ 34802527 [dot]

It becomes. (Regarding normal paper, several millimeters in the front, rear, left, and right are not formed as trim areas, but that amount is not considered). The amount of toner consumed per pixel at 600 dpi is determined to be 0.000002 [mg] by experiments. Therefore, the amount of toner consumed when an image having a uniform density is formed within the printable range in A4 is

34799360 × 0.000002 ≒ 69.6 [mg]

It becomes.

FIG. 5 is an explanatory diagram showing a pattern image for process control adjustment. When the image formation request is an image formation request for a pattern image for process control adjustment, a pattern image for process control adjustment is a patch of 17 [mm] × 10 [mm] as shown in FIG. 7 for each color, the number of dots when a uniform density image is formed in the printable range is

17 × 600 / 25.4 × 10 × 600 / 25.4 × 7≈664104 [dot]

It becomes. Therefore, the toner consumption when the process control adjustment pattern is an image is

664104 × 0.000002 ≒ 1.328 [mg]

It becomes.

FIG. 6 is an explanatory diagram showing a toner mark for color misregistration correction. When the image formation request is an image formation request of a toner mark for color misregistration correction, the toner mark for color misregistration correction has a rectangular pattern and a diagonal line pattern for each color as shown in FIG. 16 pieces are created per detection sensor. Since three detection sensors are arranged in the main scanning direction, 16 × 3 are formed. Therefore, the number of dots in the rectangular pattern is

Vertical 16 x Horizontal 236 = 3774 [dot]

The number of dots in the diagonal pattern is

Base 20 × height 236 = 4720 [dot]

So in total,

(3776 + 4720) × 16 × 3 = 407808 [dot]

It becomes. Therefore, the toner consumption in the case of a toner mark for color misregistration correction is
407808 × 0.000002 ≒ 0.816 [mg]

It becomes.

FIG. 7 is a diagram illustrating an example of a data structure of a table representing the number of pixels consumed at the time of each image formation request. This table and the toner consumption per pixel are stored in the storage unit 28.
The above calculation is based on 600 dpi, but at 300 dpi, the number of pixels is ¼ for both main scanning and sub-scanning, and conversely, the toner consumption per pixel is quadrupled, and 1200 dpi. In this case, the number of pixels is quadrupled for both main scanning and sub-scanning, but conversely, the toner consumption per pixel is ¼, so basically the total amount does not change even if the pixel density changes. . However, there may be a difference in the toner consumption per pixel depending on the pixel density. In this case, only the number of pixels is obtained based on the table in FIG. 7 and stored separately according to the pixel density. It is possible to obtain the consumption amount by multiplying the amount of toner consumption by the number of pixels.

  The toner consumption amount management unit 29 adds the calculated toner consumption amount to the accumulated toner consumption amount data stored in the storage unit 23 to update the data in the storage unit 28 (step S5). It is determined whether or not the cumulative value of the subsequent toner consumption exceeds the prescribed amount stored in advance in the storage unit 28 (toner end determination) (step S6), and then the flag information in the storage unit 28 is stored. The flag information is erased by writing “00” in the area (address) that is being processed (step S7).

  On the other hand, if no image formation request is generated, the control unit 20 determines whether or not flag information is written in the storage unit 20, that is, in an area (address) storing the flag information in the storage unit 28. It is checked whether any data of “01”, “10”, or “11” is written (step S8), flag information is not written, that is, data of “00” is written in the area. If it is, the process ends without doing anything. However, when flag information is written in the area, the control unit 20 reads the contents of the flag information, that is, “01” data indicating a print request, “10” data indicating a toner mark formation request, and a pattern image. It is determined which data is “11” indicating the formation request (step S 9), and the result is transmitted to the toner consumption management unit 29. The toner consumption amount management unit 29 calculates a toner consumption amount corresponding to the content of the flag information (type of image formation request) transmitted from the control unit 20. For example, when the content of the image formation request written in the flag information is a print request, the toner consumption management unit 29 has a uniform density in the printable range on a sheet of a size designated for printing (for example, A4). Assuming that an image (so-called “solid image”) has been formed, the consumption amount of toner of each color is calculated (step S10). Further, when the content of the image formation request written in the flag information is a request for forming a toner mark or a pattern image, the toner consumption amount management unit 29 has each image (toner mark or pattern image) formed. The amount of toner consumed for each color is calculated (step S11).

  The toner consumption amount management unit 29 adds the calculated toner consumption amount to the accumulated toner consumption amount data stored in the storage unit 23 to update the data in the storage unit 28 (step S12). It is determined whether or not the cumulative value of the subsequent toner consumption exceeds the prescribed amount stored in advance in the storage unit 28 (toner end determination) (step S13), and then the flag information in the storage unit 28 is stored. The flag information is erased by writing “00” in the area (address) that is being processed (step S14).

  Thus, in the present embodiment, when the control unit 20 receives the image formation request, it writes the flag information in the storage unit 28 and also writes it in the storage unit 28 when the image forming process corresponding to the image formation request is completed. Since the flag information is deleted and the toner consumption amount management unit 29 manages the toner consumption amount based on the image formation request and the flag information, it is determined whether or not the toner consumption amount is normally updated based on the flag information. As a result, it is possible to appropriately manage the degree of consumption (toner consumption) of consumables used for image formation. Further, when the flag information is stored in the storage unit 28 when the image forming process is not executed as in the present embodiment, the toner consumption amount management unit 29 selects an image of the maximum size among the sizes that can be formed. Since the toner consumption is updated assuming that the toner has been formed, it is possible to prevent image quality deterioration due to toner shortage by estimating a large amount of toner consumption.

  Here, data indicating the paper size included in the print request as flag information corresponding to the print request, for example, “001” if the paper size is A4, “010” if it is B4, “011” if it is legal size. "110" as flag information corresponding to the toner mark formation request and "111" as flag information corresponding to the pattern image formation request are written in the storage unit 28, and flag information when the image forming process is not executed. If the toner consumption amount is calculated by the toner consumption amount management unit 29 when the toner consumption amount is calculated by the toner consumption amount management unit 29, it is assumed that a solid image of the paper size of the flag information has been formed. Compared with the case where the toner consumption is calculated by assuming that the toner is consumed, it is possible to reduce the image quality by appropriately estimating the toner consumption. The toner cartridge before reaching the toner end can be prevented from being replaced while preventing. Alternatively, instead of the paper size, the resolution of the image may be flag information corresponding to the print request. For example, “001” if the resolution is 300 dpi, “010” if the resolution is 600 dpi, “011” if the resolution is 1200 dpi, and the like. “110” is written as flag information corresponding to the toner mark formation request and “111” is written as flag information corresponding to the pattern image formation request to the storage unit 28. When the image formation process is not executed, the toner is obtained from the flag information. When calculating the consumption amount, the toner consumption amount is similarly calculated even if the toner consumption amount management unit 29 calculates the toner consumption amount on the assumption that the image having the resolution of the flag information is formed on the maximum size paper. Can be estimated appropriately. Note that if both the paper size and the resolution included in the print request are set as flag information, the toner consumption can be estimated more appropriately than when only the paper size or the resolution is set as flag information. Is possible.

  By the way, depending on the timing at which a power failure or power failure occurs, the control unit 20 may not be able to acquire the paper size and resolution information included in the print request. In such a case, the paper size and resolution are stored as flag information. It cannot be stored in the unit 28. Therefore, the control unit 20 writes information on at least one of the paper size and resolution in the storage unit 28 in addition to the flag information (whether there is an image formation request) when the print request is received, and responds to the print request. If only the flag information written in the storage unit 28 when the image forming process is completed and the paper size or resolution information is left unerased, the flag information is stored in the storage unit 28 as described above. Even if writing could not be performed, information on at least one of the paper size and resolution in the previous print request is stored in the storage unit 28, and the toner consumption amount management unit 29 uses the information to store the toner consumption amount. If the above is calculated, it is possible to prevent deterioration in image quality by appropriately estimating the toner consumption.

  In addition, the image formation process in color misregistration adjustment and process control adjustment has a longer execution time than the image formation process for a normal print request, and the amount of toner consumed depends on when the image formation process is interrupted. There are significant differences. Therefore, for a toner mark formation request for color misregistration adjustment and a pattern image formation request for process control adjustment, information on elapsed time starting from the start point of the image forming process is stored together with flag information indicating the presence or absence of the flag information. The toner consumption amount management unit 29 calculates the toner consumption amount based on the flag information stored in the storage unit 28 according to the elapsed time stored in the storage unit 28. By calculating the toner consumption amount in the toner mark formation request or pattern image formation request, the toner consumption amount for the color misregistration adjustment toner mark formation request and the process control adjustment pattern image formation request can be estimated more appropriately. be able to. However, when the image formation process for the toner mark formation request for color misregistration adjustment and the pattern image formation request for process control adjustment is normally completed, the control unit 20 displays the elapsed time stored in the storage unit 28 together with the flag information. to erase.

  In the present embodiment, toner is exemplified as a consumable that is subject to life management. However, the consumable is not limited to toner, and the life of consumables other than toner, such as the photoreceptors 1a to 1d, is also described. It can be managed in the same way.

2 is a block diagram illustrating a functional configuration of the image forming apparatus according to Embodiment 1. FIG. 4 is a flowchart illustrating a processing procedure from image request acceptance to toner end determination and flag information deletion of the image forming apparatus according to the first embodiment. 1 is a schematic diagram illustrating a structure of an image forming apparatus according to a first embodiment. 2 is a block diagram illustrating a hardware configuration of a control system in the image forming apparatus according to Embodiment 1. FIG. It is explanatory drawing showing the pattern image for process control adjustment. FIG. 6 is an explanatory diagram illustrating a toner mark for color misregistration correction. It is a figure showing an example of the data structure of the table showing the number of pixels consumed at the time of each image formation request.

Explanation of symbols

20 Control unit 22 Plotter unit 28 Storage unit 29 Toner consumption management unit

Claims (13)

In an image forming apparatus for forming an image corresponding to an image forming request on an image forming medium using an image forming material,
Control means for executing an image forming process for forming the image on an image forming medium based on the image forming request;
A rewritable nonvolatile storage means capable of storing flag information indicating that the image formation request has been received and a consumption level of a consumable including at least an image forming material;
Management means for managing the degree of consumption of the consumables,
When the control unit further receives the image formation request, the control unit writes the fact that the image formation request has been received as flag information in the storage unit,
The management means further updates the consumption level of the consumables stored in the storage means based on the image formation request and the flag information, and erases the flag information after the update,
An image forming apparatus. The flag information further includes the type of image forming medium that has accepted the image forming request,
The management unit further refers to the flag information when the type of the image forming medium is stored in the storage unit as the flag information when the control unit is not executing the image forming process. Updating the degree of consumption of the consumables stored in the storage means, assuming that the image of the maximum size among the sizes that can be formed for the image forming medium of the type is formed.
The image forming apparatus according to claim 1. The flag information further includes the type of the image forming medium that has accepted the image forming request, and the size of the image forming medium,
The control unit further writes the type of the image forming medium included in the image forming request and the size of the image forming medium in the storage unit as flag information when the image forming request is received. ,
The image forming apparatus according to claim 1. The management unit further refers to the flag information when the size of the image forming medium is stored in the storage unit as the flag information when the control unit is not executing the image forming process. The image forming medium of the type is regarded as an image having a uniform density formed in an image-forming area of the size, and the consumption level of the consumable item stored in the storage unit is updated. ,
The image forming apparatus according to claim 3. The flag information further includes the type of the image forming medium that has accepted the image forming request, and the resolution of the image.
The control unit further writes the type of the image forming medium included in the image formation request and the resolution of the image in the storage unit as flag information when the image formation request is received.
The image forming apparatus according to claim 1. The management unit further refers to the flag information when the resolution of the image is stored in the storage unit as the flag information when the control unit is not executing the image forming process, Updating the degree of consumption of the consumables stored in the storage means, assuming that the image of the resolution is formed for the type of image forming medium;
The image forming apparatus according to claim 5. The flag information further includes the type of image forming medium that has accepted the image forming request,
The control unit further writes the type of the image forming medium included in the image formation request into the storage unit as flag information when the image formation request is received,
Writing the size of the image forming medium included in the image forming request into the storage means;
The management means further stores the size of the image medium and the type of the image forming medium as the flag information in the storage means when the control means is not executing the image forming process. The consumables stored in the storage means with reference to the storage means, assuming that an image having a uniform density is formed in the image-forming area of the size for the image forming medium of the type. The image forming apparatus according to claim 1, wherein the consumption degree is updated, and the flag information is deleted after the update. The flag information further includes the type of image forming medium that has accepted the image forming request,
When the control unit receives the image formation request, the control unit writes the type of the image forming medium included in the image formation request into the storage unit as flag information, and also includes the image included in the image formation request. Write the resolution of the forming medium to the storage means,
The management unit further stores the resolution of the image and the type of the image forming medium as the flag information when the control unit is not executing the image forming process. , Referring to the storage means, assuming that an image of the resolution is formed on the type of image forming medium, updating the consumption level of the consumables, and erasing the flag information after the update. The image forming apparatus according to claim 1, wherein: The control means further indicates that, when the type of the image forming medium included in the image formation request is an adjustment image, the type of the image medium that has received the image formation request is the adjustment image. Writing to the storage means;
The image forming apparatus according to claim 1. The management means further indicates that the type of the image forming medium and the fact that the image forming request is accepted as the flag information when the control means is not executing the image forming process of the adjustment image. When stored in the storage unit, the storage unit is referred to, and the degree of consumption of the consumables stored in the storage unit is updated assuming that the image forming process of the adjustment image has been executed. ,
The image forming apparatus according to claim 9. The control means further writes the elapsed time of the image forming process into the storage means periodically when executing the image forming process of the adjustment image.
The image forming apparatus according to claim 9. The management means further includes that the type of the image medium is the adjustment image and the elapsed time of the image formation process when the control means is not executing the image formation process of the adjustment image. If the storage means stores the fact that the image formation request has been accepted as the flag information, the image forming process of the adjustment image is executed for the elapsed time with reference to the storage means. Considering, updating the consumption degree of the consumables stored in the storage means,
The image forming apparatus according to claim 11. An image forming method executed by an image forming apparatus,
The image forming apparatus includes:
Control means for executing an image forming process for forming the image on an image forming medium based on an image forming request;
A rewritable non-volatile storage means capable of storing flag information indicating that an image formation request has been received and a consumption level of a consumable including at least an image forming material;
Management means for managing the degree of consumption of the consumables,
A control step of writing in the storage means as flag information that the control means has received the image formation request when the image formation request is received;
A management step in which the management means updates the consumption level of the consumables stored in the storage means based on the image formation request and the flag information, and deletes the flag information after the update. An image forming method.

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