INKJET PRINTING APPARATUS, AND A CONTROL METHOD THEREFOR

Abstract

When a disconnection detecting circuit detects failure, a controller of a temperature controller manipulates a duty ratio to distribute the duty ratio to normal heating rollers. Since the amount of heat decreased by failure of a heating roller can be compensated for by the other heating rollers, no defective drying will occur. It is not necessary to stop a printing process immediately when the disconnection detecting circuit detects failure, but a maintenance operation can be carried out after fully securing a preparation time for maintenance. The quick maintenance can be performed to restrain downtime of the printing apparatus.

Claims

1. An inkjet printing apparatus for dispensing ink droplets from a print head while transporting a printing medium in a predetermined transport direction to print on the printing medium, comprising: a drying unit for drying at a predetermined drying temperature the printing medium printed by the print head, and including at least three heating devices arranged downstream of the print head in the transport direction to heat the printing medium; and a temperature controller for operating the drying unit, and controlling to make temperature of the printing medium become the drying temperature by finishing a drying process in the drying unit; the temperature controller including: a temperature detector for detecting temperature of each of the heating devices; a controller for manipulating a duty ratio, which is a proportion of ON time of each of the heating devices, according to the temperature detected by the temperature detector; a storage unit for storing the duty ratio in time series of each of the heating devices; and a failure detection unit for detecting failure of each of the heating devices; wherein the controller is configured, when the failure detection unit detects failure, to manipulate the duty ratio to distribute to normal heating devices a missing duty ratio which is the duty ratio before the failure of the failed heating device among the duty ratios stored in the storage units.

2. The inkjet printing apparatus according to claim 1, wherein the controller is configured, when the failure is detected in one of the at least three heating devices, to manipulate the duty ratios so that the remaining heating devices have temperatures gradually higher from most upstream to most downstream, thereby reaching the drying temperature at most downstream.

3. The inkjet printing apparatus according to claim 1, wherein the controller is configured, when the failure is detected in a heating device upstream of a middle one of the at least three heating devices, to distribute the missing duty ratio in a larger quantity to a heating device located relatively upstream than to a heating device located relatively downstream, of the plurality of heating devices excluding the failed heating device.

4. The inkjet printing apparatus according to claim 1, wherein the controller is configured, when the failure is detected in a heating device in a middle position of the at least three heating devices, to distribute the missing duty ratio equally to the heating devices upstream and downstream of said heating device.

5. The inkjet printing apparatus according to claim 1, wherein the controller is configured, when the failure is detected in a heating device downstream of a middle one of the at least three heating devices, to distribute the missing duty ratio in a larger quantity to a heating device located relatively downstream than to a heating device located relatively upstream, of the plurality of heating devices excluding the failed heating device.

6. A control method for an inkjet printing apparatus which dispenses ink droplets from a print head while transporting a printing medium in a predetermined transport direction to print on the printing medium, and which dries the printing medium at a predetermined drying temperature with a drying unit including at least three heating devices arranged downstream of the print head in the transport direction to heat the printing medium, comprising: a step of drying the printing medium with the drying unit including the at least three heating devices arranged downstream of the print head in the transport direction, while storing in memory duty ratios in time series which are proportions of ON time of the heating unit; a step of detecting failure of each of the heating devices; and a step executed, when failure is detected, to manipulate the duty ratio to distribute to normal heating devices a missing duty ratio which is the duty ratio before the failure of the failed heating device among the duty ratios stored.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] FIG. 1 is a block diagram showing an outline construction of a printing system according to an embodiment.

[0022] FIG. 2 is a block diagram showing principal portions of a drying unit and a temperature controller.

[0023] FIG. 3 (a) shows a state of the drying unit when the most upstream heating roller is disconnected, and (b) is a schematic view showing an example of temperature distribution.

[0024] FIG. 4 is a schematic view showing a duty ratio in time series of each heating roller.

[0025] FIG. 5 (a) shows a state of the drying unit when a middle heating roller is disconnected, and (b) is a schematic view showing an example of temperature distribution.

[0026] FIG. 6 (a) shows a state of the drying unit when the most downstream heating roller is disconnected, (b) is a schematic view showing an example of temperature distribution.

DESCRIPTION OF EMBODIMENTS

[0027] One embodiment of this invention will be described hereinafter with reference to the drawings.

[0028] FIG. 1 is a block diagram showing an outline construction of a printing system according to an embodiment.

[0029] A printing system 1 according to this embodiment includes a paper feeder 3, a printing apparatus 5, and a takeup roller 7.

[0030] The paper feeder 3 unwinds and feeds web paper WP in a roll form in a transport direction X. The printing apparatus 5 is constructed to be the inkjet type for performing printing by dispensing ink droplets to the web paper WP, and performs the printing on the web paper WP. The takeup roller 7 takes up the printed web paper WP in a roll form.

[0031] The above web paper WP corresponds to the “printing medium” in this invention. The above printing apparatus 5 corresponds to the “inkjet printing apparatus” in this invention.

[0032] The printing apparatus 5 includes a drive roller 9 disposed in an upstream position for taking in the web paper WP from the paper feeder 3. The web paper WP unwound from the paper feeder 3 by the drive roller 9 is transported along a plurality of transport rollers 11 downstream toward the takeup roller 7. A drive roller 13 is disposed between the most downstream transport roller 11 and the takeup roller 7. The drive roller 13 feeds the web paper WP transported on the transport rollers 11 toward the takeup roller 7.

[0033] The printing apparatus 5 includes, between the drive roller 9 and drive roller 13, a print head 15, a drying unit 17, a cooling unit 19, and an inspecting unit 21 arranged in the stated order from upstream. The drying unit 17 heats the web paper WP printed by the print head 15 and dries the ink droplets. The cooling unit 19 cools the web paper WP heated in the drying unit 17. The inspecting unit 21 checks whether the printed portions have stains, omissions or other defects.

[0034] The print head 15 performs printing by dispensing ink droplets to the web paper WP. The print head 15 includes a plurality of nozzles (not shown) arranged in a width direction Y of the web paper WP perpendicular to the transport direction X. It would be a construction in general practice to arrange a plurality of (e.g. four) print heads 15 in the transport direction X for enabling multicolor printing. However, to facilitate understanding of the invention, this embodiment provides only one print head 15.

[0035] The printing apparatus 5 includes a printing controller 23, a printing condition setter 25, a temperature controller 27, and an alarm device 29. The printing controller 23 receives printing image data from a host computer not shown. The printing controller 23 performs overall control of the drive rollers 9 and 13, print head 15, inspecting unit 21, temperature controller 27, and so on. When performing printing based on the printing image data, the printing controller 23 controls each component according to printing conditions with reference to the printing condition setter 25. The printing conditions are, for example, types of the web paper WP, transporting speeds of the web paper WP, drying temperatures in the drying unit 17, and cooling temperatures in the cooling unit 19.

[0036] The temperature controller 27, under control of the printing controller 23, performs temperature control of the drying unit 17 and cooling unit 19. The alarm device 29, when any abnormality occurs in the drying unit 17 or other component, will report it to the operator. The alarm device 29 gives visual information on a display device, lamp, and so on, and/or by sound with a buzzer, for example.

[0037] Reference is now made to FIG. 2. FIG. 2 is a block diagram showing principal portions of the drying unit and temperature controller.

[0038] The drying unit 17 has a plurality of heating rollers 31. This embodiment assumes, for example, that the drying unit 17 has three heating rollers 31. The heating rollers 31 are distinguished, where necessary, as heating rollers 31a, 31b, and 31c in order from upstream. Each heating roller 31 contains a halogen lamp 33 adjacent the center thereof. The halogen lamp 33 efficiently radiates light of the infrared region, which heats the heating roller 31 from the interior. When distinguishing the halogen lamps 33 from each other, the term halogen lamps 33a-33c will be used. The heating roller 31 contacts the surface (lower surface) of web paper WP where the ink droplets do not adhere, to dry the ink droplets adhering to the web paper WP. The drying unit 17 in this embodiment has the three heating rollers 31a-31c arranged linearly along the transport direction X. The drying unit 17 has a temperature sensor 35 for each of the heating roller 31a-31c for detecting temperature on the outer circumferential surface of each of the heating rollers 31a-31c.

[0039] The above halogen lamps 33 correspond to the “heating devices” in this invention. The above temperature sensors 35 correspond to the “temperature detectors” in this invention.

[0040] The drying unit 17 constructed as described above is controlled by the temperature controller 27. The temperature controller 27 includes disconnection detecting circuits 37, PWM controllers 39, duty ratio memories 41, and a controller 43.

[0041] The disconnection detecting circuits 37 detect disconnections of the halogen lamps 33. The disconnection detecting circuits 37 detect the disconnections by detecting states of current supply to the halogen lamps 33. The disconnections, when detected, are notified to the controller 43.

[0042] The halogen lamps 33 are controlled by the PWM controllers 39. The PWM controllers 39 control luminance of the halogen lamps 33 through regulation of the ratios (duty ratios) of lighting time within 0 to 100%, which is done by varying pulse width while maintaining the cycles constant. At this time, feedback control is carried out with reference to outputs of the temperature sensors 35.

[0043] The duty ratio memories 41 store, in time series, duty ratios which are outputs from the PWM controllers 39. The storage of the duty ratios is performed at intervals of several seconds to several minutes, for example. The stored duty ratios in time series are referred to by the controller 43. Upon receipt of a notice about a disconnection from a disconnection detecting circuit 37, the controller 43 operates the alarm device 29 to report the occurrence of the disconnection. At the same time, the controller 43 reads the duty ratio in time series from the duty ratio memory 41 (41a-41c) corresponding to the heating roller 31 (31a-31c) disconnected and broke down. And, as described hereinafter, a control is executed to distribute the duty ratio to the normal heating rollers 31 (31a-31c). The controller 43 instructs the PWM controllers 39 a control based on the target value of a drying temperature set beforehand by the printing conditions setting unit 25.

[0044] The above disconnection detecting circuits 37 correspond to the “failure detection units” in this invention. The duty ratio memories 41 correspond to the “storage units” in this invention.

[0045] <When Failure Occurs Upstream of Middle Position>

[0046] Referring now to FIGS. 3 and 4, description will be made of a case in which the most upstream one of the three heating rollers 31a-31c breaks down, as one example of the cases where a failure occurs upstream of the middle position. In FIG. 3, (a) shows a state of the drying unit when the most upstream heating roller is disconnected, and (b) is a schematic view showing an example of temperature distribution. FIG. 4 is a schematic view showing a duty ratio in time series of each heating roller.

[0047] Assume that, as shown in FIG. 4, for example, the drive rollers 9 and 13 begin to rotate at time 0, that the speed of web paper WP reaches a transporting speed and printing is started immediately before time t1, and that a printed area of web paper WP arrives at the drying unit 17 at time t1. And assume that all the three heating rollers 31a-31c operate normally up to time t1-t2, and that the halogen lamp 33a of the most upstream heating roller 31a is disconnected at time t3. In FIG. 4, the solid line expresses the duty ratio of halogen lamp 31a, the dotted line expresses the duty ratio of halogen lamp 31b, and the two-dot chain line expresses the duty ratio of halogen lamp 31c. Up to time t1-t2 in FIG. 4, the duty ratios outputted from the respective PWM controllers 39a-39c to the halogen lamps 33a-33c are stored in time series in the duty ratio memories 41. The duty ratio memories 41 have storage capacities for storing at least duty ratios of the past for a predetermined period T1 from time t3 when the failure occurred. The predetermined period T1 preferably is on the order of several hours to several days, for example.

[0048] At time tl when drying is started, the most upstream halogen lamp 33a is controlled to have the highest duty ratio since its temperature falls easily since the web paper WP contacts the heating roller 31a immediately after dispensation of the ink droplets. The halogen lamp 31b in the middle position is operated with a lower duty ratio than the halogen lamp 33a since it heats the heating roller 33b which contacts the web paper WP heated by the most upstream heating roller 31a. The most downstream halogen lamp 33c is operated with a lower duty ratio than the halogen lamp 33b since it heats the heating roller 33c which contacts the web paper WP heated in the most upstream and middle positions.

[0049] Each duty ratio of the halogen lamps 33a-33c varies finely, and this is because temperature changes of the heating rollers 31a-31c occur according to print content printed on the web paper WP. For example, temperature lowers in locations of filling, and therefore the duty ratio is made high. The duty ratio is lowered for locations with many blanks since temperature rises there. Such variations of the duty ratio are made different by the thickness and type of web paper WP, the type of printing medium, transporting speed, and so on, besides print content.

[0050] As shown in a solid line L1 in FIG. 3(b), the duty ratio given to each of the halogen lamps 33a-33c is controlled such that the temperature distribution according to the positions of the drying unit 17 at time t1-t2 when the three heating rollers 31a-31c are operating normally has temperatures gradually higher from most downstream toward most upstream to finally become the drying temperature.

[0051] When the halogen lamp 33a breaks down at time t3 shown in FIG. 4, the controller 43 detects the failure of halogen lamp 33a by notice from the disconnection detecting circuit 37a. The controller 43 reads the duty ratio in time series of the past including time t3 from the duty ratio memory 41a. What is read now is, for example, the duty ratio in the predetermined period T1 in FIG. 4. Assume that the duty ratios given to the halogen lamps 33a-33c in the predetermined period T1 in FIG. 4 are, for example, 80%, 70%, and 60% in average values.

[0052] The controller 43 distributes the duty ratio (e.g. 80%, which corresponds to the “missing duty ratio” in this invention) of the failed halogen lamp 33a to the PWM controllers 39b and 39c of the normal halogen lamps 33b and 33c. Assume here that the duty ratios given to the halogen lamps 31a-31c at the time of normal operation are rl, r2, and r3 in order. When, for example, the duty ratio of halogen lamp 33a r1=Δr2+Δr3, the PWM controller 39b operates the halogen lamp 33b at duty ratio r2+Δr2, and the PWM controller 39c operates the halogen lamp 33c at duty ratio r3+Δr3 (two-dot chain line L2 in FIG. 3(b)). It is preferred here that Δr2 is larger than Δr3 (Δr2>Δr3).

[0053] When the most upstream heating roller 31a breaks down, the web paper WP is heated first by the heating roller 31b in the middle position, and is subsequently cooled by the cooling unit 29 after passing through the most downstream heating roller 31c. The drying time from being heated first to being cooled becomes short compared with the case of the most upstream heating roller 33a being normal. For this purpose, control is made with the duty ratio in a magnitude relation Δr2>Δr3, to heat first at a somewhat higher temperature with the heating roller 31b in the middle position. Then, a substantial drying time can be lengthened, compared with the case where control is made with a duty ratio in the magnitude relation Δr2 <Δr3. That is, the time after the temperature of web paper WP rises to some extent and before the web paper WP reaches the cooling unit 19 can be prevented from becoming short. Consequently, even when the most upstream heating roller 31a breaks down, it is possible to prevent a defective drying of the web paper WP due to insufficient drying.

[0054] <When Failure Occurs in Middle Position>

[0055] Referring now to FIG. 5, description will be made of an example of control when the middle heating roller 31b among the three heating rollers 31a-31c breaks down. In FIG. 5, (a) shows a state of the drying unit when the heating roller in the middle position is disconnected, and (b) is a schematic view showing an example of temperature distribution.

[0056] As shown in a solid line L1 in FIG. 5 (b), the duty ratio given to each of the halogen lamps 33a-33c is controlled such that, when the three heating rollers 31a-31c are operating normally, temperatures gradually become higher from most downstream toward most upstream to finally become the drying temperature.

[0057] The controller 43 detects the failure of halogen lamp 33b in the middle heating roller 31b by notice from the disconnection detecting circuit 37b. The controller 43 reads the duty ratio in time series of the past including the time of occurrence of the failure from the duty ratio memory 41b.

[0058] The controller 43 distributes the duty ratio (e.g. 70%, which corresponds to the “missing duty ratio” in this invention) of the failed halogen lamp 33b to the normal halogen lamps 33a and 33c. When, for example, the duty ratio of halogen lamp 33b r2=Δrl +Δr3, the PWM controller 39a operates the halogen lamp 33a at duty ratio r1+Δr1, and the PWM controller 39c operates the halogen lamp 33c at duty ratio r3+Δr3 (two-dot chain line L2 in FIG. 5 (b)). It is preferred here that Δr1 is equal to Δr3 (Δr1=Δr3). Thus, the most upstream heating roller 31a first effects heating at a somewhat high temperature, whereby the drying time from the start of heating to arrival at the cooling unit 19 can be made substantially the same as in normal time. Consequently, even when the middle heating roller 31b breaks down, it is possible to prevent a defective drying of the web paper WP due to insufficient drying.

[0059] <When Failure Occurs Downstream of Middle Position>

[0060] Referring now to FIG. 6, description will be made of a case in which the most downstream heating roller 31c among the three heating rollers 31a-31c breaks down, as one example of the cases where a failure occurs downstream of the middle position. In FIG. 6, (a) shows a state of the drying unit when the most downstream heating roller is disconnected, and (b) is a schematic view showing an example of temperature distribution.

[0061] The controller 43 detects the failure of halogen lamp 33c in the most downstream heating roller 31c by notice from the disconnection detecting circuit 37c. The controller 43 reads the duty ratio in time series of the past including the time of occurrence of the failure from the duty ratio memory 41c.

[0062] The controller 43 distributes the duty ratio (e.g. 60%, which corresponds to the “missing duty ratio” in this invention) of the failed halogen lamp 33c to the normal halogen lamps 33a and 33b. When, for example, the duty ratio of halogen lamp 33c r3=Δr1+Δr2, the PWM controller 39a operates the halogen lamp 33a at duty ratio r1+Δr1, and the PWM controller 39b operates the halogen lamp 33b at duty ratio r2+Δr2 (two-dot chain line L2 in FIG. 6 (b)). It is preferred here that Δr2 is larger than Δr1 (Δr2>Δr1).

[0063] The web paper WP is dried first by the most upstream heating roller 31a. When the temperature at this time is too much higher than at normal time, the web paper WP will be dried to excess, causing a phenomenon of the ink droplets on the web paper WP rapidly becoming too dry. Then, the drying process will wrinkle the web paper WP, and the wrinkles will result in defective drying. Therefore, control is performed with the duty ratio in a magnitude relation Δr2>Δr1, for the most upstream heating roller 31a to effect heating moderately first, thereby preventing wrinkle formation. As a result, even when the most downstream heating roller 31c breaks down, it is possible to prevent defective drying due to excessive drying.

[0064] According to this embodiment, when a disconnection detecting circuit 37 detects failure, the controller 43 controls the duty ratios to distribute to the normal heating rollers 31 the duty ratio having been given to operate the failed heating roller 31, among the duty ratios in time series stored in the duty ratio memories 41. Consequently, since the amount of heat decreased when the heating roller 31 breaks down can be compensated for by the other heating rollers 31, no defective drying will occur. As a result, there is no need to stop the printing process immediately when the disconnection detecting circuit 37 detects failure, but a maintenance operation can be carried out after fully securing time to prepare for the maintenance. Therefore, since a quick maintenance operation can be carried out, the downtime of the printing apparatus 5 can be restrained. Moreover, since the duty ratio for the failed heating roller 31 is distributed based on the duty ratios stored in the duty ratio memories 41, an appropriate drying process can be continued according to print content of the printing process currently carried out. Consequently, even when the heating rollers 31 working normally are substituted to continue the printing process, deterioration in print quality due to the drying process can be restrained.

[0065] This invention is not limited to the foregoing embodiment, but may be modified as follows:

[0066] (1) In the foregoing embodiment, the drying unit 17 has a plurality of heating rollers 31a-31c arranged linearly. This invention is not limited to such construction. For example, it is applicable even where the drying unit 17 has a plurality of heating rollers 31 arranged annularly.

[0067] (2) In the foregoing embodiment, the drying unit 17 has three heating rollers 31. This invention is not limited to such construction. For example, it may have four or more heating rollers 31. Even with such construction, the duty ratio (corresponding to the amount of heat) applied to the failed heating roller 31 may be distributed to the remaining normal heating rollers 31. In that case, it is preferred to prevent faulty drying or to keep drying time from becoming short as noted hereinbefore. When the amount of heat of one heating device cannot be compensated for with the amounts of heat of two heating devices, compensation may be made with the amounts of heat of three or more heating devices.

[0068] (3) In the foregoing embodiment, the failure detection unit consists of the disconnection detecting circuits 37a-37c. This invention is not limited to this construction. That is, since what is necessary is just to be able to detect failure of the halogen lamps 33a-33c, failure detection may be performed with light sensors, for example, which detect luminance of the respective halogen lamps 33a-33c.

[0069] (4) The foregoing embodiment has been described taking for example the case of halogen lamps 33 as heating devices. This invention is not limited to the halogen lamps 33. For example, the halogen lamps 33 may be replaced with heaters or warm air generators.

[0070] (5) In the foregoing embodiment, only the duty ratio of the predetermined period T1 is distributed with an average value calculated from time t3 of failure occurrence, from among the duty ratios in time series as shown in FIG. 4. However, this invention is not limited to such technique. That is, an average value may be calculated using all the duty ratios stored, or an average value of the duty ratio may be calculated only with respect to ranges that are the same as conditions set by the printing condition setter 25.

[0071] (6) In the foregoing embodiment, the web paper WP is illustrated as printing medium. This invention is applicable also to printing media other than paper. Plastic film can be cited as an example.

INDUSTRIAL UTILITY

[0072] As described above, this invention is suitable for an inkjet printing apparatus including a drying unit having a plurality of heating devices, and a control method therefor.

REFERENCE SIGNS LIST

[0073] 1 . . . printing system

[0074] 3 . . . paper feeder

[0075] X . . . transport direction

[0076] Y . . . width direction

[0077] 5 . . . printing apparatus

[0078] 7 . . . takeup roller

[0079] 9, 13 . . . drive rollers

[0080] 11 . . . transport rollers

[0081] 17 . . . drying unit

[0082] 27 . . . temperature controller

[0083] 29 . . . alarm device

[0084] 31 (31a-31c) . . . heating rollers

[0085] 33 (33a-33c) . . . halogen lamps

[0086] 35 . . . temperature sensors

[0087] 37 (37a-37c) . . . disconnection detecting circuits

[0088] 41 (41a-41c) . . . duty ratio memories

[0089] 43 . . . controller