IMAGE PRINTING APPARATUS

Abstract

An image printing apparatus that prints an image on a substrate includes: a supply unit that supplies a substrate loaded; a print unit that performs printing on the substrate supplied by the supply unit; a distinguishment unit that distinguishes a substrate category of the substrate supplied from the supply unit; a setting unit that sets a substrate category of a substrate used for printing; a detection unit provided between the print unit and the supply unit to detect a splice portion where substrates are connected; a determination unit that determines whether the substrate category distinguished by the distinguishment unit and the substrate category set by the setting unit match; and a reporting unit that reports an error in a case where the determination unit determines that the substrate categories do not match. The reporting unit does not report the error until the supply unit completes substrate supply preparation.

Claims

1. An image printing apparatus that prints an image on a substrate, the image printing apparatus comprising: a supply unit that supplies a substrate loaded; a print unit that performs printing on the substrate supplied by the supply unit; a distinguishment unit that distinguishes a substrate category of the substrate supplied from the supply unit; a setting unit that sets a substrate category of a substrate used for printing; a detection unit provided between the print unit and the supply unit to detect a splice portion where substrates are connected; a determination unit that determines whether the substrate category distinguished by the distinguishment unit and the substrate category set by the setting unit match; and a reporting unit that reports an error in a case where the determination unit determines that the substrate categories do not match, wherein the reporting unit does not report the error until the supply unit completes substrate supply preparation.

2. The image printing apparatus according to claim 1, wherein the error is reported after the splice portion is conveyed to a position downstream of the print unit.

3. The image printing apparatus according to claim 1, wherein the determination by the determination unit as to whether the substrate categories match is made after completion of the substrate supply preparation.

4. The image printing apparatus according to claim 1, comprising an information obtainment unit provided between the print unit and the supply unit to obtain information on the substrate, wherein the distinguishment unit distinguishes the substrate category based on the information obtained by the information obtainment unit.

5. The image printing apparatus according to claim 1, further comprising a replacement determination unit that determines that a substrate used for printing has been replaced, wherein in a case where the replacement determination unit determines that a substrate used for printing has been replaced, the determination unit determines whether the substrate category distinguished by the distinguishment unit and the substrate category set by the setting unit match.

6. The image printing apparatus according to claim 1, further comprising a storage unit that stores a distinguishment result obtained by the distinguishment unit, wherein the reporting unit reports the error in a case where it is determined based on the distinguishment result stored in the storage unit that the substrate categories do not match.

7. The image printing apparatus according to claim 1, wherein the substrate category distinguished by the distinguishment unit is a substrate category into which the substrate is grouped.

8. The image printing apparatus according to claim 1, wherein the distinguishment unit includes an information obtainment unit that obtains information on unevenness of a surface of the substrate, and the distinguishment unit distinguishes the substrate category of the substrate using the information on unevenness of the surface of the substrate obtained by the information obtainment unit and linked with the substrate category.

9. The image printing apparatus according to claim 8, wherein in a case where the information on unevenness of the surface of the substrate obtained by the information obtainment unit is not linked with the substrate category, the distinguishment unit links the information on unevenness of the surface of the substrate obtained by the information obtainment unit with the substrate category of the substrate and stores the information.

10. The image printing apparatus according to claim 9, wherein in an event where the information on unevenness of the surface of the substrate obtained by the information obtainment unit is linked with the substrate category of the substrate and saved, the information is not saved in a case where the substrate category set by the setting unit and the substrate category of the substrate distinguished by the distinguishment unit are different from each other.

11. The image printing apparatus according to claim 5, wherein detection of the splice portion of the substrate is performed after operation of a substrate holddown mechanism is detected, and the replacement determination unit determines that a substrate has been replaced in a case where the splice portion of the substrate is detected.

12. The image printing apparatus according to claim 8, wherein the distinguishment unit starts distinguishment once a position of the splice portion detected while the substrate is conveyed is located downstream, in a conveyance direction of the substrate, of a position of the information obtainment unit that obtains information on unevenness of the surface of the substrate.

13. The image printing apparatus according to claim 1, comprising a plurality of substrate feed buttons operated for conveyance of the substrate, wherein even in a case where one of the plurality of substrate feed buttons that corresponds to a feed speed higher than a conveyance speed for substrate distinguishment is pressed, the substrate distinguishment is performed after a substrate feed speed is decreased to a detection speed for distinguishment.

14. The image printing apparatus according to claim 13, wherein in a case where one of the plurality of substrate feed buttons that corresponds to a feed speed lower than the conveyance speed for substrate distinguishment is pressed, the substrate distinguishment is not performed, and in a case where one of the plurality of substrate feed buttons that corresponds to a feed speed higher than the conveyance speed for substrate distinguishment is pressed, the substrate distinguishment is performed after the substrate feed speed is increased to a speed for substrate distinguishment.

15. The image printing apparatus according to claim 13, further comprising: a high-speed substrate feed button for a high speed and a low-speed substrate feed button for a speed lower than the high speed which are operated to convey the substrate and a speed change control unit that changes the substrate feed speed according to a state of a cover of the image printing apparatus, wherein in a case where the cover is closed, the substrate feed speed is set to a speed higher than a speed used in a case where the cover is open, and a speed corresponding to the low-speed substrate feed button in a case where the cover is closed and a speed corresponding to the high-speed substrate feed button in a case where the cover is open are set to be same as the conveyance speed for substrate distinguishment.

16. The image printing apparatus according to claim 1, wherein in printing, in a case where the distinguishment unit has not distinguished the substrate category yet, information is displayed on a display screen to ask whether to execute, before printing, obtainment of rest of data and the determination as to whether the substrate categories match.

17. The image printing apparatus according to claim 1, wherein in printing, in a case where the distinguishment unit has not distinguished the substrate category yet, obtainment of rest of data and the determination as to whether the substrate categories match are automatically executed before printing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a side view showing an image printing apparatus according to the present embodiment;

[0009] FIG. 2 is a schematic diagram showing units according to the present embodiment disposed along a conveyance path formed by a conveyance unit;

[0010] FIG. 3 is a block diagram showing a control unit of the image printing apparatus according to the present embodiment;

[0011] FIG. 4 is a flowchart showing substrate distinguishment processing performed by the image printing apparatus according to the present embodiment;

[0012] FIG. 5A is a diagram showing the conveyance unit with a main body cover of the image printing apparatus according to the present embodiment closed;

[0013] FIG. 5B is a diagram showing the conveyance unit with the main body cover of the image printing apparatus according to the present embodiment open;

[0014] FIG. 6 is a flowchart showing processing performed by the image printing apparatus according to the present embodiment in response to an instruction to start printing;

[0015] FIG. 7 is a diagram showing an operation panel of the image printing apparatus according to the present embodiment;

[0016] FIG. 8 is a flowchart showing processing performed by an image printing apparatus according to another embodiment in response to an instruction to start printing; and

[0017] FIG. 9 is a diagram showing a screen on an operation panel of the image printing apparatus according to the other embodiment.

DESCRIPTION OF THE EMBODIMENTS

[0018] Modes for carrying out the present disclosure are described in detail with reference to the drawings. It should be noted that the dimensions, materials, shapes, relative arrangement, and the like of components in the embodiments described below may be changed as needed depending on the configuration and various conditions of an image printing apparatus to which the present disclosure is applied. The scope of the present disclosure is not limited to the embodiments described below.

First Embodiment

[0019] FIG. 1 is a side view showing an image printing apparatus 1 according to the present embodiment. As shown in FIG. 1, the image printing apparatus 1 includes a feed unit 10 that speedily feeds a substrate in a roll shape, a wind-up unit 40 that winds up a substrate conveyed thereto, and a conveyance unit 50 provided between the units 10 and 40. An image formation unit 20 is provided along a conveyance path formed by the conveyance unit 50. Specifically, the image formation unit 20 includes a white image formation unit 23 (see FIG. 2) disposed upstream in a conveyance direction and a color image formation unit 24 (see FIG. 2) disposed downstream. The conveyance unit 50 includes an upstream conveyance roller pair 12 (see FIG. 2) and a downstream conveyance roller pair 15 (see FIG. 2) and meandering correction units corresponding to the white image formation unit and the color image formation unit. A control unit 30 is configured having a controller unit 100 and a print engine unit 200 (see FIG. 3 for both) which execute, e.g., control to be described later using FIG. 4 and the like based on an operation panel and an operation performed through this operation panel. The control unit 30 performs control so that the conveyance unit 50 conveys a rolled substrate housed in the feed unit 10 to the two image formation units in the image formation unit 20. Then, the image formation unit 20 forms an image on the substrate, and the conveyance unit 50 conveys the substrate having the image formed thereon to the wind-up unit 40 along a downstream conveyance path. The wind-up unit 40 winds up the substrate having the image formed thereon. After that, the substrate wound up can be cut and removed.

[0020] A substrate in the present embodiment is a material on which an image can be formed by the image formation unit 20 and which can then be wound up. Examples of a substrate can be a film or paper. A substrate can also be release paper with labels attached thereto.

[0021] FIG. 2 is a schematic diagram showing the units according to the present embodiment disposed along the conveyance path formed by the conveyance unit 50. As shown in FIG. 2, to suppress sagging of a substrate, a dancer roller (not shown) is provided on the conveyance path between the feed unit 10 and the main conveyance unit 12 of the image formation unit 20 and between the sub conveyance unit 15 of the image formation unit 20 and the wind-up unit 40. Also, a splice mechanism 11 and a substrate holddown mechanism 26 are provided between the feed unit 10 and the image formation unit 20. The feed unit 10 keeps a substrate in a rolled state, the substrate being, for example, 1000 meters long. Then, the splice mechanism 11 and the substrate holddown mechanism 26 are disposed at positions approximately one meter downstream of the feed unit 10 holding the substrate.

[0022] The splice mechanism 11 is in the shape of a desk with a flat portion and is provided with a groove corresponding to the width direction of a substrate to cut the substrate with a cutter. Thus, a substrate can be cut with a cutter in the splice mechanism 11. Also, in the splice mechanism 11, a cut substrate can be joined with a new substrate with a splice tape. The substrate holddown mechanism 26 has a rubber member (not shown) and, using the rubber member operated up and down with a switch, can hold down a substrate so that the substrate will not move. After a substrate is cut in the splice mechanism 11, the substrate holddown mechanism 26 releases the substrate. Then, a new substrate can be loaded into the feed unit 10. Further, the leading edge of a new replacing substrate is moved to the splice mechanism 11, and with the substrate holddown mechanism 26 holding down the leading edge portion of the new substrate, the leading edge portion of the new substrate and the tailing edge portion of the substrate cut and remaining in the substrate holddown mechanism 26 are joined with a splice tape. After that, the substrate holddown mechanism 26 releases the substrates, and once a user presses a substrate feed button (see FIG. 5), the substrate is conveyed by the rollers of the main conveyance unit 12 and the sub conveyance unit 15.

[0023] In this conveyance, depending on the type of the splice tape or the joining method, the portion where the substrates are joined with a splice tape in the splice mechanism 11 (hereinafter referred to as a splice portion) may have a certain thickness or more. Thus, first, to avoid fluctuations while the main conveyance unit 12 and the sub conveyance unit 15 send the substrate, the user moves the splice portion to a location downstream of the sub conveyance unit 15. With this conveyance of substrate, substrate replacement work is completed.

[0024] Also, a step at the splice portion is detected while the substrate is conveyed. Specifically, a splice sensor 27 is disposed adjacent to the main conveyance unit 12 and detects a step on the substrate being conveyed, the step having a predetermined thickness or more (a splice portion detection unit). Thus, a print controller 202 of the control unit 30 (see FIG. 3) can learn the presence and position of the splice portion at the substrate. The splice sensor 27 is, in the present embodiment, a laser displacement meter and can detect a step on a substrate by irradiating the substrate with laser light and receiving light reflected from the substrate.

[0025] Once the splice sensor 27 detects a splice portion, the print controller 202 (see FIG. 3) determines that a new substrate has been loaded into the feed unit 10. Also, upon detection of a splice portion, the splice sensor 27 can identify the position of the splice portion on the substrate by identifying the position of an encoder (not shown). Also, in the event where the splice sensor 27 detects a step on a substrate during printing, the print controller 202 (see FIG. 3) notifies of an error so that the splice portion, as the substrate is conveyed farther, will not collide against the printhead located at a downstream position.

[0026] An information obtainment sensor 19 is provided between the first print unit 23 of the image formation unit 20 and the main conveyance unit 12. This information obtainment sensor 19 can move up and down relative to the substrate conveyance path and moves down in obtaining data for substrate distinguishment and obtains substrate data.

[0027] The information obtainment sensor 19 of the present embodiment is, for example, a contact image sensor (CIS) and obtains substrate information by capturing an image relating to unevenness of the surface of the substrate. Because a CIS captures a shadow produced by unevenness on the surface of a substrate while in direct contact therewith, image capture and detection by a CIS enables accurate substrate distinguishment based on the unevenness capturing image. As will be described, with the substrate distinguishment, a substrate or a substrate category can be determined using a model trained by machine learning, based on substrate information, i.e., the unevenness capturing image obtained by the information obtainment sensor 19. For this determination of a substrate or a substrate category, basically, for example, unevenness of Coated Paper A, unevenness of Coated Paper B, unevenness of Non-Coated Paper C, and unevenness of Non-Coated Paper D are identified and distinguished from one another by the substrate distinguishment. This makes it possible to tell apart coated paper combining unevenness of Coated Paper A and unevenness of Coated Paper B and non-coated paper combining unevenness of Non-Coated paper C and unevenness of Non-Coated Paper D. In other words, in a case where individual substrates (Coated Paper A, Coated Paper B, Non-Coated Paper C, and Non-Coated Paper D) can be distinguished from one another, substrate categories (coated paper and non-coated paper), which are categories into which the substrates are grouped, can be distinguished from each other as well.

[0028] Note that substrate information may be combined with data other than unevenness obtained by the CIS sensor, such as brightness. In another embodiment, the information obtainment sensor 19 may be a sensor that obtains information with more data, such as a sensor that directly measures paper thickness or an ultrasonic sensor.

[0029] Also, a particular substrate or substrate category may be defined for a substrate using a model trained by machine learning, based on substrate information obtained by the information obtainment sensor 19. Although information obtainment methods described above involve a CIS sensor obtaining unevenness or brightness as an example, the information may include more data obtained using, for example, a sensor that directly measures the thickness of a substrate, an ultrasonic sensor, or the like.

[0030] Image capture and detection of a substrate by the information obtainment sensor 19 described above is desirably done with the substrate conveyed at a constant speed. Thus, as will be described in detail later, image capture and detection for information obtainment are started once the splice portion being conveyed using a substrate feed button is located downstream of the information obtainment sensor 19. In this event, the print controller 202 conveys the substrate at a substrate feed speed of 4.5 mpm and carries out obtainment of substrate information once the speed reaches a constant speed.

[0031] The first print unit (white image formation unit) 23 of the image formation unit 20 is a print unit for white and is disposed downstream of the main conveyance unit 12, and the second print unit (color image formation unit) 24 of the image formation unit 20 is a print unit for color and is disposed downstream of the first print unit 23.

[0032] The first print unit 23 has a white head 20a which is a line head, and the white head 20a includes a head for white and a head for primer ink for fixating white. A substrate is printed while being conveyed with the line head fixed. The white head 20a prints a white image by ejecting white ink to a substrate conveyed in a print direction 18.

[0033] While the first print unit 23 performs printing on a substrate, ink ejected to the substrate is dried and cooled in a white fixation region 21. A heater and a fan are provided as a drier in the white fixation region 21 to dry the ink. After the ink dries, the substrate heated by the drier is cooled by a cooler provided with a fan.

[0034] After the substrate having the white image printed thereon is cooled, the substrate is conveyed to the second print unit 24. A sensor 22 in the second print unit 24 scans an eye mark printed with white ink on the surface of the substrate as described above. In alignment with the scanned position, a color head 13 which is a line head ejects color inks to the substrate conveyed in the print direction 18 and prints color images on the white image. Only color images may be printed in a case where printing with white is not needed. Specifically, in a case where the substrate is not a transparency film but formed of a white material, the second print unit 24 may print on the substrate without the first print unit 23 printing on the substrate.

[0035] Meanwhile, while the second print unit 24 performs printing on a substrate, ink ejected to the substrate is dried and cooled in a color fixation region 14. Like the white fixation region 21, the color fixation region 14 is provided with a heater and a fan as a drier to dry the ink. After the ink dries, the substrate heated by the drier is cooled by a cooler provided with a fan. After the substrate having the color images printed thereon is cooled, the substrate is conveyed through the sub conveyance unit 15 to the wind-up unit 40 and is wound up by the wind-up unit 40. After that, the substrate is cut by a cutting unit 16, and then the printed substrate can be removed from the wind-up unit 40. For the next printing, the leading edge portion of the substrate remaining after the cutting is attached to the wind-up unit 40 with a tape.

[0036] FIG. 3 is a block diagram showing the control unit 30 of the image printing apparatus according to the present embodiment. The control unit 30 includes the controller unit 100 that performs overall control of the image printing apparatus and the print engine unit 200 that performs overall control of the print engine.

[0037] The print controller 202 of the print engine unit 200 controls various mechanisms of the print engine unit 200 as instructed by a main controller 101 of the controller unit 100.

[0038] In the controller unit 100, the main controller 101 formed of a CPU controls the image printing apparatus according to programs and various parameters stored in a ROM 106, using a RAM 105 as a work area. For example, upon input of a print job from a host apparatus 300 via a host I/F 102, the main controller 101 recognizes the print job and displays the inputted job on an operation panel 103 to be described later.

[0039] Upon detection of pressing of a Print button on the operation panel 103, the main controller 101 determines whether a substrate or a substrate category set on the operation panel 103 matches a result of substrate distinguishment. If they do not match, the main controller 101 displays a mismatch error shown in FIG. 7 as will be described later. If they match, as instructed by the main controller 101, an image processing unit 107 performs predetermined image processing on image data in the order in which the data is inputted. Then, the main controller 101 transmits image data obtained by the image processing to the print engine unit 200 via a print engine I/F 104.

[0040] Note that the main controller 101 may obtain image data from an external storage device (such as, for example, USB memory) connected to the image printing apparatus. The operation panel 103 is a mechanism through which a user inputs information to the image printing apparatus or through which information is outputted to the user. Through the operation panel 103, a user can instruct an operation such as execution of print or feed of a substrate, can set a print mode, and can check information on the image printing apparatus. Also, in the present embodiment, the operation panel 103 is a substrate setting mechanism configured to set a substrate or a substrate category. The operation panel 103 is a touch panel, and a mouse and a keyboard can be connected to input information.

[0041] In the print engine unit 200, the print controller 202 formed of a CPU controls various mechanisms of the image printing apparatus according to programs and various parameters stored in a ROM 203, using a RAM 204 as a work area. Various commands and image data are received via a controller I/F 201, and the print controller 202 saves the received image data to the RAM 204.

[0042] The print controller 202 causes an image processing controller 205 to convert the saved image data into print data, and using the print data, the white head 20a and the color head 13 can perform printing on a substrate. Specifically, after the print data is generated, the print controller 202 causes the white head 20a and the color head 13 to execute a print operation based on the print data via a head I/F 206. In this event, the print controller 202 drives the feed unit 10, the main conveyance unit 12, the sub conveyance unit 15, and the wind-up unit 40 through a conveyance control unit 207 to perform control so that the substrate may be conveyed in a feeding direction or a wind-back direction.

[0043] The print controller 202 determines whether the substrate holddown mechanism 26 (see FIG. 1) has been operated via the conveyance control unit 207 and whether the splice sensor 27 has detected a splice portion. If it is determined that the substrate holddown mechanism 26 has been operated and a splice portion has been detected, the print controller 202 determines that a substrate has been replaced.

[0044] Upon pressing of a substrate feed button shown in FIGS. 5A and 5B to be described later, the print controller 202 can detect the pressing of the substrate feed button. Once a substrate feed button is pressed, the print controller 202 drives the feed unit 10, the main conveyance unit 12, the sub conveyance unit 15, and the wind-up unit 40 shown in FIG. 2 at the specified speed via the conveyance control unit 207.

[0045] After determining that a substrate has been replaced and therefore determining to execute a substrate distinguishment operation, the print controller 202 drives the information obtainment sensor 19 via the conveyance control unit 207 to obtain substrate data.

[0046] In the substrate distinguishment, the substrate is determined to be a particular substrate or substrate category using a model trained by machine learning, based on substrate data obtained by the print controller 202. The substrate or substrate category which is a result of the distinguishment is transmitted to the controller unit through a controller IF 201 and is stored in the ROM 106.

[0047] In response to an instruction to start printing, the main controller 101 determines whether the result of substrate distinguishment stored and the substrate information set on the operation panel 103 match, and if they do not, notifies the user of that by displaying a mismatch error or warning on the operation panel 103.

[0048] Similarly, the print controller 202 drives the color fixation region 14 and the white fixation region 21 through a fixation control unit 211 to drive the heater and fan as the drier and the fan as the cooler. The print controller 202 also performs positioning by controlling ejection timing based on signals from the sensor 22. Thus, as instructed by the print controller 202, the color head 13 and the white head 20a execute a print operation on a substrate in conjunction with a substrate conveyance operation, thereby performing print processing.

[0049] The color head 13 and the white head 20a can move up and down. For example, the color head 13 and the white head 20a move down in printing a substrate and move up for maintenance. A head carriage control unit 208 changes the vertical position of the color head 13 depending on the mode of the image printing apparatus: maintenance mode or print mode.

[0050] An ink supply control unit 209 controls an ink supply unit so that the pressure of the ink supplied to the color head 13 may fall within an appropriate range.

[0051] In performing a maintenance operation on the color head 13 or the white head 20a, a maintenance control unit 210 moves a maintenance unit to a position under the raised head and controls a maintenance operation performed on the head for, e.g., the cap or wiping.

[0052] Table 1 shows information on each of the substrates usable in the present embodiment.

TABLE-US-00001 TABLE 1 Substrate Surface Release No. Manufacturer Substrate Name Category Substrate Adhesive Paper/Film 1 Company A Coated Paper A Coated Paper Coated Paper 1 Permanent Release Film 1 Adhesion Type 2 Company A Coated Paper B Coated Paper Coated Paper 1 Removable Release Film 1 Type 1 3 Company A Coated Paper C Coated Paper Coated Paper 1 Weak Release Film 1 Adhesion Type 4 Company A Coated Paper D Coated Paper Coated Paper 1 Permanent Release Paper Adhesion Type 1 5 Company A Non-Coated Non-Coated Non-Coated Permanent Release Film 1 Paper A Paper Paper 1 Adhesion Type 6 Company A Non-Coated Non-Coated Non-Coated Removable Release Film 2 Paper B Paper Paper 2 Type 2 7 Company A Synthetic Paper Synthetic Paper Synthetic Paper Permanent Release Film 1 A 1 Adhesion Type 8 Company A Synthetic Paper Synthetic Paper Synthetic Paper Permanent Release Film 2 B 2 Adhesion Type 9 Company A Film A Film Film 1 Permanent Release Film 1 Adhesion Type 10 Company A Film B Film Film 1 Permanent Release Film 2 Adhesion Type 11 Company A Low Heat- Low Heat- Low Heat- Permanent Release Film 1 Resistance Film Resistance Film Resistance Film Adhesion Type A 1 12 Company A Low Heat- Low Heat- Low Heat- Removable Release Film 2 Resistance Film Resistance Film Resistance Film Type 1 B 2 13 Company B Coated Paper E Coated Paper Coated Paper 2 Permanent Release Film 3 Adhesion Type 2 14 Company B Coated Paper F Coated Paper Coated Paper 3 Permanent Release Film 4 Adhesion Type 2 15 Company B Coated Paper G Coated Paper Coated Paper 4 Removable Release Film 3 Type 3 . . . . . . . . . . . . . . . . . . . . .

[0053] Among substrates usable in the image printing apparatus of the present embodiment, especially substrates used for label printing can be ordered with freely chosen combinations of specifications such as surface substrate, adhesive, and release paper/film.

[0054] For example, substrates No. 1 to No. 3 provided by Company A all have the same surface substrate, Coated Paper 1, but are combined with different adhesives: permanent adhesion type, removable type, and weak adhesion type. Also, as the release paper, the same release paper, namely Release Film 1, is used. Because these substrates No. 1 to No. 3 have the same surface substrate but different adhesives, they are under different substrate names, namely Coated Paper A, Coated Paper B, and Coated Paper C. Similarly, No. 4 is No. 1 with different release paper, namely Release Paper 1, and is under the substrate name of Coated Paper D. In the present embodiment, these substrates with the same surface substrate are handled as the same substrate category, Coated Paper. No. 5 and No. 6 have different types of adhesive and release paper but the same surface substrate, and therefore, they are handled as the same substrate category, Non-Coated Paper. Similarly, No. 7 and No. 8, which have the same type of adhesive and different types of release paper/film, are handled as the same substrate category, Synthetic Paper, because their surface substrate types are both synthetic paper. The same applies to the films of No. 9 and No. 10 and low heat-resistance films of No. 11 and No. 12, and they are handled as Film and Low Heat-Resistance Film, respectively, as their substrate categories. No. 13 to No. 15 are substrates provided by a different company, Company B, and are made of different surface substrates from those of Company A.

[0055] The substrate category of a substrate is Coated Paper as long as its surface substrate is coated-paper based. In this way, a surface substrate can be freely combined with various types of adhesive and release paper/film. For example, a substrate different from others only in glue has its own substrate name.

[0056] In the present embodiment, substrates are categorized based on their surface substrates into five categories, namely Coated Paper, Non-Coated Paper, Synthetic Paper, Standard Film, and Low Heat-Resistance Film, which are categories shown under Substrate Category in Table 1, and the above-described information obtainment sensor 19 is used to distinguish which of these five Substrate Categories the loaded substrate belongs to. A specific description of this distinguishment is described below.

[0057] As described earlier, the information obtainment sensor 19 detects unevenness on a surface of a substrate. Then, using a model trained by machine learning, the substate category to which the unevenness corresponds is defined and held as a table in advance. If the features of unevenness detected are defined as A, B, C, D, E, . . . , in the present embodiment, they are, in a table, linked with Nos. 1, 2, 3, 4, 5, . . . , respectively, in Table 1. Thus, unevenness information is not directly linked with Substrate Category, but with Substrate itself (what is defined as No. 1, . . . in Table 1). Then, in a case where obtained unevenness information is, for example, B, Substrate Category of the substrate is distinguished to be Coated Paper because B is linked with the substrate No. 2 in the table (a distinguishment unit).

[0058] Although a substrate is distinguished by Substrate Category in Table 1 in the present embodiment, it is also possible to distinguish a substrate by Substrate Name or Surface Substrate in Table 1, as is apparent from the above description. Thus, distinguishing Substrate Category of a substrate as described herein encompasses distinguishing Substrate Name or Surface Substrate of a substrate as well.

[0059] FIG. 4 is a flowchart showing how the image printing apparatus according to the present embodiment performs substrate distinguishment processing. After confirming that a substrate has been replaced and obtaining substrate data on the substrate (e.g., unevenness information on the surface of the substrate) using the information obtainment sensor 19, the image printing apparatus distinguishes the substrate by comparing the substrate data with substrate data saved in a table in the image printing apparatus and stores the distinguishment result (the distinguishment unit). Also, because distinguishment by the substrate name and distinguishment by the substrate category can both be performed with the same procedure in the present embodiment, distinguishment of a substrate encompasses distinguishment by the substrate name and distinguishment by the substrate category.

[0060] As shown in FIG. 4, in Step S100, substrate distinguishment processing starts. Because substrate replacement can be done while the image printing apparatus is in idle mode, it is determined whether the image printing apparatus is in idle mode (Step S101). If the image printing apparatus is not in idle mode, the processing ends. If the image printing apparatus is in idle mode, it is determined whether the substrate holddown mechanism 26 has been closed/opened (Step S102). If the substrate holddown mechanism 26 has not been closed/opened, the processing proceeds back to Step S101, and if the substrate holddown mechanism 26 has been closed/opened, it is determined that a substrate has been replaced in the feed unit 10.

[0061] To avoid a possibility of a splice portion hitting against the heads during printing, after substrate replacement, the splice portion on the substrate needs to be fed downstream of the sub conveyance unit 15. The splice sensor 27 detects a step of a splice portion while the substrate is conveyed. Thus, it is determined in Step S103 whether the splice sensor 27 has detected a step of a splice portion. If a step of a splice portion is not detected, the print controller 202 cannot determine that a substrate has been replaced and therefore proceeds back to Step S101.

[0062] In the present embodiment, if it is detected that the substrate holddown mechanism has been opened/closed in Step S102 and a splice portion is detected in Step S103, the print controller 202 determines that a substrate has been replaced (replacement determination). It is thereby decided that the print controller 202 executes a substrate distinguishment operation. Note that if it is detected in Step 102 that the substrate holddown mechanism has not been opened/closed, but the splice sensor 27 has detected a splice tape, the substrate distinguishment operation is not performed because it can be determined that the substrate has not been replaced but originally has a splice tape thereon for connection.

[0063] If it is determined in Step S103 that the splice sensor 27 has detected a step of a splice portion, the print controller 202 determines whether the splice portion detected in conveyance of the substrate has been fed for a predetermined distance (a) downstream from the splice sensor 27 (Step S104). If it is not determined that the splice portion has been fed for the predetermined distance (a), the print controller 202 cannot determine that replacement of the substrate is complete and therefore proceeds back to Step S101.

[0064] Once the splice portion of the substrate has been fed for the predetermined distance (a) downstream from the splice sensor 27, the information obtainment sensor 19 starts preparing for obtainment of substrate data. Specifically, the splice portion being sufficiently away from the splice sensor 27 (a is, for example, 0.5 m) means that the splice portion at the substrate has a sufficient distance from the information obtainment sensor 19. This makes it possible to avoid a problematic situation where the information obtainment sensor 19 makes distinguishment on the splice portion and ends up obtaining data not on the substrate.

[0065] After that, preparation for obtainment of substrate data is started. First, in Step S105, to obtain substrate data, the information obtainment sensor 19 is moved down via the print controller 202, and the substrate is fixed (Step S105). In Step S105, the print controller 202 thus gives the information obtainment sensor 19 a certain distance from the substrate, and this makes it possible to capture an image of the substrate and obtain substrate data. After that, in Step S106, the print controller 202 checks whether a substrate feed button corresponding to a speed except for the lowest speed is pressed. While no such substrate feed button is pressed, the print controller 202 repeats the check of whether such a substrate feed button is pressed. Next, in Step S107, the print controller 202 performs processing related to changing of the conveyance speed of the substrate (to a substrate detection speed) (a speed change control unit).

[0066] FIGS. 5A and 5B are diagrams showing an operation unit provided to an apparatus main body cover for setting of a conveyance speed. FIG. 5A shows a plurality of buttons and a conveyance speed setting displayed with the main body cover of the image printing apparatus being closed. A substrate can be conveyed at high speed with the main body cover closed; thus, in the present embodiment, an LED 502 indicating that the conveyance unit is in high-speed mode is turned on, and an LED 503 indicating that the conveyance unit is in low-speed mode is turned off. Once a low-speed substrate feed button (low-speed button) 500 is pressed on this operation unit, the substrate conveyance speed is set to 4.5 mpm. Once a high-speed substrate feed button (high-speed button) 501 is pressed on the operation unit, the substrate conveyance speed is set to 20 mpm.

[0067] It is desirable that substrate detection be done with a substrate being conveyed at the same speed. As an example, a substrate detection speed for detecting a substrate is 4.5 mpm. Then, if the conveyance speed is set to high-speed mode as shown in FIG. 5A, the conveyance speed for a substrate is changed from 20 mpm to 4.5 mpm in Step S107 based on the determination in Step S106 as to the conveyance speed being set.

[0068] FIG. 5B shows a plurality of buttons and a conveyance speed displayed with the main body cover of the image printing apparatus being open. As shown in FIG. 5B, to prevent getting caught in the apparatus with the main body cover open, the substrate conveyance speed is decreased, turning off an LED 506 indicative of high-speed mode and turning on an LED 507 indicative of low-speed mode. Once a high-speed substrate feed button 505 is pressed on the operation unit shown in FIG. 5B, the substrate conveyance speed is set to 4.5 mpm. Once a low-speed substrate feed button 505 is pressed on the operation unit shown in FIG. 5B, the substrate conveyance speed is set to 1 mpm. This conveyance speed, 1 mpm, is lower than the substrate detection speed. Data obtained at this conveyance speed may differ from data obtained at a detection speed of 4.5 mpm. Thus, if the set conveyance speed determined in Step S106 is 1 mpm, in Step S107, the next substrate distinguishment processing (S108) is not executed, and the processing proceeds back to Step S106 and waits for pressing of a button other than the low-speed substrate feed button 504 for low-speed mode. Meanwhile, if the substrate conveyance speed determined in Step S106 is the substrate detection speed (4.5 mpm) in the state shown in FIG. 5B, the conveyance speed is not changed in Step S107. Thus, the substrate can be conveyed without the speed increased or decreased.

[0069] In another embodiment, in a case where the substrate conveyance speed is set to 1 mpm, the substrate distinguishment processing may be executed after changing the substrate conveyance speed to 4.5 mpm in Step S107 based on a determination made in Step S106.

[0070] After the substrate conveyance speed is set to the substrate detection speed in Step S107, substrate distinguishment data is obtained using the information obtainment sensor 19, which is a CIS, and stored in Step S108. After that, completion of obtainment of the substrate distinguishment data is confirmed (Step S109). Note that in a case where the conveyance of the substrate is stopped in the process of obtainment of the substrate distinguishment data, it is determined that obtainment of the substrate distinguishment data is not completed, and the processing proceeds back to Step S106.

[0071] If completion of obtainment of the substrate distinguishment data is confirmed, in a case where, for example, approximately one meter's worth of substrate data is collected at a constant feed speed of 4.5 mpm, nipping of the substrate by the distinguishment mechanism is released, and the substrate is distinguished using the substrate data obtained, and the distinguishment result is stored (Step S110).

[0072] A substrate is distinguished as follows. For example, in a case where the substrate No. 4 in Table 1 is used, data detecting unevenness of the surface of this substrate (unevenness data obtained by image capture of the substrate) is close to data with Coated Paper Data in Table 2 to be described later. In a case of the substrate No. 4 in Table 1, the unevenness data is compared with the substrate distinguishment data in Table 2, from No. 1 down, and because the unevenness data matches No. 1 in Table 2, it is determined that the substrate category of the substrate No. 4 in Table 1 is Coated Paper.

[0073] Similarly, in a case where the substrate No. 5 in Table 1 is used, the data detecting unevenness of the surface of this substrate does not match any of the substrate distinguishment data for No. 1 to No. 4 in Table 2, but matches Non-Coated Paper Data of No. 5 in Table 2; therefore, it is determined that the substrate category of this substrate is Non-Coated Paper.

[0074] Although the above description of an example distinguishment method discusses a scenario where the datasets match, in actuality, the substrate used is distinguished and determined to be a particular substrate or substrate category using a model trained using machine learning as described above. In the substrate distinguishment in the present embodiment, a substrate is categorized into one of the five substate category groups, namely coated paper, non-coated paper, synthetic paper, standard film, or low heat-resistance film, and the distinguishment result is stored.

[0075] It is also possible to distinguish substrates based not on substrate categories, but on ungrouped substrates like in the prior art, and to store distinguishment data. In regard to a method for distinguishing a substrate and a substrate category, substrates may be distinguished as described above.

[0076] Although a substrate is distinguished and the distinguishment result data is stored in Step S110 in the present embodiment, a match/mismatch determination may also be executed, and a result thereof may be stored. More specifically, in the event of substrate replacement and modification of a substrate or a substrate category on the operation panel, a match/mismatch determination is performed again, and the result thereof is stored, overwriting the existing data. After this processing, the processing proceeds back to Step S101 to either execute printing or open the substrate holddown mechanism again for substrate replacement and repeat the above processing.

[0077] Although the substrate is distinguished and the result is stored in Step S110 in the present embodiment, in another embodiment, a determination may further be made as to whether the substrate thus distinguished matches the set substrate information. In this case, in the event of substrate replacement and modification of substrate information on the operation panel, the determination is made again, and the result thereof is stored.

[0078] In this way, in the present embodiment, in a case where a mismatch is determined in the event of substrate replacement, the result is stored, and a mismatch error notification is not presented.

[0079] After completing Step S110, the processing proceeds back to Step S101. In a case where there is an instruction for starting printing, the processing proceeds to the processing shown in FIG. 6 to execute printing on the substrate. Alternatively, in idle mode, the substrate holddown mechanism 26 may be opened again as needed to repeat substrate replacement or the like.

[0080] FIG. 6 is a flowchart showing processing performed by the image printing apparatus 1 according to the present embodiment in response to an instruction to start printing. As shown in FIG. 6, upon pressing of the Print button on the operation panel 103, the main controller 101 detects the pressing of the Print button and instructs the print controller 202 to perform printing (Step S201).

[0081] After printing is instructed, first, in Step S202, the print controller 202 checks for detection of opening/closing of the substrate holddown mechanism 26 and a splice portion. If neither is detected, the print controller 202 determines that the substrate is not replaced and executes printing on the substrate (Step S203).

[0082] If confirming that opening/closing of the substrate holddown mechanism 26 and a splice portion are both detected, the print controller 202 confirms whether the detected splice portion has been conveyed to a position downstream of the sub conveyance unit 15 (Step S204). More specifically, in the present embodiment, the print controller 202 determines whether the splice portion is approximately 0.5 m downstream of the sub conveyance unit 15, and if it is determined that the splice portion is not at that position, i.e., the splice portion has not been conveyed to a position approximately 0.5 m downstream of the sub conveyance unit 15, the print controller 202 determines that substrate replacement has not been completed, displays an incomplete feed error (Step S205), and ends the present processing.

[0083] This incomplete feed error is an error displayed to prompt the user to feed the substrate farther to the above-described position because the splice portion has yet to be fed to a position downstream of the sub conveyance unit 15. In the present embodiment, a substrate is replaced with one with a different substrate width; thus, conveying the substrate directly causes a jam error. For this reason, if it is determined that substrate replacement is incomplete, an incomplete conveyance error is displayed, and the processing ends. More specifically, in a case where a substrate with a different substrate width is attached and conveyed, the various sensors need to be adjusted in position according to the substrate width. Unless the sensors are adjusted to predetermined positions, a portion that the substrate with a different width has but the former substrate does not may hit the sensors and cause a jam. For this reason, considering a case where the user attaches a substrate with a different substrate width, the processing ends after displaying an incomplete feed error beforehand because the user needs to manually feed the substrate and complete the paper feed.

[0084] Note that in another embodiment, in a case where an incomplete feed error is determined after a substrate is replaced with one with the same substrate width, the splice portion of the substrate may be automatically conveyed to a position downstream of the sub conveyance unit 15 so as not to cause an incomplete feed error or to resolve an incomplete feed error.

[0085] Meanwhile, if it is confirmed in Step S204 that the splice portion is located approximately 0.5 m downstream of the sub conveyance unit 15, it means that substrate supply preparation is complete. Thus, it is determined in Step S206 whether the substrate has already been distinguished. Note that substrate supply preparation may be determined as being completed once the splice portion has been conveyed to a position downstream of the color head.

[0086] In Step S206, based on the substrate distinguishment data obtained by the processing described using FIG. 4, it is determined whether the substrate has already been distinguished. If it is determined that the substrate has not been distinguished yet, in Step S203 printing on the substrate is executed. If it is determined that the substrate has already been distinguished, the processing proceeds to Step S207.

[0087] In Step S207, it is determined whether the distinguished substrate is not among the pre-registered substrates. Table 2 shows pre-registered substrates linked with substrate determination data (data obtained for substrate distinguishment).

TABLE-US-00002 TABLE 2 Data Obtained for Substrate No. Manufacturer Distinguishment Substrate Name SubstrateCategory 1 Company A Coated Paper Data Coated Paper A Coated Paper 2 Company A Coated Paper B Coated Paper 3 Company A Coated Paper C Coated Paper 4 Company A Coated Paper D Coated Paper 5 Company A Non-Coated Paper Non-Coated Paper A Non-Coated Paper 6 Company A Data Non-Coated Paper B Non-Coated Paper 7 Company A Synthetic Paper Data Synthetic Paper A Synthetic Paper 8 Company A Synthetic Paper B Synthetic Paper 9 Company A Film Data Film A Film 10 Company A Film B Film 11 Company A Low Heat-Resistance Low Heat-Resistance Film A Low Heat-Resistance Film 12 Company A Film Data Low Heat-Resistance Film B Low Heat-Resistance Film 13 Company B Coated Paper Data Coated Paper E Coated Paper 14 Company B Coated Paper F Coated Paper 15 Company B Coated Paper G Coated Paper 16 Company C Coated Paper H Coated Paper . . . . . . . . . . . .

[0088] The substrates No. 1 to No. 15 in Table 2 are the same as those in Table 1. The substrate information on No. 1 to No. 15 in Table 2 are stored (registered) in the image printing apparatus and are also referred to as preset media.

[0089] In a case where the substrate used is a substrate with substrate information not stored in the image printing apparatus, the substrate is registered in the image printing apparatus as a new substrate No. 16 with its substrate name and substrate category inputted based on the features detected by the information obtainment sensor 19. Items inputted also include ones other than the substrate name and the substrate category, but they are omitted here. The data obtained for substrate distinguishment is data obtained at the time of substrate distinguishment and then processed, and cannot be inputted by a user. Thus, in the event where a new substrate is used and registered, a cell corresponding to the data obtained for substrate distinguishment is empty.

[0090] In other words, for example, if the data obtained for substrate distinguishment corresponding to the substrate No. 16 in Table 2 is empty, it is determined in Step S207 that the substrate No. 16 is a new substrate. Then, the processing proceeds to Step S208.

[0091] The substrate No. 16 has already undergone the processing in Step S110 shown in FIG. 4. Thus, in that processing, among the preset media, data obtained for substrate distinguishment closest to the information on the substrate based on the features detected by the information obtainment sensor 19 is selected, and the substrate is categorized into the substate category corresponding to the data obtained for substrate distinguishment closest to the information on the substrate among the present media. Then, in Step S208, it is determined whether the substrate category of the substrate No. 16 thus categorized matches the substrate category set in the image printing apparatus.

[0092] If the substrate category of the substrate No. 16 in Table 2 (Coated Paper) matches the information set in the image printing apparatus (Coated Paper), in Step S209 data related to the substrate No. 16 is linked, and then printing is executed in Step S203.

[0093] The linking of the data related to the substrate No. 16 in Step S209 is done by storing, in Table 2, Coated Paper Data in an empty cell for the substrate No. 16 under data obtained for substrate distinguishment. After data related to the substrate No. 16 is linked in Step S209, for substrates to be printed in the future, the determination on matching is made based on a comparison with the data obtained for substrate distinguishment, Coated Paper Data, of the substrate No. 16. Specifically, if the substrate category of the substrate set on the operation panel 103 matches the substrate category categorized based on the detection result in Step S208, the main controller 101 links the read data with the data obtained for substrate distinguishment.

[0094] In a case where the substrate category of the substrate No. 16 is set as Coated Paper on the operation panel 103 and information on the substrate (substrate category) determined by distinguishment based on features detected by the information obtainment sensor 19 is Film, it is determined in Step S208 that the substrate category of the substrate set on the operation panel 103 and the substrate category categorized based on the detection result do not match. In this case, in Step S210, the main controller 101 displays information on a confirmation screen on the operation panel 103, asking whether to link the data.

[0095] If it is confirmed in Step S210 based on user operation to link the data, in S209 the data related to the substrate No. 16 is linked. While the substrate category of the substrate No. 16 is set as Coated Paper, information (substrate category) on the substrate obtained by substrate distinguishment is Film, with the data obtained for substrate distinguishment being Film Data. Thus, in Step S209, Film Data is saved to the ROM 106, which is a storage space, as the data obtained for substrate distinguishment for the substrate No. 16. Then, because the substrate category of the substrate No. 16 is set as Coated Paper but the substrate distinguishment data is Film Data, in future printing, feeding a film does not result in a mismatch error, but conversely, feeding coated paper results in a mismatch warning.

[0096] Meanwhile, if it is confirmed in Step S210 not to link the data, the data is not linked, and the processing proceeds to the processing in Step S212 to be described later. In a case where the substrate category is erroneously set and is different from the substrate category obtained by the processing shown in FIG. 4, incorrect data may be stored in the substrate's data obtained for substrate distinguishment. Thus, the main controller 101 presents a confirmation screen on the operation panel 103, preventing the incorrect data storage described above. Then, a mismatch is determined in Step S212, and a substrate can be selected anew, with no data stored in the data obtained for substrate distinguishment in Table 2.

[0097] Also, if it is determined in Step S207 that the substrate is not a new substrate, the processing proceeds to Step S211 to determine whether the substrate category categorized for the substrate by the distinguishment processing shown in FIG. 4 matches the substrate category set on the operation panel 103.

[0098] If it is determined in Step S211 that they match, the processing proceeds to Step S203 to execute printing. If it is determined in Step S211 that they do not match, a screen is displayed on the operation panel 103 in Step S212, notifying that they do not match (an error). As a result, substrate supply preparation can be continued because an error notification is not presented until Step S212.

[0099] Note that as another embodiment, in a case where whether substrate distinguishment data matches the information set in the image printing apparatus is determined in the processing shown in FIG. 4 as described above and the result thereof is stored, the result may be read in Step S211 and used for the determination.

[0100] FIG. 7 is a diagram showing a screen displayed on the operation panel 103 to notify of a mismatch. Based on the screen shown in FIG. 7 displayed in Step S212, the user determines whether to continue the printing. To perform printing on the substrate being set, an OK button shown at the lower right corner of the screen is pressed. In Step S203, pressing of this button is detected, and printing is executed in Step S203. Also, the error indication shown in FIG. 7 is displayed on the screen on the operation panel 103 in future printing as well. If pressing of a Cancel button is detected in Step S213, the present processing ends without executing printing. In this case, printing can be resumed after the error is resolved. Resolving the error is accomplished by re-selecting a correct substrate on the operation panel 103, by linking data obtained in FIG. 4 with the current substrate, or by replacing the substrate.

[0101] In Step S203, the main controller sends image data to the print engine unit 200 via the controller I/F 201 and executes printing (see FIGS. 1 and 2).

Second Embodiment

[0102] FIG. 8 is a flowchart showing processing according to another embodiment performed in response to instruction to start printing and shows the processing in a similar manner to the processing in FIG. 6 in the first embodiment. The processing shown in FIG. 8 is similar to the processing shown in FIG. 6 except for Step S206 and processing related thereto (S300 to S304). Thus, those similar steps are not described.

[0103] In Step S206 in FIG. 8, if the substrate has not been distinguished yet, the main controller 101 displays a screen on the operation panel 103 indicating that the substrate has not been distinguished yet. Specifically, in idle state, the main controller 101 displays a screen on the operation panel 103 indicating that the substrate has not been distinguished yet (Step S300). As shown in FIG. 9, this screen presents a substrate undistinguished error and can be used to check with the user whether to execute the substrate distinguishment processing again before printing (Step S301).

[0104] If the user determines that the substrate distinguishment processing does not need to be executed, they press the Cancel button. The main controller 101, receiving this, does not execute the substrate distinguishment processing and executes printing on the substrate (Step S203). If the user determines that the substrate distinguishment processing needs to be executed, they press the OK button. The main controller 101 and the print controller 202, receiving this, feed the substrate to distinguish the substrate (Step S302). In this event, like in the processing shown in FIG. 4, the substrate is conveyed at a conveyance speed of 4.5 mpm. Although the confirmation screen is presented in Steps S300 and S301 in the present embodiment, it is to be noted that Steps S300 and S301 may be omitted to always execute Step S302.

[0105] After that, in Step S303, once the conveyance speed reaches the speed for substrate distinguishment, the substrate is nipped by the distinguishment mechanism, and substrate data for substrate distinguishment is obtained (data obtainment) like in the processing shown in FIG. 4. Upon completion of the obtainment of the substrate data, the nipping of the substrate by the distinguishment mechanism is released, and the conveyance of the substrate is stopped. The substrate distinguishment processing is performed, and the result is stored (Step S304). After this processing, Step S207 is performed, and processing after that is performed in a procedure similar to the processing shown in FIG. 6.

[0106] As thus described, according to the image printing apparatus, a substrate mismatch error does not occur during substrate replacement so as not to lower operation convenience. Further, in starting printing on a substrate, a mismatch is determined using substrate data, and a mismatch error notification is issued. This prevents unnecessary issuance of a mismatch error notification before start of printing and enables a user to configure substrate information or replace a substrate in any order that they prefer.

[0107] While the present disclosure has been described with reference to exemplary embodiments, it is to be understood that the disclosure is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.

[0108] This application claims the benefit of Japanese Patent Application No. 2024-081771, filed May 20, 2024, which is hereby incorporated by reference wherein in its entirety.